System and method for preparing metal matrix composite base material for post-processing

Abstract

To provide a method for efficiently and effectively preparing the surface of a metal matrix composite material without adversely affecting the bonding characteristics of the metal matrix composite material.SOLUTION: A method comprises: subjecting one or more surfaces (109) of a metal matrix composite base material (110) including a metal matrix (112) and composite fibers to plasma treatment; and adding a sol gel layer to the one or more surfaces (109) of the metal matrix composite base material (110).SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE

[0001] Embodiments of the present disclosure generally relate to systems and methods for preparing metal matrix composite substrates for subsequent surface treatments, such as bonding or painting. [Background technology]

[0002]

[0002] Various mechanical and chemical surface preparation methods are used to remove the native oxide layer from the surface of metals. Sanding, for example, is a mechanical method that abrades the material. Acid etching, for example, is a chemical method that removes a layer of material.

[0003]

[0003] However, such processes can have adverse effects on metal matrix composites if the composite fibers are in close proximity to the exposed surface of such materials. In particular, removing a layer of material from the surface of a metal matrix composite can expose the underlying composite fibers. The bonding properties of the metal matrix composite can be adversely affected when the composite fibers are exposed. Summary of the Invention

[0004]

[0004] There is a need for an efficient and effective method for preparing the surface of a metal matrix composite. Furthermore, there is a need for a method for preparing the surface of a metal matrix composite that does not adversely affect the bonding properties of the metal matrix composite.

[0005]

[0005] With this need in mind, certain embodiments of the present disclosure provide a method that includes initially treating one or more surfaces of a metal matrix composite substrate, and, after the initial treating, applying an adhesion promoter layer onto one or more surfaces of the metal matrix composite substrate.

[0006]

[0006] The metal matrix composite substrate may form part of an aircraft.

[0007] In at least one embodiment, a metal matrix composite substrate includes a metal matrix and composite fibers.

[0008] In at least one embodiment, the first treating includes plasma treating (eg, atmospheric pressure plasma treating).

[0009]

[0009] In at least one embodiment, the initially treating comprises laser ablation.

[0010] The adhesion promoter layer may comprise one or more films or coatings of material.

[0011] In at least one embodiment, the adhesion promoter layer is or otherwise includes a sol-gel layer.

[0012] The adhesion promoter layer may comprise a chromate conversion coating.

[0013] The method may also include subsequently treating the metal matrix composite substrate on one or more surfaces after applying the adhesion promoter layer.

[0014]

[0014] For example, the subsequent processing step includes painting.

[0015] The method may also include forming the thermal emitter using a metal matrix composite substrate. [Brief explanation of the drawings]

[0016] [Figure 1] 1 shows a flowchart of a method according to one embodiment of the present disclosure. [Figure 2]

[0017] FIG. 1 shows a simplified block diagram of an adhesion promoter layer applied over a surface of a metal matrix composite substrate according to one embodiment of the present disclosure. [Figure 3]

[0018] FIG. 1 illustrates a block diagram of an aircraft, according to one embodiment of the present disclosure. [Figure 4]

[0019] 1 illustrates a perspective front view of an aircraft according to one embodiment of the present disclosure. [Figure 5]

[0020] 1 shows a schematic representation of a plasma processing device according to one embodiment of the present disclosure. [Figure 6]

[0021] 1 shows a perspective view of a nozzle of a plasma processing device according to one embodiment of the present disclosure. [Figure 7]

[0022] 7 illustrates a bottom view of the tip of the nozzle of FIG. 6 according to one embodiment of the present disclosure. [Figure 8]

[0023] 7 illustrates a perspective view of a nozzle similar to FIG. 6, but with a 2 degree exit angle and the plasma plume removed for clarity, according to one embodiment of the present disclosure. [Figure 9]

[0024] 9 illustrates a bottom view of the nozzle tip of FIG. 8 according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0017]

[0025] The foregoing summary, as well as the following detailed description of specific embodiments, will be better understood when read in conjunction with the accompanying drawings. As used herein, the use of the singular form "a" or "an" preceding an element or step does not necessarily exclude a plurality of such elements or steps. Furthermore, references to "one embodiment" are not intended to be interpreted as excluding the existence of additional embodiments that incorporate features described herein. Furthermore, embodiments that "comprising" or "having" one or more elements having certain conditions may include additional elements that do not have those conditions (unless expressly stated otherwise).

[0018]

[0026] FIG. 1 shows a flowchart of a method according to one embodiment of the present disclosure. At 100, a metal matrix composite substrate is provided. The metal matrix composite substrate can be a variety of structures, such as a panel, a beam, a structural assembly, etc. In at least one embodiment, the metal matrix composite substrate forms a portion of an aircraft, such as a wing or fuselage. The metal matrix composite substrate is a semi-metallic material (rather than simply metal) and includes a matrix formed of a metal (e.g., aluminum, copper, steel, etc.) and composite fibers (e.g., aluminum oxide fibers, carbon fibers, ceramic fibers, metallic fibers, polymeric fibers, etc.).

[0019]

[0027] At 102, one or more surfaces of the metal matrix composite substrate are first treated. For example, the outer surface of the metal matrix composite substrate is first treated. In at least one embodiment, the first treatment is a plasma treatment. That is, the method includes first plasma treating the surface(s) of the matrix composite substrate. As another example, the first treatment can be a laser ablation treatment.

[0020]

[0028] After the initial treatment, an adhesion promoter layer is applied onto the surface(s) of the metal matrix composite substrate at 104. In at least one embodiment, the adhesion promoter layer comprises one or more films of material deposited onto the surface(s). In at least one further embodiment, the adhesion promoter layer is a sol-gel layer (e.g., a coating or film), such as those described in U.S. Pat. No. 5,789,085 entitled "Paint Adhesion," U.S. Pat. No. 5,814,137 entitled "Sol for Coating Metals," U.S. Pat. No. 5,849,110 entitled "Sol Coating of Metals," U.S. Pat. No. 5,869,140 entitled "Sol Coating of Metals," U.S. Pat. No. 5,869,141 entitled "Surface Pretreatment for Sol Coating of Metals," U.S. Pat. No. 5,939,197 entitled "Sol-Gel Coated Metal," U.S. Pat. No. 5,958,578 entitled "Hybrid Laminate Having Improved Metal-To-Resin Adhesion," or U.S. Pat. No. 6,037,060 entitled "Sol for Bonding Epoxies to Aluminum or Titanium Alloys." As another example, the adhesion promoter layer may include a chromate conversion coating.

[0021]

[0029] In particular, the sol-gel layer has been found to effectively covalently bond to the surface(s) of the metal matrix composite substrate without adversely affecting the metal matrix composite substrate (e.g., by not exposing the aluminum oxide, ceramic, or carbon fibers of the metal matrix composite substrate). In contrast, surface preparation by chemical etching, sanding, etc., can adversely expose the composite (e.g., aluminum oxide, ceramic, or carbon) fibers and damage the metal matrix composite substrate, such as along bond lines.

[0022]

[0030] 2 shows a simplified block diagram of an adhesion promoter layer 108 applied over a surface 109 of a metal matrix composite substrate 110, according to one embodiment of the present disclosure. Referring to FIGS. 1 and 2, the adhesion promoter layer 108 is applied onto the surface 109 of the metal matrix composite substrate 110 after the surface 109 has first been treated (such as by plasma treatment). The metal matrix composite substrate 110 includes a metal matrix 112 and composite fibers 114.

[0023]

[0031] To prepare the metal matrix composite substrate 110 for subsequent processing (such as painting), the native oxide layer is removed. A non-invasive initial treatment with a plasma treatment has been found to effectively clean and activate the surface 109 for adhesion by removing the native oxide layer without exposing the composite fibers of the metal matrix composite substrate 110. A sol-gel layer (such as the adhesion promoter layer 108) has been found to effectively and efficiently prepare the surface 109 of the metal matrix composite substrate 110.

[0024]

[0032] After the adhesion promoter layer 108 is applied to the surface 109 of the metal matrix composite substrate 110, the surface(s) 109 including the adhesion promoter layer 108 are treated (e.g., a second or subsequent treatment). Examples of such treatments include painting or bonding.

[0025]

[0033] The plasma treatment does not remove material from the metal matrix composite substrate 110. Instead, the plasma treatment physically activates the surface 109 to promote bonding and adhesion. For example, the plasma treatment cleans or otherwise prepares the surface 109 by removing oils, debris, etc. The plasma can be applied to the surface 109 in a variety of ways. The plasma improves the bond strength and durability of the metal matrix composite substrate 110.

[0026]

[0034] In at least one embodiment, during plasma treatment, plasma is applied at a constant rate and intensity to the surface 109 of the metal matrix composite substrate 110. Bonding wedge testing and imaging using a scanning electron microscope indicates that the plasma treatment efficiently and effectively cleans the surface 109 of the metal matrix composite substrate 110 and activates the surface 109 for improved cohesion with dissimilar materials (such as paint or fiberglass prepreg materials).

[0027]

[0035] 3 illustrates a block diagram of an aircraft 200 according to one embodiment of the present disclosure. The aircraft 200 includes external structures 202, such as a fuselage, wings, a tail, vertical stabilizers, horizontal stabilizers, and control surfaces (ailerons, flaps, etc.). One or more thermal emitters 204 are coupled to one or more of the external structures 202. In at least one embodiment, a thermal emitter 204 is coupled to all of the external structures 202 of the aircraft 200. In at least one embodiment, a thermal emitter 204 is coupled to less than all of the external structures 202 of the aircraft 200.

[0028]

[0036] The thermal emitter 204 may be integrated with the external structure 202. For example, the thermal emitter 204 may be attached to an exterior surface (e.g., an exterior mold line) of the external structure 202. The thermal emitter 204 may be secured to the exterior surface of the external structure 202 via adhesives, fasteners, bonding, etc. As another example, the thermal emitter 204 may be embedded within the external structure 202. For example, the external structure 202 may be formed of a composite material, and the thermal emitter 204 may be secured within one or more plies or layers of the external structure 202. As another example, the thermal emitter 204 may be secured to an interior surface (opposite from the exterior surface) of the external structure 202, such as an interior wall of the fuselage.

[0029]

[0037] In at least one embodiment, the thermal emitter 204 is formed of a material configured to conduct, radiate, and / or emit heat when activated and connected to a power source 206. In particular, the thermal emitter 204 is formed of a metal matrix composite, such as a composite matrix having fibers or particles dispersed within a metal matrix, such as copper, aluminum, steel, etc. Referring to FIGS. 1-3 , the thermal emitter 204 is formed of one or more metal matrix composite substrates 110. The one or more metal matrix composite substrates 110 are first processed as described herein before an adhesion promoter layer 108 (such as a sol-gel layer) is applied thereon. The thermal emitter 204 is merely one example of a component formed of one or more metal matrix composite substrates to which an adhesion promoter layer has been applied. Various structures, components, assemblies, etc., may be formed with such materials.

[0030]

[0038] The thermal emitters 204 are coupled to the power source 206 via one or more wired or wireless connections. During operation, the thermal emitters 204 may be activated, such as by a pilot in the cockpit. When activated, the thermal emitters 204 draw power from the power source 206 and generate heat to melt ice on the external structure 202 and / or prevent ice from forming on the external structure 202. The thermal emitters 204 de-ice the external structure 202 without the need for a separate de-icing fluid. Furthermore, the thermal emitters 204 may be operated to de-ice the external structure 202 when the aircraft 200 is parked at a gate or moving along a taxiway or runway.

[0031]

[0039] FIG. 4 illustrates a perspective front view of an aircraft 200 according to one embodiment of the present disclosure. The aircraft 200 includes a propulsion system 212 including, for example, engines 214. Optionally, the propulsion system 212 may include more engines 214 than shown. The engines 214 are supported by wings 216 of the aircraft 200. In other embodiments, the engines 214 may be supported by a fuselage 218 and / or a tail section 220. The tail section 220 may also support a horizontal stabilizer 222 and a vertical stabilizer 224. The fuselage 218 of the aircraft 200 defines an interior cabin 230, which may include a cockpit or flight deck, one or more work sections (e.g., a galley, a crew baggage area, etc.), one or more passenger sections (e.g., first class, business class, and economy class), one or more restrooms, etc. FIG. 4 illustrates an example of an aircraft 200. It should be understood that aircraft 200 may be sized, shaped, and configured differently than that shown in FIG.

[0032]

[0040] In at least one embodiment, thermal emitter 204 is coupled to one or more external structures of aircraft 200. For example, thermal emitter 204 may be coupled to wings 216, fuselage 218, tail 220, horizontal stabilizer 222, vertical stabilizer 224, etc.

[0033]

[0041] 1-4 , in at least one embodiment, a thermal emitter 204 is formed from a metal matrix composite substrate 110 having an adhesion promoter layer 108 applied to one or more surfaces 109 of the metal matrix composite substrate 110, as described herein. The thermal emitter 204 is configured to emit conductive heat energy that is used to heat the outer mold line of the wing 216 to a desired temperature, melt any ice that has accumulated thereon, and prevent ice from forming thereon.

[0034]

[0042] 5-9 illustrate various aspects of a plasma treatment process. With reference to FIG. 1 and FIG. 5-9, in at least one embodiment, treatment step 102 is a plasma treatment. The plasma treatment process shown and described with respect to FIG. 5-9 is exemplary and non-limiting.

[0035]

[0043] FIG. 5 illustrates an atmospheric pressure plasma treatment device 310. The plasma treatment device 310 generates a plasma plume 312 (or ionized gas) from compressed air to treat a surface 314 of a substrate 316. The surface 314 is an example of the surface 109 shown in FIG. 2, and the substrate 316 is an example of the metal matrix composite substrate 110 shown in FIG. 2. While the substrate 316 is shown in FIG. 5 as a flat structure, it will be understood that the substrate 316 may actually have a more complex (e.g., curved) shape. Plasma treatment of the surface 314 with the plasma plume 312 modifies and / or cleans the surface 314 to improve bonding of the substrate 316 to an applied substance, such as a paint, adhesive, coating, ink, or other material. Specifically, the plasma plume 312 contains charged species that can remove microscopic surface contaminants and / or modify the surface 314 with chemical groups (e.g., oxygen-functional) that enhance bonding with added materials (paints, adhesives, coatings, inks, etc.) The plasma treatment can increase the surface energy of the surface 314, thereby improving the surface's properties for bonding compared to the surface before plasma treatment.

[0036]

[0044] The plasma processing device 310 can be manually operated or robotically operated, such as with a robotic gantry system. As shown in FIG. 5 , the plasma processing device 310 includes a plasma generator 318 connected to a plasma jet 320. Among other features, the plasma jet 320 includes a chamber 322, one or more inlets 324 for compressed air 326, and a nozzle 328. The nozzle 328 can be removed from the device 310 and replaced with another nozzle having a different configuration to achieve a desired effect on the plasma plume 312. When excited with power from the plasma generator 318, the compressed air 326 in the chamber 322 is ionized to generate the plasma plume 312. The plasma plume 312 exits the chamber 322 through the nozzle 328 and impinges on the surface 314 perpendicular to the surface 314 for treatment of the surface 314. Furthermore, the plasma plume 312 exits the nozzle 328 at an angle controlled by the configuration of the nozzle 328. As explained further below, the ejection angle is the angle of deflection between the plasma plume 312 and the central axis 330 of the nozzle 328 .

[0037]

[0045] In at least one embodiment, the nozzle 328 has a jetting angle of about 5 degrees (±0.2%) or less. The lower jetting angle of the nozzle 328 provides a more focused (less divergent) plasma plume compared to a nozzle with a higher jetting angle. The more focused plasma plume provided by the nozzle 328 improves the bonding quality of the substrate surface in a reduced processing time compared to a nozzle with a higher jetting angle.

[0038]

[0046] In at least one embodiment, the nozzle 328 is a 0-degree nozzle 332 having an exit angle of approximately 0 degrees (±0.2%), as shown in Figures 6-7. The exit angle is defined as the angle between the central axis 330 of the nozzle and the central axis 334 of the plume opening 336. Through the plume opening 336, the plasma plume 312 exits at the tip 338 of the nozzle 332 (as shown in Figure 7). Thus, the central axis 330 of the nozzle 332 and the central axis 334 of the plume opening 336 may be aligned, or at least parallel, in a 0-degree nozzle 332.

[0039]

[0047] While nozzles with larger ejection angles can be rotated to provide a more diffuse, annular plume or plasma "cone" or "ring," 0-degree nozzles 332 are generally not rotated during plasma processing. Due to the lower ejection angle, 0-degree nozzles 332 can provide a more focused, intense plasma plume for impingement on the substrate surface 314 in a given direction, such as the vertical direction, compared to nozzles with larger ejection angles. The diameter (d) of the plasma plume 312 emanating from the 0-degree nozzle 332 can be approximately 6.4 millimeters (±2%), understanding that the outer periphery or outer edge of the plasma plume 312 is fluid and therefore variable in nature. Thus, the plasma plume diameter (d) disclosed herein is an approximation but is generally constant when generated by the plasma device 310. Furthermore, the plasma plume 312 can have a height (h) ranging from approximately 1.2 centimeters to approximately 2.0 centimeters. Thus, the distance between the tip 338 of the nozzle 332 and the substrate surface 314 during plasma treatment can range from about 1.2 centimeters to about 2.0 centimeters during the plasma treatment process. In contrast, a 17-degree nozzle with a 17-degree ejection angle and rotating (typically at about 2800 rpm) during plasma treatment produces an annular plume with a plasma plume diameter of about 24 millimeters and a height of about 1.3 centimeters. Thus, a 0-degree nozzle 332 can have a larger working distance than a 17-degree nozzle, providing a plasma plume that is about four times more focused than the wider (more diffuse) annular plasma plume of the 17-degree nozzle. A larger working distance can facilitate treatment of substrates with complex geometries. Depending on the configuration of the 0-degree nozzle 332 and / or other factors, the diameter (d) and height (h) of the plasma plume can deviate from the values ​​described above.

[0040]

[0048] The intense plasma plume 312 generated by the 0 degree nozzle 332 can substantially reduce the plasma treatment time required to improve the bonding quality of the substrate surface compared to nozzles with ejection angles greater than 5 degrees.

[0041]

[0049] In one embodiment shown in Figures 8-9, the nozzle 328 is a 2-degree nozzle 340 with a discharge angle of approximately 2 degrees (±0.2%). In the 2-degree nozzle 340, the central axis 334 of the plume opening 336 is at a 2-degree angle relative to the central axis 330 of the nozzle. The 2-degree nozzle 340 can be rotated during plasma processing to provide an annular plasma plume that is slightly wider and more divergent than the plasma plume provided by the 0-degree nozzle 332. Nevertheless, the plasma plume provided by the 2-degree nozzle 340 is significantly more focused and intense than the plasma plume generated by a nozzle with a larger discharge angle. Therefore, similar to the 0-degree nozzle 332, the 2-degree nozzle 340 can enable shorter substrate processing times compared to nozzles with larger discharge angles.

[0042]

[0050] Furthermore, the present disclosure includes embodiments according to the following clauses.

[0043]

[0051] Article 1. first treating one or more surfaces of a metal matrix composite substrate; and The method includes, after said initial treating, applying an adhesion promoter layer onto said one or more surfaces of said metal matrix composite substrate.

[0044]

[0052] Article 2. 10. The method of claim 1, wherein the metal matrix composite substrate forms a portion of an aircraft.

[0045]

[0053] Article 3. 3. The method of claim 1 or 2, wherein the metal matrix composite substrate comprises a metal matrix and composite fibers.

[0046]

[0054] Article 4. 4. The method of any one of clauses 1 to 3, wherein the first treating comprises plasma treating.

[0047]

[0055] Article 5. 5. The method of any one of clauses 1 to 4, wherein said initially treating comprises laser ablation.

[0048]

[0056] Article 6. 6. The method of any one of clauses 1 to 5, wherein the adhesion promoter layer comprises one or more films of material.

[0049]

[0057] Article 7. 7. The method of any one of clauses 1 to 6, wherein the adhesion promoter layer comprises a sol-gel layer.

[0050]

[0058] Article 8. 8. The method of any one of clauses 1 to 7, wherein the adhesion promoter layer comprises a chromate conversion coating.

[0051]

[0059] Article 9. 9. The method of any one of clauses 1 to 8, further comprising, after applying the adhesion promoter layer, subsequently treating the metal matrix composite substrate having the adhesion promoter layer applied on one or more surfaces thereof.

[0052]

[0060] Article 10. 10. The method of clause 9, wherein the subsequently treating comprises painting.

[0053]

[0061] Article 11. 11. The method of any one of clauses 1 to 10, further comprising forming a thermal emitter using the metal matrix composite substrate.

[0054]

[0062] Article 12. plasma treating one or more surfaces of a metal matrix composite substrate, the metal matrix composite substrate comprising a metal matrix and composite fibers; applying an adhesion promoter layer onto the one or more surfaces of the metal matrix composite substrate after the plasma treating; and subsequently treating the metal matrix composite substrate having the adhesion promoter layer applied on one or more surfaces thereof after applying the adhesion promoter layer.

[0055]

[0063] Article 13. 13. The method of clause 12, wherein the metal matrix composite substrate forms a portion of an aircraft.

[0056]

[0064] Article 14. 14. The method of claim 12 or 13, wherein the adhesion promoter layer comprises one or more films of material.

[0057]

[0065] Article 15. 15. The method of any one of clauses 12 to 14, wherein the adhesion promoter layer comprises a sol-gel layer.

[0058]

[0066] Article 16. 16. The method of any one of clauses 12 to 15, wherein the adhesion promoter layer comprises a chromate conversion coating.

[0059]

[0067] Article 17. 17. The method of clause 16, wherein the subsequently treating comprises painting.

[0060]

[0068] Article 18. 18. The method of any one of clauses 12 to 17, further comprising forming a thermal emitter using the metal matrix composite substrate.

[0061]

[0069] Article 19. plasma treating one or more surfaces of a metal matrix composite substrate, the metal matrix composite substrate comprising a metal matrix and composite fibers; applying a sol-gel layer onto the one or more surfaces of the metal matrix composite substrate after the plasma treating; and after applying the sol-gel layer, painting the metal matrix composite substrate having the sol-gel layer applied on one or more surfaces.

[0062]

[0070] Article 20. 20. The method of clause 19, wherein the metal matrix composite substrate forms a portion of an aircraft.

[0063]

[0071] As described herein, several embodiments of the present disclosure provide efficient and effective methods for preparing the surface of metal matrix composites, and further provide methods for preparing the surface of metal matrix composites that do not adversely affect the bonding properties of the metal matrix composites.

[0064]

[0072] For purposes of describing the embodiments of the present disclosure, various spatial and directional terms may be used, such as top, bottom, lower, center, sideways, horizontal, vertical, front, etc., but it should be understood that such terms are used solely with reference to the orientations shown in the drawings. These orientations may be flipped, rotated, or otherwise changed so that top becomes bottom, bottom becomes top, horizontal becomes vertical, etc.

[0065]

[0073] As used herein, a structure, limitation, or element that is "configured to" perform an task or operation is structurally shaped, configured, or adapted specifically to correspond to the task or operation. For clarity and to avoid doubt, an object that can merely be modified to perform a task or operation is not "configured / set up to" perform a task or operation as used herein.

[0066]

[0074] It should be understood that the above description is intended to be illustrative, not limiting. For example, the above-described examples (and / or aspects thereof) can be used in combination with each other. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the various embodiments of the present disclosure without departing from the scope of the present disclosure. While the dimensions and types of materials described herein are intended to define aspects of the various embodiments of the present disclosure, the examples are by no means limiting, but are illustrative examples. Many other examples will be apparent to those skilled in the art upon reviewing the above description. The scope of the various embodiments of the present disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the accompanying claims and the detailed description herein, the words "including" and "in which" are used as the plain English equivalents of the words "comprising" and "wherein," respectively. Furthermore, terms such as "first," "second," and "third" are used merely as labels and are not intended to impose numerical requirements on their objects. Moreover, the limitations of the following claims are not written in means-plus-function form, and are not intended to be construed under 35 U.S.C. §112(f) unless such claim limitations expressly use the phrase "means for," followed by a statement of function lacking further structure.

[0067]

[0075] The description herein uses examples to disclose various embodiments of the present disclosure, including the best mode, and to enable any person skilled in the art to practice various embodiments of the present disclosure, including making and using any device or system and practicing any methods incorporated therein. The patentable scope of various examples of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims, or if the examples include equivalent structural elements that differ only insignificantly from the literal language of the claims.

Claims

1. first treating one or more surfaces (109, 314) of a metal matrix composite substrate (110); and After said initial treating, applying an adhesion promoter layer (108) onto said one or more surfaces (109, 314) of said metal matrix composite substrate (110).

2. The method of claim 1 , wherein the metal matrix composite substrate forms a portion of an aircraft.

3. The method of claim 1 , wherein the metal matrix (112) composite substrate (110) comprises a metal matrix (112) and composite fibers.

4. The method of claim 1 , wherein the first treating comprises plasma treating.

5. The method of claim 1 , wherein the first treating comprises laser ablation.

6. The method of claim 1 , wherein the adhesion promoter layer (108) comprises one or more films of material.

7. The method of claim 1 , wherein the adhesion promoter layer (108) comprises a sol-gel layer.

8. The method of claim 1 , wherein the adhesion promoter layer (108) comprises a chromate conversion coating.

9. 10. The method of claim 1, further comprising, after applying the adhesion promoter layer, subsequently processing the metal matrix composite substrate (110) having the adhesion promoter layer (108) applied on the one or more surfaces (109, 314).

10. 10. The method of claim 9, wherein the subsequent processing comprises painting.

11. The method of claim 1, further comprising forming a thermal emitter (204) using the metal matrix composite substrate (110).

12. plasma treating one or more surfaces (109, 314) of a metal matrix composite substrate (110), the metal matrix composite substrate (110) comprising a metal matrix (112) and composite fibers; applying an adhesion promoter layer (108) onto the one or more surfaces (109, 314) of the metal matrix composite substrate (110) after said plasma treating; and subsequently treating the metal matrix composite substrate (110) having the adhesion promoter layer (108) applied on the one or more surfaces (109, 314) after applying the adhesion promoter layer.

13. The method of claim 12 , wherein the metal matrix composite substrate (110) forms a portion of an aircraft (200).

14. The method of claim 12, wherein the adhesion promoter layer (108) comprises one or more films of material.

15. The method of claim 12 , wherein the adhesion promoter layer (108) comprises a sol-gel layer.

16. The method of claim 12, wherein the adhesion promoter layer (108) comprises a chromate conversion coating.

17. 13. The method of claim 12, wherein the subsequent processing comprises painting.

18. The method of claim 12, further comprising forming a thermal emitter (204) using the metal matrix composite substrate (110).

19. plasma treating one or more surfaces (109, 314) of a metal matrix composite substrate (110), the metal matrix composite substrate (110) comprising a metal matrix (112) and composite fibers; applying a sol-gel layer onto the one or more surfaces (109, 314) of the metal matrix composite substrate (110) after the plasma treating; and after applying the sol-gel layer, painting the metal matrix composite substrate (110) with the sol-gel layer applied on the one or more surfaces (109, 314).

20. The method of claim 19, wherein the metal matrix composite substrate forms a portion of an aircraft.

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