Metal Replacement in Aeronautics Applications Using Two‐Dimensional Multifunctional Composites

Carbon-based composites have replaced metals in many structural components of modern airplanes; however, functional applications still require metal conductors and devices. Here, the production and integration in small-scale airplane parts of electric devices based on metal-free layered composites of graphene, boron nitride, and polymers are described. Thanks to their two-dimensional structure, these materials feature excellent tunable thermoelectrical properties and high flexibility. We describe the production and performance of heaters and ice sensors installed on scaled NACA-0012 airfoils to avoid ice formation, to remove ice or to detect the ice on the outer skin of the airfoil. We demonstrate that we can tune the electrical conductivity of the composite heating element from 105 to 103 S m−1 that is preserved even after 1000 bending cycles. The heaters successfully achieve anti-icing and deicing in representative icing conditions and can sustain high-power densities as required for electrothermal ice-protection systems in aviation. The composite material can be readapted into a sensor able to detect ice formation in real time in an icing wind tunnel. Moreover, the possibility to use the heaters developed as heating molds to cure composite materials by out-of-oven curing, with a significant energy saving potential, is demonstrated.