A galvanic corrosion-resistant carbon fiber-reinforced metal laminate (CFML) is created in this paper. Aluminum alloy 2024-T3 is selected as the metal layer. A surface treatment method of composite coating combining a sulfuric acid anodizing with a hybrid sol-gel coating for the aluminum alloy is developed. This composite coating is used to prevent CFML from galvanic corroding. Electrochemistry tests are conducted to evaluate the properties of electrochemistry of aluminum alloy treated by the present method. The test results prove that the composite coating can provide good protection for CFML against the galvanic corrosion. CFML consisting of carbon fiber-reinforced epoxy layer and the aluminum alloy sheet with composite coating is fabricated by autoclave cure processing. The cross-section of CFML is analyzed by scanning electron microscope (SEM) and electron probe micro analyzer (EPMA). Good thin interlayer consisting of composite films is formed between the aluminum alloy and carbon fiber-reinforced epoxy layer. Corrosion tests of CFML with and without composite coating are conducted and the CFML with composite coating shows excellent corrosion resistance.
