Method and system for corrosion-resistant fastening of carbon fiber and metal structures

A method for joining a carbon fiber structure and aluminum to guard against galvanic corrosion, the method comprising:

• arranging sheets of carbon fiber and sheets of fiberglass into a stack such that edge regions of the sheets of carbon fiber and edge regions of the sheets of fiberglass overlap in an alternating arrangement, wherein a region of the stack where the sheets of carbon and the sheets of fiberglass overlap is a transition band, a region of the stack where the sheets of fiberglass extend a first direction away from the transition band is an edge band, and a region of the stack where the sheets of carbon fiber extend a second direction away from the transition band is a primary band, wherein the first direction is opposite the second direction;
• curing the stack into a single rigid part;
• and
• mechanically attaching the edge band of the single rigid part to the aluminum such that the primary band and the transition band are separated from the aluminum by the edge band.

An apparatus comprising:

• a composite structure comprising:
• a primary band comprising cured composite carbon fiber or composite graphite,
• a transition band comprising alternating layers of fiberglass and the cured composite carbon fiber or the composite graphite, and
• an edge band comprising the fiberglass and absent any of the composite carbon fiber or the composite graphite;
• and
• an aluminum structure mechanically attached to the edge band or forming a butt joint with the edge band.