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J Mater Sci (2012) 47:8044–8051

DOI 10.1007/s10853-012-6694-6

The effect of surface modification with carbon nanotubes


upon the tensile strength and Weibull modulus of carbon fibers
Kimiyoshi Naito • Jenn-Ming Yang •

Yuta Inoue • Hiroshi Fukuda

Received: 19 March 2012 / Accepted: 20 June 2012 / Published online: 10 July 2012
Ó Springer Science+Business Media, LLC 2012

Abstract Carbon fibers are widely used as reinforce- The results also clearly show that for CNT-grafted and
ments in composite materials because of their high specific as-received PAN- and pitch-based carbon fibers, there is a
strength and modulus. Today, a number of ultrahigh linear relation between the Weibull modulus and the
strength polyacrylonitrile (PAN)-based (more than 6 GPa), average tensile strength on log–log scale.
and ultrahigh modulus pitch-based (more than 900 GPa)
carbon fibers have been commercially available. In con-
trast, carbon nanotube (CNT) with the extremely high Introduction
tensile strength have attracted attention as reinforcements.
An interesting technique to modify the carbon fiber is CNT Carbon fibers are widely used as reinforcements in com-
grafting on the carbon fiber surface. CNT-grafted carbon posite materials because of their high specific strength and
fibers offer the opportunity to add the potential benefits of modulus. Such composites have become a dominant
nanoscale reinforcement to well-established fibrous com- material in the aerospace, automotive, and sporting goods
posites to create micro-nano multiscale hybrid composites. industries [1]. Current trends toward the development of
In the present study, the tensile properties of CNT grown carbon fibers have been driven in two directions; ultrahigh
on T1000GB PAN- and K13D pitch-based carbon fibers tensile strength fiber with a fairly high strain to failure
have been investigated. Single filament tensile test at gauge (*2 %), and ultrahigh modulus fiber with high thermal
lengths of 1, 5, and 25 mm were conducted. The effect of conductivity. Today, a number of ultrahigh tensile strength
gauge length on tensile strength and Weibull modulus of PAN-based (more than 6 GPa), and ultrahigh modulus
CNT-grafted PAN- and pitch-based carbon fibers were pitch-based (more than 900 GPa) carbon fibers have been
evaluated. It was found that grafting of CNT improves the commercially available. Naito et al. [2, 3] characterized the
tensile strength and Weibull modulus of PAN- and pitch- tensile, flexural properties and Weibull modulus of ultra-
based carbon fibers with longer gauge length (C5 mm). high strength PAN-based, ultrahigh modulus pitch-based
and high ductility pitch-based single carbon fibers.
In contrast, carbon nanotube (CNT) with the extremely
K. Naito (&)  Y. Inoue
high tensile strength (*150 GPa) [4] has attracted atten-
Composite Materials Group, Hybrid Materials Unit, National
Institute for Materials Science, 1-2-1 Sengen, Tsukuba, tion as reinforcements, but they cannot grow as long,
Ibaraki 305-0047, Japan continuous fibers. Although it is possible to obtain twisted
e-mail: NAITO.Kimiyoshi@nims.go.jp CNT yam that are continuous fibers, this strength is
exceedingly low compared to the carbon fibers [5, 6]. An
J.-M. Yang
Department of Materials Science and Engineering, University of interesting technique to modify the carbon fiber is CNT
California Los Angeles, Los Angeles, CA 90095-1595, USA grafting on the carbon fiber surface. The grafting of CNT
on carbon fibers has been reported in the literature [7–9].
Y. Inoue  H. Fukuda
CNT can be grown on the carbon fibers by chemical vapor
Department of Materials Science and Technology, Tokyo
University of Science, 2641 Yamazaki, Noda, Chiba 278-8510, deposition (CVD) [7, 8], electrodeposition [9], etc. CNT-
Japan grafted carbon fibers offer the opportunity to add the

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potential benefits of nanoscale reinforcement to well- The physical properties of PAN- and pitch-based carbon
established fibrous composites to create micro-nano mul- fibers are listed in Table 1. Both as-received fibers had
tiscale hybrid composites [9–11]. However, the effect of been subjected to commercial surface treatments and sizing
CNT grafting on the mechanical properties of carbon fiber (epoxy compatible sizing).
has not been fully evaluated. Naito et al. [12] reported that To grow CNT on the carbon fibers, a Fe(C5H5)2 (fer-
the grafting of CNT improves the tensile strength and rocene) catalyst was applied to the T1000GB and K13D
Weibull modulus of ultrahigh strength PAN- and ultrahigh fiber bundles using thermal CVD in vacuum. Experimental
modulus pitch-based carbon fibers. The growth of the details on the synthesis technique of CNT can be found
dense networks of CNT on carbon fibers may lead to elsewhere [7, 8]. Prior to the application of the catalyst, the
reduction of the strength-limiting defects, which in turn, carbon fiber bundles were heat-treated at 750 °C for an
improves the tensile strength and Weibull modulus [12]. hour in vacuum to remove the sizing. The growth tem-
To evaluate the effect of gauge length on the tensile perature and time for the deposition of CNT were selected
strength is essentially important for understanding the as 750 °C (T1000GB) and 700 °C (K13D) for 900 s.
mechanical properties of the carbon fibers that contribute to
failure. The effects of gauge length on tensile properties of Tensile test
carbon fibers have been reported in the literature [13–15].
Naito et al. also reported that the effect of gauge length on Single carbon filament specimens were prepared on the
tensile strength and Weibull modulus of PAN- and pitch- stage with the help of a stereoscope. A single filament was
based carbon fibers, and concluded that the Weibull mod- selected from carbon fiber bundles and cut perpendicular to
ulus and the average tensile strength increased with the fiber axis by a razor blade. The diameter of the single
decreasing gauge length, a linear relation between the as-received carbon fiber, df was measured using a laser
Weibull modulus, the average tensile strength, and the scanning microscope (Lasertec Corp., 1LM15 W) before
gauge length was established on log–log scale [16]. These testing and a high resolution scanning electron microscope
results also clearly showed that for PAN- and pitch-based (JEOL, JSM-6500F) during the fractured surface observa-
carbon fibers, there was a linear relation between the tion. No difference was observed between two techniques.
Weibull modulus and the average tensile strength on log– The diameter of the single CNT-grafted carbon fiber
log scale [16]. without CNT, df was measured using a high resolution
In the present study, the tensile tests of single filaments scanning electron microscope (JEOL, JSM-6500F) during
at several gauge length for CNT-grafted ultrahigh strength the fractured surface observation. The measured fiber
PAN- and ultrahigh modulus pitch-based carbon fibers diameters, df are shown in Table 1 (average diameters and
were performed. The effect of gauge length on tensile standard deviations are obtained from the same kind of all
strength and Weibull modulus of CNT-grafted PAN- and carbon fibers at various gauge lengths). All specimens were
pitch-based carbon fibers were evaluated. stored in a desiccator at 20 ± 3 °C and at 10 ± 5 % rel-
ative humidity prior to testing.
Tensile tests of single carbon fibers were performed
Experimental procedure using a universal testing machine (Shimadzu, Table top
type tester EZ-Test) with a load cell of 10 N. The tensile
Materials specimen was prepared by fixing the filament on a paper
holder with an instant high viscosity type cyanoacrylate
The carbon fibers used in this study were ultrahigh tensile adhesive, as reported elsewhere [17, 18]. The specimen
strength T1000GB PAN- and ultrahigh modulus K13D was set up to the testing machine using active gripping
pitch-based carbon fibers.1 The T1000GB PAN-based systems. To allow for ease of severing of the paper holder
carbon fiber was supplied from Toray Industries, Inc. The and to avoid the fracture during gripping of the shorter
K13D pitch-based carbon fiber was supplied from Mitsu- length samples (L = 1 and 5 mm), a scalpel was used to
bishi Plastics, Inc. widen the slot [14]. The holder was cut into two parts,
before testing. Plastic films were set on both sides of the
1 carbon fiber filament, and water was filled between them to
The cross-sections of the T1000GB PAN-based and the K13D
pitch-based carbon fibers are almost circular. The T1000GB fiber has avoid secondary damage of the carbon fiber. The gauge
a particulate or granular microstructure. The K13D fiber has a sheet- length, L of 1, 5, and 25 mm, and crosshead speed of
like microstructure. The fractured surfaces of the T1000GB PAN- 0.5 mm/min were applied. All tests were conducted under
based carbon fiber show the initiation of failure from surface defects
the laboratory environment at room temperature (at
and a rough, rather poorly defined granular texture. However, the
K13D pitch-based fiber obscures the initiation of failure and observes 23 ± 3 °C and 50 ± 5 % relative humidity). Twenty
the crystallite sheets are a result of pull out at failure [2, 3, 12]. specimens were tested for all carbon fibers. The fracture

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8046 J Mater Sci (2012) 47:8044–8051

Table 1 Mechanical and physical properties of ultrahigh strength T1000GB PAN- and ultrahigh modulus K13D pitch-based carbon fibers
Fiber Gauge length L (mm) PAN-based Pitch-based
T1000GB K13D
T1000GB-12000-40D K13D2U
b
As-received CNT-grafted As-receivedb CNT-grafted
a
Filaments (Count) 12000 – 2000 –
a
Yield (Tex) (g/1000 m) 485 – 365 –
  
Densitya q g cm3 1.80 – 2.20 –
Average tensile strength rf:ave ðGPaÞ 1 8.98 (0.80) 8.97 (0.80) 5.12 (0.85) 5.16 (0.87)
5 7.71 (0.88) 8.23 (0.84) 4.00 (0.82) 4.65 (0.84)
12.5 6.27 (0.98) – 3.64 (0.87) –
25 5.69 (1.02) 6.73c (1.01) 3.21 (0.81) 4.09c (0.85)
50 5.03 (0.90) – 3.20 (0.86) –
100 4.81 (0.88) – – –
250 4.46 (0.84) – – –
Diameter df (lm) 5.06 (0.22) 5.06 (0.24) 11.68 (0.63) 11.65 (0.67)
Values in braces indicate standard deviations
T1000GB Catalog for TORAYCA, Toray Industries, Inc., High performance carbon fiber Torayca in Japanese. 2004, K13D catalog for
DIALEAD, Mitsubishi Plastics, Inc., High performance coal tar pitch carbon fiber. 2009
a
Producer’s data sheet
b
Single filament tensile data from previous investigation [2, 16]
c
Single filament tensile data (25 mm gauge length) from previous investigation [12]

surfaces of these carbon fibers were examined using a high remained for the CNT-grafted K13D fiber. Morimoto et al.
resolution scanning electron microscope (JEOL, JSM- indicated the gauge length dependence on the Weibull
6500F) at an operating voltage of 5 kV. parameters of the silicon carbide (SiC: Tyranno ZMI
Si–Zr–C–O) fiber provided biased estimation and classified
the fracture surfaces into the characteristic fracture patterns
[19]. In this study, however, the fracture pattern differences
Results
among the all gauge lengths for PAN- and pitch-based
carbon fibers were not observed and it was difficult to
For all the carbon fibers, the stress applied to the specimen
classify the fracture surfaces of all carbon fibers into the
was linearly proportional to the strain until failure. The
characteristic patterns.
tensile fracture surfaces of the CNT-grafted and
The tensile strength, rf was calculated using:
as-received T1000GB PAN- and K13D pitch-based carbon
fibers at gauge length of 25 mm were showed in our Pmax
rf ¼ pd2  ; ð1Þ
previous report [2, 12] and the fracture surfaces of the 4
f

CNT-grafted and as-received T1000GB PAN- and K13D


pitch-based carbon fibers at gauge lengths of 1 and 5 mm where Pmax is the maximum fracture load.
were also observed in this study. Figures 1 and 2 show the The average tensile strengths (rf.ave) at various gauge
scanning electron microscope (SEM) micrographs of length are summarized in Table 1 and the relation between
transverse cross-sectional views for the tensile fractured the enhancing ratio, ((rf.ave (CNT-grafted) - rf.ave (as-received))/
surfaces of the CNT-grafted and as-received T1000GB rf.ave (as-received)*100) and the gauge length, L ranging from
PAN-based and K13D pitch-based carbon fibers at gauge 1 to 25 mm was shown in Fig. 3. These results show that
lengths of 1, 5 and 25 mm. The failure initiation sites were the average tensile strength of CNT grown on ultrahigh
clearly observed for the CNT-grafted and as-received strength T1000GB fiber at gauge length of 1, 5, and 25 mm
T1000GB fibers and the some of CNT were lost for the is 8.97 ± 0.80, 8.23 ± 0.84, and 6.73 ± 1.01 GPa [12],
CNT-grafted T1000GB fibers due to impact of fracture of which is 0, 7, and 18 % higher than that in the as-received
fiber. However, for the K13D carbon fiber, the failure state (8.98 ± 0.80, 7.71 ± 0.88, and 5.69 ± 1.02 GPa [2,
initiation sites were obscured for the CNT-grafted and 12, 16]). The average tensile strength of CNT grown on
as-received K13D fibers and the almost CNT were K13D fiber at gauge length of 1, 5, and 25 mm is

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Fig. 1 SEM micrographs of the tensile fractured surfaces showing 5 mm (high magnification), e CNT-grafted fiber at gauge length of
the transverse cross-section views of CNT-grafted and as-received 25 mm [12], f CNT-grafted fiber at gauge length of 25 mm (high
T1000GB PAN-based carbon fibers at gauge lengths of 1, 5 and magnification), g as-received fiber at gauge length of 1 mm [16],
25 mm. a CNT-grafted fiber at gauge length of 1 mm, b CNT-grafted h as-received fiber at gauge length of 5 mm [16], and i as-received
fiber at gauge length of 1 mm (high magnification), c CNT-grafted fiber at gauge length of 25 mm [2, 12, 16]
fiber at gauge length of 5 mm, d CNT-grafted fiber at gauge length of

5.16 ± 0.87, 4.65 ± 0.84, and 4.09 ± 0.85 GPa [12], i


PF ¼ ; ð3Þ
which is 1, 16, and 27 % higher than that in the as-received nþ1
state (5.12 ± 0.85, 4.00 ± 0.82, and 3.21 ± 0.81 GPa
where i is the number of fibers that have broken at or below
[2, 12, 16]). Evidently, the grafting of CNT improved the
a stress level and n is the total number of fibers tested.
average tensile strength of PAN- and pitch-based carbon
Rearrangement of the two-parameter Weibull statistical
fibers at gauge lengths of 5 and 25 mm. However, the
distribution expression (Eq. 2) gives the following:
average tensile strength of CNT-grafted PAN- and pitch-
based carbon fibers at gauge length of 1 mm is almost 
  m1 !
1   L0 f
identical to that in the as-received state. ln ln ¼ mf ln rf  mf ln r0 : ð4Þ
1  PF L
The results shown in Table 1 clearly indicate that there
is an appreciable scattering of tensile strength for these Hence the Weibull modulus, mf can be obtained by
carbon fibers. The statistical distribution of fiber strengths linear regression from a Weibull plot of Eq. (4).
is usually described by means of the Weibull equation [20]. Figure 4 shows the Weibull plots of CNT grown on
The two-parameter Weibull distribution is given by ultrahigh tensile strength T1000GB PAN- and ultrahigh
 
tensile modulus K13D pitch-based carbon fibers. A
L rf mf
PF ¼ 1  exp  ; ð2Þ threshold of the tensile strength was observed. The influ-
L0 r0
ence of threshold stress on the estimation of the Weibull
where PF is the cumulative probability of failure of a statistics was discussed by Lu et al. [21, 22]. It was con-
carbon fiber of length L at applied tensile strength rf, mf is cluded that the two-parameter Weibull distribution is still a
the Weibull modulus (Weibull shape parameter) of the preferred choice, if test specimens are limited in number
carbon fiber, r0 a Weibull scale parameter (characteristic and threshold stress is not too large. As a result, the two-
stress), and L0 a reference gauge length. The cumulative parameter Weibull distribution was applied in this study.
probability of failure, PF, under a particular stress is The Weibull modulus, mf, for the CNT grown on
given by T1000GB and K13D fibers at gauge lengths of 1, 5, and

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Fig. 2 SEM micrographs of the tensile fractured surfaces showing (high magnification), e CNT-grafted fiber at gauge length of 25 mm
the transverse cross-section views of CNT-grafted and as-received [12], f CNT-grafted fiber at gauge length of 25 mm (high magnifi-
K13D pitch-based carbon fibers at gauge lengths of 1, 5 and 25 mm. cation), g as-received fiber at gauge length of 1 mm [16],
a CNT-grafted fiber at gauge length of 1 mm, b CNT-grafted fiber at h as-received fiber at gauge length of 5 mm [16], and i as-received
gauge length of 1 mm (high magnification), c CNT-grafted fiber at fiber at gauge length of 25 mm [2, 12, 16]
gauge length of 5 mm, d CNT-grafted fiber at gauge length of 5 mm

5.86 and 6.38, 5.24, 4.23, respectively [2, 12, 16]. The
results clearly show that the grafting of CNT improves the
Weibull modulus of PAN- and pitch-based carbon fibers at
gauge lengths of 5 and 25 mm. However, the Weibull
modulus of CNT-grafted PAN- and pitch-based carbon
fibers at gauge length of 1 mm is almost identical to that in
the as-received state as well.
The Weibull modulus (mf) of PAN- and pitch-based
carbon fibers at various gauge lengths were summarized in
Table 2.

Discussion

The grafting of CNT improved the tensile strengths and


Weibull modulus of T1000GB PAN- and K13D pitch-
based carbon fibers at the gauge length of 5 and 25 mm
Fig. 3 Relation between the enhancing ratio and the gauge length for (longer gauge length). However, the tensile strengths and
T1000GB PAN- and K13D pitch-based carbon fibers Weibull modulus of the CNT grafted T1000GB PAN- and
K13D pitch-based carbon fibers were almost similar to
25 mm were calculated to be 11.92, 10.44, 7.15 [12], and those in the as-received state at the gauge length of 1 mm
6.38, 5.75, 5.09 [12], respectively. The Weibull modulus, (shorter gauge length). It is important to evaluate the
mf, for the T1000GB and K13D fibers with sizing at gauge ‘‘true’’ improvement of the CNT-grafted PAN- and pitch-
lengths of 1, 5 and 25 mm were found to be 11.92, 9.24, based carbon fibers. However, it is difficult to estimate the

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effect of CNT grafting is observed in the surfaces and flaws


(surface and internal) of both carbon fibers which are
related to the lower tensile strengths of both fibers. The
grafting of CNT helps to reduce the lower strength (the
threshold strength) which is observed in the longer gauge
length. As a result, the average tensile strengths of both
carbon fibers increase and the strength distributions
decrease (the Weibull modulus is strongly related to the
strength distribution and the Weibull modulus increase). In
the shorter gauge length, the almost tensile strengths of
both carbon fibers observe in higher stress levels (more
than the threshold strengths of both fibers) which are
strongly related to the potential (ideal) strengths of both
carbon fibers. Therefore, the effect of grafting CNT is
disappeared and, the average tensile strengths, the strength
distributions (the Weibull modulus) of the CNT grafted on
both carbon fibers are almost similar to those in the
as-received state.
In our previous investigation [16], it was found that
when the gauge length of as-received T1000GB PAN- and
K13D pitch-based carbon fibers is less than 100 mm, the
Weibull modulus and the average tensile strength increased
with decreasing gauge length. Also, there is a linear rela-
tion between the Weibull modulus, the average tensile
strength and the gauge length on log–log scale. For the
CNT-grafted T1000GB PAN- and K13D pitch-based car-
bon fibers, there is also a linear relation between the
Weibull modulus, the average tensile strength and the
gauge length on log–log scale. Thus, the Weibull modulus
and the average tensile strength is given by
 a
L
mf ¼ ð5Þ
L0
  1
L0 mf
rf:ave ¼ r0 ð6Þ
L
where, L0, a and m*f are the characteristic length, the length
Fig. 4 Weibull plots for T1000GB PAN- and K13D pitch-based factor of Weibull modulus and the Weibull modulus
carbon fibers at gauge lengths of 1, 5 and 25 mm. Open circle 1-mm (Weibull shape parameter) obtained from the tensile
gauge length, open triangle 5 mm gauge length, open diamond strength versuss the gauge length relations.
25-mm gauge length as-received carbon fibers, and filled circle 1-mm
gauge length, filled triangle 5-mm gauge length, filled diamond From Eqs. (5) and (6), the Weibull modulus is modified
25-mm gauge length CNT-grafted carbon fibers. a T1000GB PAN-   

and b K13D pitch-based carbon fiber


rf:ave amf
mf ¼ : ð7Þ
r0
‘‘true’’ improvement of the CNT-grafted carbon fibers Rearrangement of the Eq. (7) gives the following:
quantitatively.
lnðmf Þ ¼ a  mf lnðrf:ave Þ þ a  mf lnðr0 Þ: ð8Þ
It is considered that the characters of PAN- and pitch-
based carbon fibers are difficult to change in this CVD Hence, there is a linear relation between the Weibull
process (maximum temperature is 750 °C) because both modulus, mf and the average tensile strength, rf.ave on log–
the carbon fibers are heat-treated at more than 1000 °C log scale and this relation can be obtained from
during the producing process and are relatively thermal experimental data.
stable materials in an inactive atmosphere. The potential Figure 5 shows the relation between the Weibull mod-
(ideal) strengths of both carbon fibers are not changed. The ulus, mf and the average tensile strength, rf.ave of the

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Table 2 Weibull modulus of T1000GB PAN-based and K13D pitch-based carbon fibers at various gauge lengths
Fiber Gauge length L (mm) PAN-based Pitch-based
T1000GB K13D
As-receiveda CNT-grafted As-receiveda CNT-grafted

Weibull modulus mf 1 11.92 11.92 6.38 6.38


5 9.24 10.44 5.24 5.75
12.5 6.79 – 4.63 –
25 5.86 7.15b 4.23 5.09b
50 5.78 – 3.99 –
100 5.72 – – –
250 5.67 – – –
a
Single filament tensile data from previous investigation [2, 16]
b
Single filament tensile data (25 mm gauge length) from previous investigation [12]

CNT-grafted and as-received T1000GB PAN- and K13D This means that the high strengths of both carbon fibers
pitch-based carbon fibers. The results clearly show that for cause the narrow strength distributions. It is important to
both types of carbon fibers, the Weibull modulus increased consider this phenomenon. In the longer gauge length, the
with increasing the average tensile strength. It is evident surfaces (features and modifications) and the flaws (surface
that there is a linear relation between the Weibull modulus and internal) of both carbon fibers strongly depend on the
and the average tensile strength of the CNT-grafted and tensile strengths of both carbon fibers. The strength dis-
as-received PAN- and pitch-based carbon fibers on log–log tributions of both carbon fibers are varied from the lower
scale. (related to the surfaces and flaws) to the higher stress
(related to the potential strength) levels. Therefore, the
average tensile strengths and the Weibull modulus of both
carbon fibers become lower value. However, in the shorter
gauge length, it is difficult to observe the lower tensile
strengths of both carbon fibers because the effect of sur-
faces and flaws on the tensile strengths becomes small. The
almost tensile strengths of both carbon fibers observe in the
higher stress level and the strength distributions of both
carbon fibers become narrow. As a result, the average
tensile strengths and the Weibull modulus of both carbon
fibers become higher value.
A potential mechanism for enhanced tensile strength at
longer gauge length is thought to be the three-dimensional
network structures of CNT. Figure 6 shows the schematic
model of CNT-grafted carbon fiber filament. The growth of
the dense networks of CNT on carbon fibers lead to
reduction of the strength-limiting defects. Especially, the
grafting of CNT healed the flaws (surface and internal) that
relate to lower tensile strength. In addition, it is highly
possible that the growth of CNTs on the fibers could
change the slippage regions to shorten effective gauge
Fig. 5 Relation between the Weibull modulus and the average tensile length. These effects were similar to that of gauge length
strength of the CNT-grafted and as-received T1000GB PAN-based on tensile strength for as-received carbon fibers. The
and K13D pitch-based carbon fibers. Open square as-received fracture behaviors of CNT-grafted carbon fiber at longer
T1000GB PAN-based, open diamond as-received K13D pitch-based
carbon fibers, and filled square CNT-grafted T1000GB PAN-based,
gauge length could be seen as that of as-received
filled diamond CNT-grafted K13D pitch-based carbon fibers. (ungrafted) carbon fiber at shorter gauge length, which in
-am*f = 1.23 (T1000GB) and 0.94 (K13D) turn, improves the tensile strength and Weibull modulus.

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J Mater Sci (2012) 47:8044–8051 8051

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Acknowledgements This study was supported by JSPS (Japan 18. Sung MG, Sassa K, Tagawa T, Miyata T, Ogawa H, Doyama M,
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(Japan Science and Technology Agency) through Advanced Low S0008-6223(02)00059-3
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