Carbon Fibres Snigdha ChakrabortyIndex ® Introduction of carbon fibre ® Production of carbon fibre ® Process diagram of production ® Fibre morphology ® Properties- physical, chemical, biological properties ® Carbon composites ® Uses ® Future scopeWhat is carbon fibre? Carbon fiber, also called graphite fibre is basically very thin strands of carbon, consisting of strong crystalline regions within the fibre. It is very well oriented carbon atoms. Diameter of carbon fibre is 5-10 jim. They can be either drawn as carbon filaments or cut at equal Jengths to form carbon staple fibres. They can also be twisted together to form carbon rovings. The carbon rovings are measured by the no. of strands of carbon hair in each roving. The most commonly available ones are 3K (3000 strands in a roving), 5K, 10K, 12K.(T-B) 50K ribbon, 10K, 6K, 3K Or-leeolam lees) oy Raw Materials: The raw material used to make carbon fiber is called the precursor, About 90% of the carbon fibers produced are made from polyacrylonitrile (PAN). The remaining 10% are made from rayon or petroleum pitch. Zoltek, a hungarian company is world’s largest producer of carbon fibreCARBON FIBERS FROM POLYACRYLONITRILE (PAN) On een acre lees elle oe Mela 1) er a Lee ecole into high-performance carbon fibers. 1) Oxidation stabilization: The PAN precursor is first stretched and drawn into long strands of fibers and simultaneously oxidized in a temperature range of 200-300°C which results in stabilization, meaning the fibre changes from thermoplastic to non plastic. 2) CARBONIZATION: Then itis heated at 1000 °C (without oxygen) in nitrogen for a few hours. Without oxygen the fiber cannot burn. Instead, the high temperature causes the atoms in the fiber to vibrate violently until most of the non-carbon atoms are expelled. 3) GRAPHITIZATION: Depending on the type of fiber required, the fibers are treated at temperatures between 1500-3000°C, which improves the ordering, and orientation of the crystallites in the direction of the fiber axis.PAN PROCESS PAN THERMOSET Pic Process 200-300°C 1000 C 1100° C to PITCH PROCESS , 3000° C EPOXY SIZING SURFACE TREATMENTCARBON FIBERS FROM PITCH Carbon fiber fabrication from pitch generally consists of the following Balt aest- 101i SOs iea eee) erelealCelera SAL nie (| PicLUaT eM Ole UTM el The coated fibers are wound onto cylinders called bobbins. The bobbins cleo Mi nl ml Me (exct cre olay earn areFibre Morphology Certefolami comes microscope. Itis entirely a mass of carbon atoms. The small pores are created during carbonization when the other components present in PAN are vaporized.Fibre morphology depends on: 1) Degree of polymerization Pa evag ier ye= |g) 3) Draw ratio 4) Orientation be S Oia -it-]| lo e-la lo} amorphous region And these factors are all interrelated Here in the picture, we can see the atomic structure of carbon fibre, By increasing the setting temperature gradually, the orientation of fibres (or Ta el -ael C1 g-0] The crystalline region is increasing in the fibre gradually and amorphous is decreasing.Physical properties ® 1) Tensile Strength- is the maximum stress that a material can withstand while being stretched or pulled before breaking. @ Carbon fibre has a tensile strength of 4137 MPa compared to normal steel's 2693 Mpa. And carbon nanotube’s 11000-13000 Mpa. ® Carbon fiber (Toray T1000G)(the strongest man-made fibres) has 6370 Mpa /fibre . 2) Weight — light weight Carbon Fiber has High Strength to Weight Ratio (also known as specific strength) which is 2457 kN.m/kg, glass has 1307 and steel 254. 3) Elasticity- Elasticity is very poor as carbon is a very rigid fibre. Hence young's modulus is high. For carbon it’s 180 compared to.0.01-0.1 of fiVls)otne @ 4) Dimensional stability- Very stable dimensionally. Hence used as composites to make spare parts of missiles, automobiles, aircrafts, etc.5) Fineness- of carbon fibre is 5-10 micrometer, where as that of carbon roving is given in the following chart. Renee A CR Ac eet an le eel CCIM Uy oven dry weight of the material express in percentage. For carbon alc -te ROR U a= kr elm) Ma an eae 7) Thermal property- a measure of how easily heat flows through a material. Carbon has fairly good thermal conductivity. Carbon Fiber Reinforced Epoxy has 24, carbon steel is 54. Air is 0.025, Aluminium has the highest 250.8 Electrical property- Carbon fibre is electrically conductive. Nanotubes of carbon are used as high conducting materials. 9) Fire retardance- As carbon is chemically inert, it does not get affected by flame. Can be use to make flame retardant jackets. 10)Affect of oxidation and chemicals- Carbon fiber is Corrosion Resistant and Chemically Stable. 11) Non Poisonous, Biologically Inert, X-Ray Permeable- These quality make Carbon fiber useful in Medical applications. Prosthesis use, implants and tendon repair, x-ray accessories surgical instruments, are all in development. Although not poisonous, the carbon fibers can be quite irritating and long term unprotected exposure needs to be Tinie 12) Low Coefficient of Thermal Expansion- This is 4 measure of how much a material expands and contracts when the temperature goes up or down. Units are in Inch / inch degree F. For carbon fibre it's <2, for keviar <3, Aluminium it is 13.13) Dye ability- carbon fibres are not dyeable. 14) Carbon fibre is brittle- The layers in the fibers are formed by strong covalent bonds. They readily allow the propagation of cracks. Carbon fibre does not bend much before failing, the reason being their high young’s modulus. CARBON FIBRES COMPOSITES: Carbon fibres are very expensive. Hence glass or Aramid fibres are used while weaving a matrix or mesh fabric. These are called carbon composites. The composite of glass n carbon is called FIBREGLASS Some properties of carbon fibres and their applications are given in the aoe1. Physical strength, toughness, light ight 2. High dimensional stability and low Aerospace, road and marine transport, sporting goods Missiles, aircraft brakes, aerospace antenna ind support structure, large telescopes, optical enches, waveguides for stable high-frequency (GHz) precision measurement frames 3. Good vibration damping, strength, land toughness Audio equipment, loudspeakers for Jequipment, pickup arms, robot arms 4. Electrical conductivity \utomobile hoods, novel tooling, casings and ases for electronic equipments 5. Biological inertness and x-ray permeability 6. Fatigue resistance, self-lubrication, high damping . Chemical inertness, high corrosion resistance Electromagnetic properties Medical applications in prostheses, surgery and -ray equipment, implants, tendon/ligament Textile machinery, genera engineering Chemical industry; nuclear field; valves, seals, jand pump components in process plants Large generator retaining ring: equipmentmy ce) Bo} 8 ee co ae a= (iS) , x Carbon tubesCarbon fiber-reinforced polymer, carbon fiber-reinforced plastic or carbon fiber— reinforced thermoplastic (CFRP, CRP, CFRTP), is an extremely strong and light fiber-reinforced plastic which contains eT elelp lei Carbon-fiber-reinforced polymers are composite materials. They consists of two Peo Murtha Le eM ccll (elgecinnl carbon fiber, which provides the strength. The matrix is usually a polymer resin, such as epoxy, to bind the reinforcements together. Carbon nano-tube reinforced polymer (CNRP) In 2009, Zyvex Technologies introduced carbon nanotube-reinforced epoxy and carbon prepregs. (CNRP) is several times stronger and tougher than CFRP and was used in the Lockheed Martin F-35 Lightning emcee Ucar cial elm l cere LiApplication of carbon composites ori) engineering cai Automotive engineering Aerospace iP es | iid —————— (or Tolan ols SBullecers\tstetcers os iCarbon fiber market share by company Mitsubishi Zoltek2 a @ 2 & 758 Trends and Forecast in Carbon Fiber Shipment ‘Consumption in milion tbs wen, Consumption in million Ibs 2004 2008, Industrial ‘Automotive Wind Energy Fuel cellg E = Z z & 5 2 2 x : 3 2 > z Ez & © ® © $20 SLO 1988 1990 Enters Industrial Market UseThank you