First

carbon fibers are made by pyrolizing Polyacrylo-nitrile (PAN) fibers Pyrolized fibers then woven into the desired pattern Spaces between the fibers are filled by Chemical Vapor Deposition (CVD) & Infiltration process
Carbon matrix deposition Carbon reinforcement

 Liquid

Phase Infiltration process Chemical Vapor Deposition process

Polymer or Pitch Binder

Carbon Fiber Cured Carbon/Resin Part

Carbonization (up to 1000 oC)

Impregnation by Gas or Liquid

Graphitization 2500-3000 oC

Carbon/Carbon Composite 2500-3000 oC

Preparation of carbon/Graphite fiber preform of the desired structure and shape

Infiltration of the preform with a liquid precursor: petroleum pitch/phenolic resin/coal tar.

Pyrolysis/carbonization (chemical decomposition by heat in the absence of Oxygen) of the polymer precursor at 1000-1830F (5381000C) under normal or high pressure.

Infiltration pyrolysis cycle is repeated several (3-10) times until the desired density is achieved.

Graphitization heat treatment. At this stage amorphous carbon is transformed into crystalline graphite. The temperature of the treatment may vary within the range 2700-5400F (1500-3000C). Typical graphitization temperature is 4530F (2500C). Graphitization of carboncarbon composites results in increase of Modulus of Elasticity andstrength of the composite.

Preparation of carbon/Graphite fiber preform of the desired structure and shape

Densification of the composite by Chemical Vapor Deposition (CVD) technique. The CVD process involves infiltration of the preform with a pressurized hydrocarbon gas (propane, methane, propylene, acetylene, benzene) at 1800-2200F (982-1204C). The gas is pyrolyzed forming carbon deposition on the fiber surface. The process duration is determined by the thickness of the preform, through which the gas diffuses.

Graphitization heat treatment. At this stage amorphous carbon is transformed into crystalline graphite. The temperature of the treatment may vary within the range 2700-5400F (15003000C). Typical graphitization temperature is 4530F (2500C). Graphitization of carbon-carbon composites results in increase of Modulus of Elasticity and strength of the composite.

The invention relates to find the field of high temperature composites made by the chemical vapoure infilteration and deposition of a bonding matrix within a porous structure.
More perticularly the invention relates to high pressure gradient processes for forcing a infiltration of reactant gas in to a porous structure. Chemical vapoure infilteration and deposition is a well known process for depositing binding matrix within in a porous structure.

The technique particularly suitable for fabricating high temperature structural composites by depositing ceramic matrix within a ceramic porous structure resulting in a very use full structure such as carbon/carbon AIR BRAKE DISC AND TURBINE COMPONENTS. The generally CVD/CVI process are classified 4 types 1.Isothermal process 2. thermal gradient process 3. pressure gradient process 4. pulsed flow process

in a pressure gradient CVI/CVD process, A fibre preform is placed in a gas tight unit and heated.

the reactant gas is forced to flow through the porous structure by inducing a pressure gradient from one surface of the porous structure to an opposing surface of porous structure.
The flow rate of reactant gas is greatly increased relative to the iso-thermal and thermal gradient process which results in increased deposition rate of the binding matrix.

This process also known as forced-flow CVI/CVD. Pressure gradient CVI/CVD tend to become complex, expensive and difficult to implement for densifying large quantities of porous structure.

These are the plastics which can be reheated and reformed into new shapes for an number of times without significant change in their properties .

Thermoplastics consists of very long main chain of carbon atoms which are covalently bonded together.
Plastic materials have relatively low density. The tensile strength of the plastics are relatively low.

Thermosetting plastics will be formed into permanent shapes and set by a chemical reaction . It cannot be remelted and reformed into desired shape once it set. When it is heated to high temperature it will decomposes or degrade so thermosetting plastics cannot be recycled or re worked. Ex: phenolics, epoxies, melanine, bakelite etc

It is a thermo-chemical decomposition of organic material at elevated temperatures without the participation of oxygen. It involves the simultaneous change of chemical composition and physical phase and is irreversible.

Here

laminated structure is pyrolysed in an inert atmosphere to around 1000 C. the resulting product is heated to 2500 C to bring about graphitisation of carbon matrix this is an extremely in efficient process nevertheless. It is inexpensive and quick and imposes no size limitation The techniques such as hand lay-up, pultrusion, pre pegging, filament winding or compression molding may be used to obtain the laminating structure.

Hot iso-static pressure impregnation carburization often referred to as a HIPIC process is used to form C-C composites it involves the following steps.
1.

A dry fibre preforms or porous laminate is vaccume impregnated with molten pitch.

2. It is placed in a metal can or container and surrounded by a excess pitch.

3.

The can is evacuated and sealed .

4. It is then placed in a HIP unit . 5. Temperature is raised above the melting point of pitch

6 . Pressure is increased to 100 Mpa ,pitch melts, expands and is forced into the pores in the sample. 7. The sealed container acts like a rubber container and helps in carrying the pitch to the interior portion of the sample through the pores. 8.Carbonisation takes place, the pressure applied increases the yield of carbon from pitch. 7. After processing, the preform is removed from the container and it is cleaned. 8. It is graphitized by heating to 2300 C.

the above step is repeated till the required density is obtained