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Questions and Answers
Which application of carbon materials falls under the 'Traditional Carbon' era, as defined in the content?
Which application of carbon materials falls under the 'Traditional Carbon' era, as defined in the content?
- Electrodes for Fe, Al & Si production (correct)
- Carbon fiber composites for BMW vehicles
- Nanotubes
- Fullerenes
The RAE patent involving carbon fibers, developed by Hercules and Morganite, utilized PAN (polyacrylonitrile) as the precursor material.
The RAE patent involving carbon fibers, developed by Hercules and Morganite, utilized PAN (polyacrylonitrile) as the precursor material.
False (B)
Name the year that fullerenes were discovered, marking the beginning of what era of carbon research?
Name the year that fullerenes were discovered, marking the beginning of what era of carbon research?
1985; Novel Carbon
Edison's light bulb, represented in Fig. 1, demonstrates an early application of ______.
Edison's light bulb, represented in Fig. 1, demonstrates an early application of ______.
Match the carbon fiber development with its corresponding era:
Match the carbon fiber development with its corresponding era:
What was the primary initial use of early carbon fibers before their application as reinforcement materials?
What was the primary initial use of early carbon fibers before their application as reinforcement materials?
The first carbon fibers were derived from petroleum pitch.
The first carbon fibers were derived from petroleum pitch.
Which company developed the first oxidized PAN fiber known as 'Orlon'?
Which company developed the first oxidized PAN fiber known as 'Orlon'?
The Royal Aircraft Establishment of Farnborough (RAE) obtained a patent related to PAN-based carbon fiber production in the year ______.
The Royal Aircraft Establishment of Farnborough (RAE) obtained a patent related to PAN-based carbon fiber production in the year ______.
What type of material was predominantly used by Thomas Edison in his early light bulbs?
What type of material was predominantly used by Thomas Edison in his early light bulbs?
Match the year with the corresponding development in carbon fiber history:
Match the year with the corresponding development in carbon fiber history:
In what decade did US production of carbon fibers begin according to the timeline?
In what decade did US production of carbon fibers begin according to the timeline?
Early carbon fibers were primarily developed for their high tensile strength in structural applications.
Early carbon fibers were primarily developed for their high tensile strength in structural applications.
Which material, when compared to carbon fiber, has the lowest specific tensile strength?
Which material, when compared to carbon fiber, has the lowest specific tensile strength?
Carbon fiber is only used in aerospace applications due to its high cost.
Carbon fiber is only used in aerospace applications due to its high cost.
Name one application of carbon fiber in the automotive industry that improves vehicle performance or efficiency.
Name one application of carbon fiber in the automotive industry that improves vehicle performance or efficiency.
The Boeing 787 Dreamliner utilizes carbon fiber in its ______ section.
The Boeing 787 Dreamliner utilizes carbon fiber in its ______ section.
Match the following applications with the corresponding industry:
Match the following applications with the corresponding industry:
What is the approximate density range of the carbon fiber mentioned?
What is the approximate density range of the carbon fiber mentioned?
The tensile strength of carbon fiber is generally lower than that of steel.
The tensile strength of carbon fiber is generally lower than that of steel.
Besides aerospace and automotive, name one other industry that utilizes carbon fiber composites.
Besides aerospace and automotive, name one other industry that utilizes carbon fiber composites.
The Airbus A350 XWB utilizes carbon fiber in its lower ______ cover.
The Airbus A350 XWB utilizes carbon fiber in its lower ______ cover.
What is a key advantage of using carbon fiber reinforced parts in the BMW 7 series?
What is a key advantage of using carbon fiber reinforced parts in the BMW 7 series?
What is the primary purpose of surface treatment for carbon fibers?
What is the primary purpose of surface treatment for carbon fibers?
Vapor-grown carbon fibers typically require a stabilization process similar to PAN-based fibers.
Vapor-grown carbon fibers typically require a stabilization process similar to PAN-based fibers.
What is the purpose of applying 'sizing' or 'surface finish' to carbon fibers?
What is the purpose of applying 'sizing' or 'surface finish' to carbon fibers?
The manufacturing of vapor-grown carbon fibers involves the ______ of a filament using a submicron activated catalyst.
The manufacturing of vapor-grown carbon fibers involves the ______ of a filament using a submicron activated catalyst.
Match the carbon fiber type with its typical production method:
Match the carbon fiber type with its typical production method:
Which of the following oxidative methods is most commonly used for surface treatment of carbon fibers?
Which of the following oxidative methods is most commonly used for surface treatment of carbon fibers?
The 'interphase' in composite materials refers to a two-dimensional boundary between the fiber and matrix.
The 'interphase' in composite materials refers to a two-dimensional boundary between the fiber and matrix.
What is the typical diameter range for a carbon fiber monofilament?
What is the typical diameter range for a carbon fiber monofilament?
Heavy tow carbon fibers typically contain between ______ and ______ filaments.
Heavy tow carbon fibers typically contain between ______ and ______ filaments.
Which carbon fiber type is most likely to be used in aerospace applications, considering both strength and Young's modulus?
Which carbon fiber type is most likely to be used in aerospace applications, considering both strength and Young's modulus?
Carbon fibers based on PAN require higher graphitization temperatures than pitch-based fibers to achieve ultra-high modulus.
Carbon fibers based on PAN require higher graphitization temperatures than pitch-based fibers to achieve ultra-high modulus.
Explain the concept of an 'interphase' in the context of carbon fiber reinforced composites.
Explain the concept of an 'interphase' in the context of carbon fiber reinforced composites.
To achieve High Modulus (HM) or Ultra-High Modulus (UHM) in carbon fibers, an additional heat treatment process called ______ is performed at high temperatures.
To achieve High Modulus (HM) or Ultra-High Modulus (UHM) in carbon fibers, an additional heat treatment process called ______ is performed at high temperatures.
Which of the following is NOT a requirement for sizing/surface finish?
Which of the following is NOT a requirement for sizing/surface finish?
Match the tow size with its typical application:
Match the tow size with its typical application:
What is the primary purpose of the stabilization process in the manufacturing of PAN-based carbon fibers?
What is the primary purpose of the stabilization process in the manufacturing of PAN-based carbon fibers?
Increasing the density of oxidized fiber during stabilization will increase the density of the resulting carbon fiber after carbonization.
Increasing the density of oxidized fiber during stabilization will increase the density of the resulting carbon fiber after carbonization.
What type of atmosphere is required during the carbonization process of stabilized PAN fibers, and why?
What type of atmosphere is required during the carbonization process of stabilized PAN fibers, and why?
During carbonization, approximately ______ wt.-% of mass is lost due to thermal degradation of non-carbon atoms.
During carbonization, approximately ______ wt.-% of mass is lost due to thermal degradation of non-carbon atoms.
Match the manufacturing process with its effect on carbon fiber properties:
Match the manufacturing process with its effect on carbon fiber properties:
Which of the following factors is NOT a target to be achieved before carbonization of PAN fibers?
Which of the following factors is NOT a target to be achieved before carbonization of PAN fibers?
Graphitization is typically conducted under an oxygen-rich atmosphere to promote oxidation of impurities.
Graphitization is typically conducted under an oxygen-rich atmosphere to promote oxidation of impurities.
What happens to the tensile strength of carbon fibers when the graphitization temperature reaches approximately 1800°C?
What happens to the tensile strength of carbon fibers when the graphitization temperature reaches approximately 1800°C?
During the production of carbon fiber from pitch, the process of ______ involves oxidation and cross-linking to retain and freeze the orientation of molecules.
During the production of carbon fiber from pitch, the process of ______ involves oxidation and cross-linking to retain and freeze the orientation of molecules.
Which application is NOT typically associated with PANOX fibers?
Which application is NOT typically associated with PANOX fibers?
Defects within the carbon fiber structure promote the formation of an ideal graphite structure.
Defects within the carbon fiber structure promote the formation of an ideal graphite structure.
During the graphitization process, what effect does increasing the temperature above 1800°C have on the tensile strength of carbon fibers?
During the graphitization process, what effect does increasing the temperature above 1800°C have on the tensile strength of carbon fibers?
What is the typical oxygen content range (wt.-%) aimed for in stabilized PAN fiber to achieve maximum carbon yield during subsequent carbonization?
What is the typical oxygen content range (wt.-%) aimed for in stabilized PAN fiber to achieve maximum carbon yield during subsequent carbonization?
The two-phase emulsion or low molecular weight single phase used in pitch based precursor carbon fiber production is called ______ pitch.
The two-phase emulsion or low molecular weight single phase used in pitch based precursor carbon fiber production is called ______ pitch.
What is the theoretical Young's modulus for carbon fiber?
What is the theoretical Young's modulus for carbon fiber?
Why are methods like melt spinning and solution spinning generally unsuitable for creating carbon fibers?
Why are methods like melt spinning and solution spinning generally unsuitable for creating carbon fibers?
The use of organic polymeric fibers as raw materials for carbon fiber production eliminates the need for complex and costly processes.
The use of organic polymeric fibers as raw materials for carbon fiber production eliminates the need for complex and costly processes.
In the carbon fiber production process, what is the main purpose of the 'spinning' stage after polymerization?
In the carbon fiber production process, what is the main purpose of the 'spinning' stage after polymerization?
The 'spin dope' used in carbon fiber production typically consists of 10% to over 20% PAN (Polyacrylonitrile) dissolved in a highly polar ______.
The 'spin dope' used in carbon fiber production typically consists of 10% to over 20% PAN (Polyacrylonitrile) dissolved in a highly polar ______.
Match the following solvents with their classifications used in the polymerization of acrylonitrile during carbon fiber production:
Match the following solvents with their classifications used in the polymerization of acrylonitrile during carbon fiber production:
What happens to the fiber structure during the spinning process, and why is it critical to monitor and control?
What happens to the fiber structure during the spinning process, and why is it critical to monitor and control?
The stabilization (oxidation) stage is conducted on white, flammable PAN fiber to transform it into a black, non-flammable oxidized PAN fiber.
The stabilization (oxidation) stage is conducted on white, flammable PAN fiber to transform it into a black, non-flammable oxidized PAN fiber.
What temperature range is typically used during the stabilization (oxidation) phase of carbon fiber production?
What temperature range is typically used during the stabilization (oxidation) phase of carbon fiber production?
During carbonization, the carbonized structure must exhibit regions with ______ layers to utilize high C-C binding energy.
During carbonization, the carbonized structure must exhibit regions with ______ layers to utilize high C-C binding energy.
What is the key structural characteristic that the carbonized fiber must possess to effectively utilize the high binding energy of C-C bonds?
What is the key structural characteristic that the carbonized fiber must possess to effectively utilize the high binding energy of C-C bonds?
During carbonization, a higher processing temperature always results in carbon fibers with optimum tenacity.
During carbonization, a higher processing temperature always results in carbon fibers with optimum tenacity.
What is the main purpose of carbonization in the production of carbon fibers?
What is the main purpose of carbonization in the production of carbon fibers?
Every carbonaceous matter exhibits a theoretical ______ yield when subjected to pyrolysis.
Every carbonaceous matter exhibits a theoretical ______ yield when subjected to pyrolysis.
Which properties are most important when assessing whether a carbonaceous matter is suitable as a raw material for carbon fiber production?
Which properties are most important when assessing whether a carbonaceous matter is suitable as a raw material for carbon fiber production?
Match the following polymer types with their corresponding classification as precursor materials for carbon fiber production:
Match the following polymer types with their corresponding classification as precursor materials for carbon fiber production:
Flashcards
Viscose Rayon Origin
Viscose Rayon Origin
Early carbon fibers were made from viscose rayon.
Edison's Carbon Use
Edison's Carbon Use
Edison’s light bulb used early forms of carbon.
Electrode Use
Electrode Use
Traditional carbon applications include electrodes in the production of Fe, Al, and Si.
Fullerene Discovery
Fullerene Discovery
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Nanotube Discovery
Nanotube Discovery
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Carbon Fibers
Carbon Fibers
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Early Carbon Fiber Use
Early Carbon Fiber Use
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Initial Carbon Fiber Application
Initial Carbon Fiber Application
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1950, DuPont
1950, DuPont
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1959 - First PAN Carbon Fibers
1959 - First PAN Carbon Fibers
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1968 Carbon Fiber Patent
1968 Carbon Fiber Patent
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PAN based Carbon Fiber
PAN based Carbon Fiber
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1964: Thornel 25
1964: Thornel 25
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Transverse Strength
Transverse Strength
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Density
Density
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Tensile Strength
Tensile Strength
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Specific Tensile Strength
Specific Tensile Strength
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Aerospace Applications
Aerospace Applications
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Automotive Applications
Automotive Applications
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Sports and Leisure Applications
Sports and Leisure Applications
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Schürmann (2007)
Schürmann (2007)
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Morgan (2005)
Morgan (2005)
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Fitzer and Manocha (1998)
Fitzer and Manocha (1998)
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PAN-Based Fibers
PAN-Based Fibers
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Ultra-High Modulus
Ultra-High Modulus
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Vapor Grown Carbon Fibers (CCVD)
Vapor Grown Carbon Fibers (CCVD)
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Nucleation of a filament
Nucleation of a filament
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Surface Treatment
Surface Treatment
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Sizing/Surface Finish
Sizing/Surface Finish
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Oxidative Methods
Oxidative Methods
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Adhesion Determinants
Adhesion Determinants
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Sizing Methods
Sizing Methods
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Interphase
Interphase
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Monofilament
Monofilament
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Multi-filaments (k)
Multi-filaments (k)
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Low Tow Fibers
Low Tow Fibers
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Carbon Fiber Types
Carbon Fiber Types
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Production Temperatures
Production Temperatures
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PAN
PAN
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PANOX Fiber Applications
PANOX Fiber Applications
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Influencing Factors Before Carbonization
Influencing Factors Before Carbonization
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Target Density for Stabilization
Target Density for Stabilization
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Oxygen Content for Carbon Yield
Oxygen Content for Carbon Yield
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C-C Bond Alignment
C-C Bond Alignment
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Density Relationship
Density Relationship
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Preferred Oxidized Fiber Density
Preferred Oxidized Fiber Density
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Carbon Fiber Making
Carbon Fiber Making
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Carbonization Process
Carbonization Process
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Graphite Layer Distance
Graphite Layer Distance
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Carbon Fiber Production
Carbon Fiber Production
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Carbon Fiber Process Chain
Carbon Fiber Process Chain
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Graphite Lattice Formation
Graphite Lattice Formation
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Graphitization
Graphitization
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Acrylonitrile
Acrylonitrile
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Strength vs. Temperature
Strength vs. Temperature
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Spin Dope
Spin Dope
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Polymerisation
Polymerisation
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Types of Defects
Types of Defects
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Mesophase Pitch-Based Carbon Fiber Production
Mesophase Pitch-Based Carbon Fiber Production
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Solvents for PAN
Solvents for PAN
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Spinning
Spinning
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Fiber Formation
Fiber Formation
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Stabilization (Oxidation)
Stabilization (Oxidation)
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Stabilisation Temperature
Stabilisation Temperature
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Carbonisation
Carbonisation
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Optimum Carbonisation Temperature
Optimum Carbonisation Temperature
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Carbon Yield
Carbon Yield
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Precursor Materials
Precursor Materials
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Study Notes
- Composite Materials and Structure-Property-Relationship are key elements
- Carbon Fibers are also key
Introduction to Carbon Fibers
- Carbon fibers were initially not used as reinforcement material
- First incandescent electric lamps by Thomas Edison used cellulosic materials like bamboo and cotton
- In 1950, DuPont created the first oxidized PAN fiber, "Orlon"
- In 1959, carbon fibers from PAN were first made in Japan
- Royal Aircraft Establishment of Farnborough (RAE) secured a patent in 1968
- "Thornel 25" made from viscose rayon in the US by Union Carbide in 1964
- US production according to the RAE patent began in 1971 by Hercules and Morganite
- JV SGL Group and BMW Group (SGL ACF) occurred in 2009
- Traditional carbon research fields were electrodes for Fe, Al, and Si production, and graphite parts for the solar and semiconductor industry
- Modern carbon research involves lightweight CFRP
- Novel carbon research includes Fullerenes in 1985, Nanotubes in 1991, and Graphene in 2004
- Carbon fibers are made from carbon-based precursors on a large scale through pyrolysis
- This conversion results in a specific carbon structure with high tensile strength
- Carbon fibers have been used as reinforcing materials since the 1970s
- Carbon fibers exhibit strong covalent bonds with a binding energy of 350 kJ/mol
- They also have a highly oriented graphite structure
- The market segments include aerospace, automotive, and sports & leisure
- The global annual production of crude steel was 1.62 billion tons
- Aluminum production annually was 57.7 million tons
- CFRP production yearly was 58 kilotons in 2015
- In 2016, the yearly carbon fiber capacity by region/countries totalled 130,900 tons
- The largest capacity was with the USA & Mexico at 35%
- China, Taiwan, and South Korea come at 31% together
Carbon Fiber Market
- Carbon fiber demand in 2013 was led by Aerospace & Defense at 30%
- Sport/Leisure was also an important segment at 14%
- Global carbon fiber revenue in 2013 totaled $1.7 billion (USD)
- Aerospace & Defense account for 50% of the market
Characteristics of Carbon Fibers
- Low density measures around 1.74 – 1.90 [g/cm³]
- Negative thermal expansion coefficient is -0.5 to -1.1 [10-6/°C]
- Filaments smaller than 5 µm pose no significant inhalation problems
- Material properties are anisotropic in axial and transverse directions
- High modulus (especially pitch based)
- Good thermal stability (in absence of O2)
- High thermal conductivity
- High strength (especially PAN based)
- Excellent creep resistance
- High cost
- Low strain to failure
- Oxidation at temperatures above 450°C
Manufacturing of Carbon Fibers
- Carbon atoms arranged in strong hexagonal layers that are stiffly and tightly bonded
- Carbon layers within the fiber arranged along the fiber direction
- Single, dense thin fibers measure between 6-7 µm in diameter
- Carbon Fiber tow ranging from 1,000 to 50,000 single fibers clustered for cost efficiency
- Classical methods such as Melt Spinning, Solution Spinning or Ceramic fiber making are not suitable for Carbon Fibers
Process Chain
- Crude Oil becomes Acrylonitrile for PAN C Fiber Precursor to make Carbon Fiber
- The final product is a Composite Material
- This requires Polymerization, Spin Dope Preparation, Spinning, Stabilization, Carbonization, Surface Treatment & Sizing
- This requires Dis-solving, and then also Polymerisation
- Solution Polymerization, Dispersion Polymerization, and Precipitation Polymerization are different Polymerisation methods
- Dissolving requires highly polar Solvents like DMAC, DMF, DMSO
Spinning
- Fiber forms and stretches in a spinning bath
- Fiber structure develops during spinning, and all defects reduce tenacity
- Stabilisation (Oxidation) sees PAN Fiber, which is white and flammable, oxidise between 220-280 degrees turning non-flammable
- A optimum tenacity is achieved via temperatures between 1300-1500C for HT and IM Fibers
- An increase in stiffness occurs with a temperature increase where > 2000 degree gives HM Fibers
- Surface Treatment & Sizing requires Electrolysis
- Raw materials must exhibit sufficient carbon yield which is > 50 wt-%
- The carbonized structure needs to show graphitic layers with oriented structure Every carbonaceous matter exhibits a theoretical carbon yield
Precursor Materials
- Synthetic materials such as Polyester, Polyamide 6.6
- Synthetic elastomers
- Cellulosic fibers such as Viscose, Cupro, Acetate, Modal, Lyocell fibres
- Polyacrylonitrile (PAN) has 50 % carbon yield with a 95% market share
Raw Materials
- PAN has a molecular mass share of 36
- Lignin can be produced via Thermo-chemical enzymatic hydrolysis or via thermal transformation
- There is Wet Spinning with cellulose and thermal transformation
- Production starts with PAN dissolved in solvent being spun, and then washed, stretched and then dried
- The main goal for Spinning is for the alignment of covalent bonds in longitudinal direction of future carbon fiber
- High exothermal reaction required for irreversible thermal stabilization
- Stabilisation involves heat treatment between 200-300C to get PANOX as a result
- PANOX needs to not burn under air or melt in order for carbonization
- Stabilization requires Disentanglement of the polymer chains by externally applied stretching, and additional inner stretching
- Stabilization depends on the The process of stretching is dependent on reaction temperature and reaction progress
Applications
- Stabilisation can be used for Reinforcing carbon and carbon aircraft brakes
- Can reinforce brake pads in automotive applications, therefore can replace asbestos
- Heat and flammability resistant insulation
- Carbonization helps achieve fireproof fibers, high oxygen content, an alignment of C-C bonds, and therefore minimize defects
- Carbonization is conducted in a nitrogen atmosphere, thermal degradation, formation of carbon rings, with a mass loss around 50%
Graphitization
- Graphitization includes higher heat treatment under argon atmosphere.
- Improves preferred orientation and Young's Modulus
- High strength can be optimized via Heat Treatment
- Pitch establishes graphite order during graphitization, and therefore optimizes Young's modulus
- Defects prohibit formation of ideal graphitic structure
- A pitch carbon fiber is a thermoplastic fiber which leads to retention and freeze of the raw material
Vapor Grown Carbon Fibers
- Production via catalytic chemical vapor deposition (CCVD)
- The final prodcut is discontinuous fibers with diameters between 1-100 μm
- These fibers do not need stabilization, which provides the material with a one-step process
- Surface Treatment has been added to improve Fiber-matrix adhesion
- Using Oxidative methods also help the Surface Treatment
- Oxidative methods also includes interaction with sizing, and Supply of polar links (oxidic surface groups)
- Surface Treatment includes Removal of outer, weak surface layer, changes in surface area, and modification the surface
- Fiber types can be Monofilament at a individual filament range between 0.005 - 0.1 mm to a Mulitfilament comprised of several monofilaments
- HT fibers have high tensile properties, which enables aviation applications
- HM: High Modulus, UHM: Ultra High Modulus for space applciations
- HT, IM: produced by carbonization at temperatures between 1200-1400°C
- HM, UHM: additional heat treatment (graphitization) at temperatures between 2000-3000°C
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