Report on:

CarbonFibers

Submitted to:
Dr. Hussien,
Faculty of Engineering Helwan University

By:
Yousef Ahed Al-Habashi
Section 12 No:312
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Abstract
Carbonfibershavebeenusedforoveradecade
scientists are constantly trying to enhance it
andcustomizeittotheirneeds.Hereweshow
whatarecarbonfibers,areviewofitshistory.
Also, a quick view of how carbon fibers are
manufactured. Carbon fibers have physical
properties that are needed in many wide
industries, we show the properties and their
applicationsinvariousindustries.Themarket
ofcarbonfibersissettoexpandmorebutthere
are some difficulties and the manufacturers
need to eliminate them, here we show what
arethedifficultiesthemarketfaces.

TableofContent
Topic
Page
Abstract.................................................. 2
Introduction...........................................
5
History...................................................
6
Manufacturing........................................ 6
ClassificationandTypes......................... 7
CarbonFiberProperties.........................
8
UsesCarbonFiber.............................. 9
CarbonFiberMarket.............................. 11

ListofIllustrations
Figures
Figure

Page

Fig.1: Fibers under microscope.

Fig.2 Carbon Fiber Golf Clubs

Fig.3 Carbon Fiber race car.

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Tables
Table

Page
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Table 1: Characteristics and

Applications of Carbon Fibers

Introduction
First of all, to know what carbon fibers are we should
know what are fibers. It is a natural or synthetic string used as
a component of composite materials(a material made from two or
more constituent materials with significantly different physical or chemical
properties) or, when matted into sheets, used to make products

such as paper or felt. Fibers can occur naturally or

synthesized from materials such as petrochemicals. Carbon
fibers are synthesized.

Fig.1: Fibers under microscope.

History
In the late 1800s cotton threads or bamboo slivers were heated
at high temperatures so they will carbonize into wire filament used in
light bulbs to be heated by electricity, a year later a reliable carbon
wire filament was developed. Ever since scientists and
manufactures tried to produce carbon fibers with high strength and
stiffness, but the results were unreliable until 1960s, a Japanese
scientist developed a process where he was able to produce a carbon
fiber with 55% carbon, and a manufacturer in the United States
developed a process in which a carbon fiber with 99% carbon were
produced. These carbon fibers had sufficient strength (modulus of
elasticity and tensile strength) to be used as a reinforcement for composites
having high strength to weight properties and for high temperature
resistant applications. During the 1960s, experimental work to find
alternative raw materials led to the introduction of carbon fibers made
from a petroleum pitch derived from oil processing. These fibers
contained about 85% carbon and had excellent strength.

Manufacturing
In Textile Terms and Definitions, carbon fiber has been described
as a fiber containing at least 90% carbon obtained by the controlled
pyrolysis of appropriate fibers. The term "graphite fiber" is used to
describe fibers that have carbon in excess of 99%. Large varieties of
fibers called precursors are used to produce carbon fibers of different
morphologies( morphology: the study of the forms of things) and different
specific characteristics. The most prevalent precursors are
polyacrylonitrile (PAN), cellulosic fibers (viscose rayon, cotton), petroleum
or coal tar pitch and certain phenolic fibers.
Carbon fibers are manufactured by the controlled
pyrolysis(decomposition brought about by high temperatures) of organic
precursors (a precursor is a compound that participates in the chemical reaction
that produces another compound)in fibrous form. It is a heat treatment of the
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precursor that removes the oxygen, nitrogen and hydrogen to form

carbon fibers. It is well established in carbon fiber literature that the
mechanical properties of the carbon fibers are improved by increasing
the crystallinity and orientation, and by reducing defects in the fiber.
The best way to achieve this is to start with a highly oriented precursor
and then maintain the initial high orientation during the process of
stabilization and carbonization through tension.

Classification and Types

Based on modulus, strength, and final heat treatment temperature,
carbon fibers can be classified into the following categories:
Based on Carbon Fiber properties:
Ultra-high-modulus, type UHM (modulus >450 kN/mm 2)
High-modulus, type HM (modulus between 350-450 kN/mm 2)
Intermediate-modulus, type IM (modulus between 200-350 kN/mm 2)
Low modulus and high-tensile, type HT (modulus < 100 kN/mm 2 , tensile
strength > 3.0 kN/mm2)
Super high-tensile, type SHT (tensile strength > 4.5 kN/mm 2 )

Based on Precursor Fiber Material

PAN-based carbon fibers

Pitch-based carbon fibers
Mesophase pitch-based carbon fibers
Isotropic pitch-based carbon fibers
Rayon-based carbon fibers
Gas-phase-grown carbon fibers

Based on Final Heat Temperature

Type-I, high-heat-treatment carbon fibers (HTT), where final heat
treatment temperature should be above 2000C and can be associated
with high-modulus type fiber.
Type-II, intermediate-heat-treatment carbon fibers (IHT), where final heat
treatment temperature should be around or above 1500C and can be
associated with high-strength type fiber.
Type-III, low-heat-treatment carbon fibers, where final heat treatment
temperatures not greater than 1000C. These are low modulus and low
strength materials.

Carbon Fiber Properties

High Strength to weight ratio

Rigidity
Corrosion resistance
Electrical Conductivity
Fatigue Resistance
Good tensile strength but Brittle
Fire Resistance/Not flammable
High Thermal Conductivity in some forms
Low coefficient of thermal expansion
Non poisonous
Biologically inert
X-Ray Permeable
Self Lubricating
Excellent EMI (Electromagnetic Interference) Shielding Property
Relatively Expensive
Requires specialized experience and equipment to use.

Uses of Carbon Fibers

Carbon fibers are used where low weight, high stiffness, high
conductivity, or where the look of the carbon fiber weave desired.
Below are examples of where carbon fiber is commonly used:
Aerospace and space were some of the first industries to adopt
carbon fiber. The high modulus of carbon fiber make it suitable
structurally to replace alloys such as aluminum and titanium. The
weight savings carbon fiber provides is the primary reason carbon
fiber has been adopted by the aerospace industry. Every pound of
weight savings can make a serious difference in fuel consumption,
which is why Boeing's new 787 Dreamliner has been the best selling
passenger plane in history. The majority of this plane's structure is
carbon fiber reinforced composites.

Fig.2 Carbon Fiber Golf Clubs

Recreational sports is another market segment which is more then

willing to pay more for higher performance. Tennis rackets, golf clubs,
softball bats, hockey sticks, and archery arrows and bows are all
products commonly manufactured with carbon fiber reinforced
composites.

Fig.3 Carbon Fiber race car.

Automotive Mass produced automobiles are not yet adopting carbon

fiber; this is because the increased raw material cost and necessary
changes in tooling, still outweighs the benefits. However, Formula 1,
NASCAR, and high end cars are using carbon fiber. In many cases, it
is not because of the benefits of properties or weight, but because of
the look. There are many after market automotive parts being made
out of carbon fiber, and instead of being painted, they are clearcoated. The distinct carbon fiber weave has become a symbol of hitech and hi-performance. In fact, it is common to see an after market
automotive component that is a single layer of carbon fiber, but has
multiple layers of fiberglass below to lower costs. This would be an
example where the look of the carbon fiber is actually the deciding
factor.
1. Physical strength, specific toughness, light
weight

Aerospace, road and marine transport, sporting

goods

2. High dimensional stability, low coefficient of

thermal expansion, and low abrasion

Missiles, aircraft brakes, aerospace antenna

and support structure, large telescopes, optical
benches, waveguides for stable high-frequency
(GHz) precision measurement frames

3. Good vibration damping, strength, and

toughness

Audio equipment, loudspeakers for Hi-fi

equipment, pickup arms, robot arms

4. Electrical conductivity

Automobile hoods, novel tooling, casings and

bases for electronic equipments, EMI and RF
shielding, brushes

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5. Biological inertness and x-ray permeability

Medical applications in prostheses, surgery and

x-ray equipment, implants, tendon/ligament
repair

6. Chemical inertness, high corrosion resistance

Chemical industry; nuclear field; valves, seals,

and pump components in process plants

7. Electromagnetic properties

Large generator retaining rings, radiological

equipment

Table 1: Characteristics and Applications of Carbon Fibers.

The Carbon Fiber Market

Carbon Fiber is a material consisting of very thin filaments of carbon
atoms. Superior properties of carbon fiber such as high strength, high
stiffness, low density, non-corrosiveness; electrical conductivity, and
chemical inertness make it an ideal material in plenty of applications
such as aerospace, military, automotive, wind energy, sporting goods,
and industrial applications.
The factors leading to increased interest in the carbon fiber
market include demand for more fuel efficient vehicles, structural &
performance advantages, continuous emergence of novel
applications, and increased demand from emerging economies.
However, the market's potential is somewhat obstructed by high price
of carbon fiber, insufficient production capacity, processing difficulties,
and lack of automation. In spite of this, there is a huge opportunity for
existing & new carbon fiber producers.
Although, the adoption rate of carbon fiber is increasing, mass-market
adoption will not be achieved until a few major challenges are
addressed. These challenges are: high cost of production, the gap
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between the supply and demand, and uneven competition. Carbon

fiber continues to do very well in aerospace, consumer and industrial
sector, with a number of application-specific capabilities. Carbon fiber
finds its application in large number of industries for example wind
energy, oil and gas, automotive, civil infrastructure and tooling etc.
Aerospace and defense is the top contributor of the carbon fiber
market and together held more than 50% of the carbon fiber market in
2013. This growth is attributed to their wide application area. The
advantages of carbon fiber make it a very attractive market for
investment.

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