1st Edition

Carbon Fibers and Their Composites

By Peter Morgan Copyright 2005
    1194 Pages 993 B/W Illustrations
    by CRC Press

    Most literature pertaining to carbon fibers is of a theoretical nature. Carbon Fibers and their Composites offers a comprehensive look at the specific manufacturing of carbon fibers and graphite fibers into the growing surge of diverse applications that include flameproof materials, protective coatings, biomedical and prosthetics applications, textiles, batteries and fuel cells, automotive applications, construction, and even musical instruments.

    This useful guide provides a hands-on approach to the fabrication of carbon fibers. The book begins with a blueprint of the international history and development of carbon fiber, clearly defined terminology for all forms of solid carbon products, and the properties for elemental carbon and its allotropic forms. It then elaborates upon precursor materials, relevant surface treatment, and sizing for each carbon fiber type available in the world market. Several chapters also examine the types of matrices, their properties, and fracture mechanics of thermoset and thermoplastic polymers, carbon, glass, metal, and ceramics matrices.

    Carbon Fibers and their Composites reveals straightforward guidelines for the day-to-day operations of a carbon fiber plant, such as safety testing, quality control, design of equipment, packaging, air flow/dust control, maintenance, and environmental policies. Based on over 30 years of experience in the field, the author offers insight and possible solutions to the problems associated with production and testing of carbon fibers and their related composites. He details the use of analytical chemistry techniques, instrumentation requirements, and statistics to evaluate the results.

    Carbon Fibers and their Composites offers an excellent clarification of how carbon fibers yield reinforced composites, their physical and chemical characteristics, the diverse manufacturing techniques for each type, and the advantages they offer to a variety of applications.

    PREFACE
    Introduction
    Recommended terminology for the Description of carbon as a Solid
    A Bibliography of Books on Carbon Fibers and Their Composites
    Acknowledgements
    STRUCTURE OF THE CARBON ATOM
    Introduction – The Element Carbon, Its Isotopes and Allotropes
    Structure of Carbon
    THE FORMS OF CARBON
    The Allotropes of Carbon
    The Carbon Phase Diagram
    Diamond
    Graphite
    Pyrolytic Carbon and Pyrolytic Graphite
    Glass-like Carbon
    Carbon Fibers
    Graphite Whiskers
    Vapor-Grown Carbon Fibers (VGCF) and Catalytic Chemical Vapor-Deposited (CCVD) Filaments
    Other Forms of Carbon
    New Forms of Carbon
    Summary of Allotropic Forms of Carbon
    HISTORY AND EARLY DEVELOPMENT OF CARBON FIBERS
    The Early Inventors
    Work in the USA
    Work in Japan
    Work in the UK with PAN Precursors
    Early UK Prepreggers
    PRECURSORS FOR CARBON FIBER MANUFACTURE
    Introduction
    PAN Precursors
    Cellulosic Precursors
    Pitch Precursors
    Other Precursors
    CARBON FIBER PRODUCTION USING A PAN PRECURSOR
    Introduction
    Carbon Fiber Manufacturers
    World Supply of PAN-based Carbon Fiber
    Manufacturing Costs of PAN-based Carbon Fiber
    Choice of Precursor
    Desirable Attributes of a PAN-based Precursor Polymer and its Subsequent Production
    Types of PAN–based Carbon Fiber
    A Carbon Fiber Production Line
    CARBON FIBER PRODUCTION USING A CELLULOSIC BASED PRECURSOR
    Introduction
    Current Production
    Mechanisms for the Pyrolysis and Carbonization Stages of PAN Carbon Fibers
    CARBON FIBER PRODUCTION USING A PITCH BASED PRECURSOR
    Introduction
    Choice of Melt Spun Precursor
    The Manufacturing Process
    The Structural Ordering and Morphology of Mesophase Pitch Fibers
    PRODUCTION OF VAPOR GROWN CARBON FIBERS (VGCF)
    Introduction
    Preparation of VGCF
    Growth Process
    Mode of Tensile Failure
    Mechanical Properties
    SURFACE TREATMENT AND SIZING OF CARBON FIBERS
    Introduction
    Oxidative Processes
    Plasma
    Non-oxidative Surface Treatment – Whiskerization
    Effect of Surface treatment Upon the Fiber Properties
    Coupling Agents
    Sizing Carbon Fiber
    GUIDELINES FOR THE DESIGN OF EQUIPMENT FOR CARBON FIBER PLANT
    Introduction
    Precursor Handling
    Drive Systems
    Ovens for Oxidation
    Removal of Effluent Gases Evolved in the Oxidation Process
    Application of an Antistatic Finish
    Plaiter Table
    LT Carbonization Furnace
    LT Furnace Exhaust Removal
    HT Carbonization Furnace
    Typical Calculations for the Design of an HT Furnace
    Sodium Removal
    HM Heat Treatment Furnace
    Surface Treatment
    Sizing
    Drying
    On-Line Collection
    Off-line Winding
    Packaging
    Exhaust System
    Dust Extraction
    Application of Closed Circuit Television (CCTV)
    OPERATION OF CARBON FIBER PLANT AND SAFETY ASPECTS
    Introduction
    Serendipity
    Maintenance
    Protecting Electrical Equipment
    Air Flow Measurement
    Collimation and Spreading of Oxidized and Carbonized Fiber
    Splicing Small Tows
    Drive Systems and Rotating Rollers
    Precursor Creel
    Oxidation Plant
    Pyrolysis Plant
    Low Temperature Carbonization Furnace
    High Temperature Carbonization Furnace
    High Modulus Furnace
    Surface Treatment
    Sizing
    Winding
    Dealing with Emissions
    Treatment of Cyanide Effluent
    Protecting the Environment
    Safety Committee
    COSH-H Requirements
    Toxicology of Carbon Fibers
    The Risks of Carbon Fiber Composites in a Fire
    TECHNIQUES FOR DETERMINING THE STRUCTURE OF CARBON FIBERS
    Introduction
    Optical Microscope
    Scanning Electron Microscope
    Transmission Electron Microscope
    X-Ray Diffraction
    Auger Electron Spectroscopy
    X-Ray Photoelectron Spectroscopy
    Ultraviolet Photoemission Spectroscopy
    Infrared Spectroscopy
    Electron Energy Loss Spectroscopy
    Raman Spectroscopy
    Secondary Ion Mass Spectrometry
    Scanning Tunnelling Microscopy
    Atomic Foce Microscopy or Scanning Force Microscopy
    POLYMER MATRICES FOR CARBON FIBER COMPOSITES
    Selected Thermoset resins
    Selected Thermoplastic Resins
    Improving the Bond with Carbon Fiber/Thermoplastics
    CARBON FIBER CARBON MATRIX COMPOSITES
    Introduction
    Selection of Materials for Carbon-Carbon Processing
    Methods of Processing Carbon-Carbon Matrix Materials
    Some Thoughts of Carbon-Carbon Processng
    Provision for Providing Oxidation Protection
    CARBON FIBER REINFORCED CERAMIC MATRICES
    Introduction
    Cement, Concrete, and Gypsum Matrices
    Glass Matrices
    Ceramic Matrices
    CARBON FIBERS IN METAL MATRICES
    Introduction
    Metal Matrix Composites
    Carbon Fiber for Reinforcement of Metal Matrices
    Coating Processes to Improve Wettability
    Metal Matrices
    Techniques for Fabricating Carbon Fiber Reinforced Metal Matrix Composites
    TESTING PAN PRECURSOR, VIRGIN CARBON FIBERS, CARBON FIBER COMPOSITES AND RELATED PRODUCTS     
    Introduction
    PAN Precursor testing
    Testing Oxidized PAN Fiber (OPF) and Virgin Carbon Fiber
    Carbon Fiber Tow Testing
    Carbon Fiber Yarn and Fabric Testing
    Matrix Testing
    Carbon Fiber Prepreg Testing
    Carbon Fiber Composite Testing
    Testing Carbon Fiber Filled Thermoplastics
    Instrumental Analysis
    Non-Destructive Testing (NDT)
    Supplement
    STATISTICS AND STATISTICAL PROCESS CONTROL (SPC)
    Frequency Distribution
    Location of Data
    Measures of Dispersion
    Standard Error
    Sample Correlation Coefficient
    Linear Regression
    Normal Distribution
    Weibull Distribution
    Variation
    Control Chart Methods
    Statistical Process Control Charts
    Capability Index
    Failure Mode Effect Analysis
    QUALITY CONTROL
    In-house testing
    Quality Management and Quality Assurance Standards
    The ISO 9000 Family of Standards and Quality Systems
    Quality Gurus
    Quality Circles
    Total Quality Management
    Quality Costing
    PROPERTIES OF CARBON FIBERS
    The Role of Carbon Fibers
    Types of Carbon Fibers Available on the World Market
    Tensile Properties
    Factors Affecting Composite Strength
    The Importance of Critical Aspect Ratio
    Elastic Constants
    Flexural Properties
    Effect of surface treatment and Sizing on Composite Properties
    Compressional Properties
    Thermal Properties
    Thermal Expansion of Carbon Fibers
    Thermal Conductivity of Carbon Fibers
    Creep Properties
    Impact Strength and Fracture Toughness
    Fatigued Properties
    Electrical Properties
    Chemical Resistance
    Friction and Wear
    Hybrid Composites
    Some Selected Properties of Composites
    MANUFACTURING TECHNIQUES FOR CARBON FIBER REINFORCED COMPOSITES IN THERMOSET AND THERMOPLASTIC MATRICES
    Carbon Fiber Reinforcement and Architecture
    Core Materials
    Manufacturing Processes for Carbon Fibers in Thermoset Matrices
    Carbon Fibers in Thermoplastic Matrices
    Hybrid Composites
    DESIGN
    Design Considerations
    Micromechanics
    Selection of Materials
    Elastic Behavior of Multidirectional Laminates
    Choice of Composite Manufacturing Method
    Bonding and Joining
    Fabrication
    Testing and Inspection
    Smart Devices
    Design Cases
    THE USES OF CARBON FIBERS
    Uses of Oxidized PAN Fiber (OPF)
    Uses of Virgin Carbon Fiber
    Electrical Applications
    Thermal Insulation
    Packing Materials and Gaskets
    Carbon Fibers in Thermoset Matrices
    Carbon Fibers in Thermoplastic Matrices
    Carbon Fibers in Carbon-Carbon Applications
    Carbon Fibers in Cement and Concrete
    Carbon Fibers in Glass Matrices
    Carbon Fibers in Ceramic Matrices
    Carbon Fibers in Metal Matrices
    Other End Uses for Carbon Fibers
    LOOKING TO THE FUTURE
    The Future
    The Production Process
    Carbon Fiber
    Composite Manufacturing Techniqes
    Quality Management Standartds
    Recycling
    Innovative Developments
    Conclusions
    Appendices

    Biography

    Peter Morgan