CARBON FIBRE REINFORCED COMPOSITES

ASeminar

On

ByDhanraj Desai

Under the guidance ofDr. Sujata Pariti

INTRODUCTION

•CompositesEngineered or naturally occurring materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct at the macroscopic or microscopic scale within the finished structure.• E.g.- Concrete, Plywood

WHY COMPOSITES?

• Weight Saving• Directionality• Excellent fatigue• Cost• Ease of Assembly

• Ease of fabrication • Wide range of shapes • Inherent Mechanical

Properties• Tailor ability• Don’t Corrode

Properties of Composites

• 25% Reduction in weight.• Tensile strength of composites is four to six times

greater than Steel & aluminium.• Composites enjoy reduced maintenance cost.• Improved torsion stiffness and impact properties.• Composites are less noisy while in operation and

provide lower vibration transmission.• Lower embedded energy.

Cont.….

• Long life offers excellent fatigue, impact, environmental resistance and reduced maintenance• Composites exhibit excellent corrosion resistance and fire

retardant capability.• Long life offers excellent fatigue, impact, environmental

resistance and reduced maintenance.• Composites are more versatile and can be tailored to meet

performance needs and complex design requirements• Higher fatigue endurance limit (up to 60% of the ultimate

tensile strength).

Construction of Composites

Classification of Composites

Carbon Fibre Reinforced Composites

• Carbon fibre is very rarely used alone like other textile fibres because of its brittleness.• It is reinforced with other material like plastic to manufacture various

composites. • The composites containing carbon fibres have become an important

construction material due to their weight, rigidity, high tensile strength and modulus• These versatile properties of carbon fiber have made its composites

suitable for a particular end use.• The application of these composites ranges from a tiny traverse guide of

winding machine to the body of space vehicle.

Manufacturing Methods of Carbon Composites

• Sheet Molding Compound (SMC)

• Direct-Compounded Long-Fiber thermoplastic (D-LFT)

• Directed Fiber Preforming Processes via Robotic Deposition

• Structural Reaction Injection Molding (SRIM)

• Resin Transfer Molding (RTM)

CARBON FIBRE

• A Carbon Fiber is a fibrous carbon material having a micro graphite crystal structure made by fibrillation of PAN or from Rayon or coal pitch and then by being given a certain heat treatment.• It is also called graphite fiber or carbon graphite.• Carbon fiber consists of very thin strands of the element carbon. Each

fiber is 5-10 microns in diameter.• Carbon fibers have high tensile strength and are very strong for their size.• Carbon fibers are twice as stiff as steel and five times as strong as steel,

(per unit of weight).• "Light in weight, Strong and Durable!“

CONT……

PROPERTIES OF CARBON FIBRES

• Highly chemically resistant.• Low specific gravity.• High specific tensile strength.• High specific elastic modulus.• Electrical conductivity.• Heat resistance.

• Low thermal expansion coefficient.• Chemical stability.• Self-lubrication property.• High heat conductivity.

PRECURSORS FOR CARBON FIBRE

• PITCH or COAL• PAN• RAYON

Manufacturing of Carbon Fibre

CARBON FIBRE FROM PITCH PRECURSOR

CARBON FIBRE FROM PAN PRECURSOR

CARBON FIBRE FROM RAYON PRECURSOR

Major Carbon Fibre Manufacturers in the World

• Toray• Cytec• SGL Group• TOHO Tenax• Hexcel• Zoltek• Mitsubishi Rayon Co., Ltd.• Nippon Graphite Fiber Corporation

Properties of PAN, Pitch and Rayon Precursor

PROPERTY PITCH PAN RAYON

Fiber Diameter (microns)

10 to 11 5 to 8 6.5

Specific Gravity 2.0 to 2.2 1.71 to 1.96 1.7

Tensile modulus (GPa) 170 to 980 230 to 595 415 to 550

Tensile strength (MPa) 2275 to 4060 1925 to 6200 2070 to 2760

Elongation at failure (%)

0.25to 0.70 0.40 to 1.20 0.90 to 1.10

Thermal conductivity 

(W/mK)

120 to 1100 10 to 25 3.5 to 4.0

Application of Carbon fiber

AEROSPACE• Aircraft• Rockets• Satellites

SPORT• Fishing

equipment• Golf clubs• Rackets• Marine

INDUSTRIAL MATERIALS• Automobiles• Bicycles• Motorcycles• Cars and containers• Machinery parts• High-speed rotors• Electronic parts• Pressure vessels• Chemical equipment• Medical equipment• Construction• Office equipment• Precision equipment• Corrosion resistant equipment• Others

SOME APPLICATIONS

CONT…..

CONSUMPTION OF CARBON FIBRE

AEROSPACE38%

SPORTS19%

INDUSTRIAL43%

AEROSPACESPORTSINDUSTRIAL

ADVANTAGES OF CARBON FIBRE

• It has greatest compressive strength of all reinforcing material.• Low coefficient of thermal

expansion.• Its density is much lower

than that of steel.• Exhibit properties better

than any other metal.

• Long Service Life.• Insensitive to temperature

changes. • Tailorable mechanical

properties• Corrosion Resistance.• Fatigue Resistance.• Weight Reduction (approx.20%

to 50%).

Disadvantages of Carbon Fiber Composites

• The main disadvantage of carbon fiber is its cost.• This fibre will cause some form of cancer of the lungs.• Non visible impact damage.• Repairs are more different than those to metal

structure.

GLOBAL MARKET FOR CARBON FIBRE

Key manufacturers of Carbon Composites in India

• Saertex India.• DSM Engineering Plastics. • Kemrock Industries.

CONCLUSION• It is revolutionized field of light weight material.• Carbon fiber have a great potential and bright future due to

their unique properties.• Carbon fiber composites receiving world-wide attention,

pushed by need for energy saving, for various high tech applications.• It is the new substitute for metal.• Composites, especially carbon fiber composites, offer

outstanding potential in attacking vehicle weight and other Department of energy missions – biggest challenge is cost/performance balance.

REFERENCES

1) G. Savage: Carbon - Carbon Composites. (Chapman &hall, London. 1993).2) http://nptel.iitm.ac.in/courses/101104010/lecture1/1_3.htm3) E. Fitzer, in Carbon Fibers Filaments and Composites, edited by J.L. Figueiredo, C.A.

Bernardo, R.T.K. Baker, and K.J. Huttinger, Kluwer Academic, Dordrecht, 1990, pp. 3-41.4) Bob norris, Manufacturing Processes for Carbon Fiber Composites – A Brief Overview,

Oak Ridge Carbon Fiber Composites Consortium Meeting, April 12, 2012.5) Xiaosong Huang, Fabrication and Properties of Carbon Fibers, Materials 2009, 2, 2369-

2403.6) http://www.lucintel.com/carbon_fiber_market.aspx7) Arman sedghi, Composite materials, Imam Khomeini International University.8) E. Fitzer, L. M. Manocha: Carbon Reinforcements and Carbon/Carbon Composites.9) http://composite.about.com/od/Industry/a/History-Of-Carbon-Fiber.htm10) John Buckley, Dan Edie, Carbon-carbon materials and composites.

CONT…..

11) Peter morgan: Carbon fiber and their composites.12) D.J. Johnson, Structure and properties of carbon fibres, High-tech textiles.13) Nachiketa Tiwari, Introduction to Composite Materials and Structures, Indian institute of

technology, Kanpur.14) Yutaka Arai, Structure and properties of pitch-based carbon fiber, Nippon steel technical

report No.59, Octomber 1993.15) K. M. Akato, Pretreatment and Pyrolysis of Rayon-based Precursor for Carbon Fibers,

August 2012.16) http://web.utk.edu/~mse/Textiles/CARBON%20FIBERS.htm17) R.K. Datta, A.B. Talele, R.S.Gandhi, Carbon fibres- Retrospects and prospects, Synthetic

fibres, January/march 1990.18) M.Y. Gudiyawar, Carbon fibers in composite materials, Department of textile technology,

D.K.T.E’s Textile and engg. Institute,Man-made textiles in India, September 2002.19) http://www.toray.com/ir/individual/ind_012.html

THANK YOU