CARBON-CARBON COMPOSITE

INTRODUCTION
Carbon-Carbon Composites are composite materials consisting of a carbon matrix reinforced by carbon fibres. CC composites are a new class of engineering materials that are ceramic in nature but exhibit brittle to pseudoplastic behavior. Carbon fibre reinforcements when embedded in carbonaceous matrix material results in CC composites.

 As in all composites, the aim is to combine the advantage of high specific strength and stiffness of carbon fibres with the refractory properties of carbon matrix. When the fibres are laid in near-net shapes with multidirectional reinforcements, the result is an ideal high temperature structure.

FABRICATION PROCESS
The material is made in three stages. First, material is laid up in its intended final shape, with carbon filament and/or cloth surrounded by an organic binder such as plastic or pitch. Often, coke or some other fine carbon aggregate is added to the binder mixture.

 Second, the lay-up is heated, so that pyrolysis transforms the binder to relatively pure carbon. The binder loses volume in the process, so that voids form; the addition of aggregate reduces this problem, but does not eliminate it. Third, the voids are gradually filled by forcing a carbon-forming gas such as acetylene through the material at a high temperature, over the course of several days. This long heat treatment process also allows the carbon to form into larger graphite crystals.

 Classically, carbon ceramics are fabricated by combining solid particles of pure carbon (known as primary carbon) with a preliminary binder which acts as a precursor for secondary carbon formed during the carbonisation process. In CC composites the carbon fibres (based on rayon/PAN/pitch) in the form of 2-D, 3-D and multi-directional preforms are used as primary carbon.

CARBON fibres PREFORM

3-D array

5-D array

 There are two distinct techniques used to fill the interstices between the carbon fibres. These are (i) Gas Phase Impregnation (Chemical Vapour Deposition, CVD), and (ii) Liquid Phase Impregnation Process.

Liquid Phase Impregnation Process

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 538-1000C.

 Infiltration pyrolysis cycle is repeated several (310) 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 1500-3000C.

Carbon-carbon manufacturing process

Gas Phase Impregnation (Chemical Vapour Deposition, CVD)

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 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 1500-3000C. Typical graphitization temperature is 4530F (2500C). Fabrication of Carbon-Carbon Composites by Chemical Vapor Deposition process results in higher modulus of elasticity and mechanical strength as compare to Liquid Phase Infiltration technique.

PROPERTIES
The strength of carboncarbon with unidirectional reinforcement fibres is up to 700 MPa. Carboncarbon materials retain their properties above 2000 C. Excellent thermal shock resistance. Low coefficient of thermal expansion. High modulus of elasticity (200 GPa). High thermal conductivity.

Low density (about 1.61.98 g/cm3). High strength. Low coefficient of friction. Excellent heat resistance in non-oxidizing atmosphere. High abrasion resistance. High electrical conductivity. Non-brittle failure.

APPLICATIONS
High performance braking systems (eg. brake discs for high speed aircrafts). Refractory material (eg. protection tubes and grids). Hot-pressed dies. Heating elements. Turbojet engine components (eg. rocket nozzles).

COST OF C-C COMPOSITE

SOURCES OF PURCHASE OF CARBON fibres & C-C COMPOSITE

Currently, the United States of America uses nearly 60% of the world production of carbon fibres and the Japanese account for almost 50% of the world capacity for production. The largest producer of this fiber is Toray Industries of Japan. The world production capacity of pitch-based carbon fiber is almost totally based in Japan. We can purchase C-C composite online or by physical ordering.

SUPPLIERS AROUND THE WORLD

Rock West Composites West Jordan, Utah, USA US Composites, Inc. West Palm Beach, Florida

ACP Composites Inc. Livermore, California

SUPPLIERS IN INDIA
S. G. L. Carbon India Private Limited Pune, Maharashtra Valeth Hightech Composites P. Ltd. Kelambakkam, Chennai, Tamil Nadu Kemrock Industries And Exports Limited Vadodara- Halol Express Way, Waghodia, Gujarat Sunrise Traders Kolkata, West Bengal