Carbon Fibers

337 Pages·2015·13.246 MB·English

by  Soo-Jin Park (auth.)

Springer Series in Materials Science 210
Soo-Jin Park
Carbon
Fibers
Springer Series in Materials Science
Volume 210
Series editors
Robert Hull, Charlottesville, USA
Chennupati Jagadish, Canberra, Australia
Richard M. Osgood, New York, USA
Jürgen Parisi, Oldenburg, Germany
Tae-Yeon Seong, Seoul, Korea, Republic of (South Korea)
Shin-ichi Uchida, Tokyo, Japan
Zhiming M. Wang, Chengdu, China
The Springer Series in Materials Science covers the complete spectrum of
materialsphysics,includingfundamentalprinciples,physicalproperties,materials
theory and design. Recognizing the increasing importance of materials science in
future device technologies, the book titles in this series reflect the state-of-the-art
in understanding and controlling the structure and properties of all important
classes of materials.
More information about this series at http://www.springer.com/series/856
Soo-Jin Park
Carbon Fibers
123
Soo-JinPark
Department of Chemistry
InhaUniversity
Incheon
Korea,Republic of (SouthKorea)
ISSN 0933-033X ISSN 2196-2812 (electronic)
ISBN 978-94-017-9477-0 ISBN 978-94-017-9478-7 (eBook)
DOI 10.1007/978-94-017-9478-7
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Preface
Recently, carbon-based materials have received much attention for their many
potential applications. The carbon fibers are very strong, stiff, and lightweight,
enabling the carbon materials to deliver improved performance in several appli-
cations such as aerospace, sports, automotive, wind energy, oil and gas,
infrastructure, defense, and semiconductors. However, the use of carbon fibers in
cost-sensitive, high-volume industrial applications is limited because of their rela-
tively high costs. However, its production is expected to increase because of its
widespreaduseinhigh-volumeindustrialapplications;therefore,themethodsused
for manufacturing carbon fibers and carbon fiber-reinforced composites and their
structures and characteristics need to be investigated.
This book contains eight chapters that discuss the manufacturing methods,
surface treatment, composite interfaces, microstructure–property relationships with
underlying fundamental physical and mechanical principles, and applications of
carbon fibers and their composites.
Chapter1providesabriefoverviewofcarbonsandcarbonfibers,includingtheir
origin,history,manufacturingtechnologies,performance,andglobalmarkettrends.
Chapter 2 introduces the precursors and manufacturing processes of carbon fibers.
Chapter 3liststhevariousmatrices forcarbon fibercompositesandfocusesonthe
thermosetting resins and thermoplastic resins. Chapter 4 reviews the effect of sur-
face treatment on the properties of carbon fiber composites. The characteristics of
carbon fibers were measured using XPS, x-ray diffraction (XRD), EA, Raman
spectroscopy,scanningtunnelingmicroscopy(SEM),andatomicforcemicroscopy
(AFM)are presentedin Chap. 5. The selection of manufacturing processes, matrix
type, and molding processes for carbon fiber composites are presented in Chap. 6.
v
vi Preface
Chapter 7 describes the recent use of carbon fibers for applications such as
adsorbents, energy storage, molecular sieves, catalysts, carbon fiber-reinforced
composites, and carbon/carbon composites. Lastly, Chap. 8 introduces low-cost
techniquesforgeneralindustries,thincarbonfibersforextremeindustriesandsmart
carbon/carbon composites.
The authors are grateful to everyone who has contributed to this book.
Soo-Jin Park
Contents
1 History and Structure of Carbon Fibers . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Origin and History of Carbon Fibers . . . . . . . . . . . . . . . . . . . . 3
1.3 Definition of Carbon Fibers. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Classification of Carbon Fibers . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1 Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 Precursor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.3 Commercial Availability. . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Structure of Carbon Fibers . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6 State of Carbon Fiber Industry. . . . . . . . . . . . . . . . . . . . . . . . . 21
1.6.1 Technology Development Trends . . . . . . . . . . . . . . . . . 21
1.6.2 Utility Development Trends . . . . . . . . . . . . . . . . . . . . . 23
1.6.3 Market Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.7 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2 Precursors and Manufacturing of Carbon Fibers. . . . . . . . . . . . . . 31
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.2 Acrylic Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2.1 PAN Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.2.2 Polymerization Methods for Production of PAN-Based
Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2.3 Manufacture of Carbon Fibers from PAN-Based
Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2.4 Types of Polyacrylonitrile-Based Carbon Fibers . . . . . . . 44
2.3 Cellulosic Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.1 Cellulosic Precursors. . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3.2 Rayon Precursor for Production of Cellulose-Based
Carbon Fibers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.3 Manufacture of Carbon Fibers from Cellulosic
Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
vii
viii Contents
2.4 Pitch Precursors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.4.1 Petroleum Pitch Precursors. . . . . . . . . . . . . . . . . . . . . . 54
2.4.2 Coal Tar Pitch Precursors. . . . . . . . . . . . . . . . . . . . . . . 55
2.4.3 Preparation Methods of Pitch-Based Precursors. . . . . . . . 55
2.4.4 Manufacture of Carbon Fibers from Pitch-Based
Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.5 Other Forms of Precursors . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Matrices for Carbon Fiber Composites . . . . . . . . . . . . . . . . . . . . . 67
3.1 Thermosetting Resins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.2 Cyanate Ester Resins. . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.3 Epoxy Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.1.4 Phenolic Resins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.1.5 Polyester Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1.6 Polyimide Resins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1.7 Vinyl Ester Resins. . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Thermoplastic Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2.2 Acrylonitrile Butadiene Styrene Resins. . . . . . . . . . . . . . 86
3.2.3 Polyamide Resins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2.4 Polycarbonate Resins. . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.2.5 Polyetheretherketone Resins . . . . . . . . . . . . . . . . . . . . . 89
3.2.6 Polyetherimide Resins . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.2.7 Polyethersulfone Resins. . . . . . . . . . . . . . . . . . . . . . . . 92
3.2.8 Polyethylene Resins. . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.2.9 Polyphenylene Sulfide Resins. . . . . . . . . . . . . . . . . . . . 94
3.2.10 Polypropylene Resins. . . . . . . . . . . . . . . . . . . . . . . . . . 95
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4 Surface Treatment and Sizing of Carbon Fibers . . . . . . . . . . . . . . 101
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2 Oxidation of Carbon Fibers. . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2.1 Gaseous Oxidants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2.2 Acid Oxidation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.2.3 Electrochemical Oxidation . . . . . . . . . . . . . . . . . . . . . . 113
4.2.4 Treatment with Nonoxidative Agents. . . . . . . . . . . . . . . 116
4.3 Plasma Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Contents ix
4.4 Other Surface Modification Methods . . . . . . . . . . . . . . . . . . . . 119
4.4.1 Radiation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.4.2 Fluorination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.4.3 Polymer Coating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.4.4 Grafting with Inorganic Materials . . . . . . . . . . . . . . . . . 124
4.5 Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5 Testing of Carbon Fibers and Their Composites . . . . . . . . . . . . . . 135
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.2 Evaluation of Carbon Fibers . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2.2 Elemental Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.2.3 X-ray Photoelectron Spectroscopy. . . . . . . . . . . . . . . . . 137
5.2.4 X-ray Diffraction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
5.2.5 Raman Spectroscopy . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.2.6 Auger Electron Spectroscopy . . . . . . . . . . . . . . . . . . . . 142
5.2.7 Scanning Tunneling Microscopy (STM). . . . . . . . . . . . . 143
5.2.8 Atomic Force Microscopy . . . . . . . . . . . . . . . . . . . . . . 144
5.2.9 Titration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.2.10 Moisture Content. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.2.11 Thermal Stability and Oxidative Resistance . . . . . . . . . . 147
5.2.12 Filament Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.2.13 Electrical Resistivity . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.2.14 Coefficient of Thermal Expansion. . . . . . . . . . . . . . . . . 153
5.2.15 Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.2.16 Specific Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.2.17 Thermal Transition Temperature . . . . . . . . . . . . . . . . . . 155
5.2.18 Tensile Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
5.3 Evaluation of Composites. . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.3.2 Coefficient of Thermal Expansion. . . . . . . . . . . . . . . . . 156
5.3.3 Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.3.4 Poisson’s Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5.3.5 Rheological Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . 159
5.3.6 Tensile Behavior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.3.7 Shear Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.3.8 Flexural Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.3.9 Uniaxial Compressive Behavior . . . . . . . . . . . . . . . . . . 166
5.3.10 Fatigue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.3.11 Creep. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.3.12 Impact Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.3.13 Fracture Toughness. . . . . . . . . . . . . . . . . . . . . . . . . . . 171