What are carbon fibers?

Carbon fibers are industrially produced fibers which are refined in such a way that they consist almost exclusively of carbon. They are microscopically small and about eight times thinner than a human hair. In order to make them usable for various applications, 1000 to 60000 filaments are combined into a multifilament yarn (roving), which is wound onto a spool. Carbon fibers are the product of a high-tech manufacturing process. It starts with a starting product such as polyacrylonitrile (PAN). Polyacrylonitrile is a solid in the form of a white powder. It is hard and stiff as well as resistant to chemicals and solvents. In a first process step, thin threads are produced from it, which are then wound onto a spool – the so-called PAN “precursor” has been created. In the next step, these threads are placed in the oven. First, they are oxidized at 200 to 300 degrees Celsius and then carbonized at 1200 to 1800 degrees Celsius. What remains are threads with a very high carbon content and high strength. After surface treatment and application of a sizing, the carbon fiber is wound up and is ready for use.

On top of being strong, carbon fiber has the following advantageous properties :

High tensile strength
High stiffness
High strength to weight ratio
High chemical resistance
Temperature tolerant to excessive heat
Low thermal expansion

SECTORS

Aviation and space
Defence
Shipping
Mass Transportation (Rail & Metro Rail)
Telecommunication
Infrastructure & Construction
Power & Renewable Energy
Industrial pipes
Automobile

AVIATION

The development of light-weight, high-temperature resistant composite materials will allow the next generation of high-performance, economical aircraft designs to materialize. Usage of such materials will reduce fuel consumption, improve efficiency and reduce direct operating costs of aircrafts.

Composites are widely used in the Aircraft Industry and have allowed engineers to overcome obstacles that have been met when using the materials individually. The constituent materials retain their identities in the composites and do not merge completely into each other. Together, the materials create a ‘hybrid’ material that has improved structural properties.

DEFENCE

In the defence sector, fiber-reinforced polymer composites (FRPs) are used in application such as land systems, military aircraft, UAVs, naval vessels, and weapons. The properties that make FRPs desirable for use in defence applications are its lightweight, impact resistance, corrosion resistant, design flexibility.

POWER & RENEWABLE ENERGY

Wind Energy

Wind Mill Blade
Nacelle Cover
Nose Cone

Solar Energy

Solar Structure
Solar Street Light Poles
Meter Boxes
Cooling Tower FRP parts

Cooling Tower FRP parts

Structural Profiles
Decking System
Fanstacks / Fanrings
Moulded / Pultruded Gratings
Fan blades
Cooling Water Circulation Pipes
Implant Piping System

AUTOMOBILE

Composites are being considered to make lighter, safer and more fuel-efficient vehicles. A lot of companies are laying their efforts on producing automotive vehicles with composites. Carbon fibers can be extensively used for the upcoming revolution of electric vehicles.

The major products being manufactured are as mentioned below :

Front Fascia
Dash board
Seat Pan & Structure
Roof Panels
Floor Module with flooring
Wheel for LMV
Steering
Interior Side Window Panels
Partition Panel
Bonnet Cover

CONSTRUCTION

Carbon fiber is use primarily in the strengthening and reinforcement of concrete, steel, timber, and masonry. The properties of carbon fiber, such as high strength, rigidness, and tensile strength make it a popular material in civil engineering.