What is Carbon Composite?

As the fields continuously raise requirements for materials in terms of lightweighting, high strength, and corrosion resistance, traditional metal materials are gradually unable to meet these demands. However, carbon composite stands out due to its outstanding comprehensive performance, becoming the focus application in the modern materials field. So it is important to understand its definition, composition, characteristics, and applications in related industries.

Basic Definition and Composition of Carbon Composites

Definition

Carbon composite material is a new type of composite material with specific functions and mechanical properties. It is composed of carbon fibers as the reinforcing material, with resins, metals, ceramics, etc. as the matrix materials. And through molding processes such as compression molding, winding, hot pressing, etc., the two are closely bonded. It achieves a performance breakthrough, which is far exceeding the combined performance of a single material such as steel.

Key Components

Reinforcing Materials

The reinforcing body directly determines the core mechanical properties such as strength and modulus of the material. Its main component is carbon fiber, which is includes many organic fibers such as the polyacrylonitrile, viscose fibers, and etc. They are made by removing impurities and reorganizing the carbon atomic structure through processes such as high-temperature carbonization and graphitization. Eventually, it forms a fiber-like material with a diameter of only 5-10 micrometers and a carbon content of over 90%. And based on performance differences, carbon fibers can be classified into several grades:

General-purpose grade (such as T300)

Its strength and modulus is moderate, and it has lower cost, mostly used in sports equipment and ordinary industrial components.

High-performance grade (such as T800, T1100)

The tensile strength can reach 5-6 times that of steel, whose elastic modulus is far higher than that of aluminum alloy. So you can use it for fields with extremely high performance requirements such as aerospace and high-end equipment.

In addition, the form of carbon fibers such as continuous fibers, chopped fibers also affects the material properties.

Matrix Materials

The matrix material is responsible for bonding the dispersed carbon fibers into a whole, which evenly transmits external loads. And it prevents damage to the carbon fibers caused by harsh environments such as corrosion and high temperatures. Currently, the mainstream matrix materials are mainly divided into three categories:

Resin matrix

Epoxy resin:

It has strong adhesion, simple molding process, and controllable cost, which is the preferred choice for aerospace and sports equipment.

Phenolic resin:

It has good heat resistance and flame retardancy, so it is mostly used in fireproof components.

Polyimide resin:

It can work stably at temperatures above 200℃, which is suitable for high-end engine components.

Metal matrix

It is predominantly composed of light metals such as aluminum, magnesium, and titanium, along with their alloys. It possesses both high strength and high thermal conductivity, but the forming process is complex and the cost is relatively high. So it is suitable for heat dissipation components in electronic devices and aircraft engine blades, which requires the thermal conductivity.

Ceramic matrix

It primarily consists of materials such as silicon carbide and alumina, which has excellent heat resistance and outstanding wear resistance. It is able to withstand temperatures above 1000℃, which is the core material for components in extreme environments.

Core Characteristics of Carbon Composites

High Strength and High Modulus

Its tensile strength reaches several times that of steel, and its elastic modulus far exceeds that of traditional metals. This enables carbon composite material components to be smaller in size, lighter in weight, which ensures stability. And it is more capable of effectively resisting deformation, which can reduce wing deformation, and ensure flight safety and performance.

Low Density

Carbon composite materials have an extremely low density, being only 1/4 – 1/5 of that of steel and about 1/2 that of aluminum. So you can use it to manufacture components such as car bodies and chassis, which can significantly reduce weight. And in the aerospace field, it reduces the weight of aircraft, which reduces launch costs and increases payload and range.

Corrosion Resistance and Fatigue Resistance

Because of the strong chemical stability and excellent corrosion resistance, it does not react with acids, alkalis, and salts. So it can work in harsh chemical environments for a long time, which extends the lifespan of the equipment and reduces maintenance costs. Additionally, with the  exhibit outstanding fatigue resistance, the damage spreads slowly and the fatigue life is long  under alternating loads.

Designability

Carbon composite materials possess high designability, the performance of components can be designed as needed. You can alter the types, content, lay direction and method of carbon fibers, as well as choose different matrix materials. Moreover, by modifying the molding process, you can manufacture complex-shaped components without the need for extensive cutting operations. It reduces material waste and improving efficiency, enables the satisfaction of special requirements in various fields and expands the application scope.

Main Application Areas of Carbon Composites

Aerospace Field

In terms of passenger aircraft

It reduces weight and improves fuel efficiency, so the fuselage, wings and other core components are extensively made of it. And some fighter jets use it to make skins and bomb bay doors, which enhances maneuverability and improves stealth performance.

In spacecraft

You can use it to reduce weight and increase load capacity for satellite frames and solar panel supports. And it can withstand temperatures above 3000℃ and ensure the launch, which can be use for high-temperature components.

Transportation Field

In the automotive sector

Because its transmission shafts are 40% lighter than metal, it is helpful for achieving lightweighting and energy conservation. And it has higher transmission efficiency, which the weight of the springs is halved, maintaining fatigue resistance.

In the high-speed rail sector

You can use it for the body shells and seat frames of the train, which reduces body weight over 10%. And it can decrease the traction energy consumption by 8% to 10%, and it has good corrosion resistance. So it can reduce maintenance in humid and coastal environments and lower operating costs.

Sports Equipment Field

In ball equipment

For the frame, it is 30% lighter than metal and has good elasticity, efficient force transmission and reduces arm injuries. For golf clubs, you can adjust the shaft by changing the fiber layout to achieve rigid shaft and hard head.

In cycling and track and field equipment

You can use it for high-end bicycle frames and wheels to achieve extremely lightweight and have strong rigidity. Using it for pole vaulting, it is hlepful for the pole stores energy and helps athletes break through the height.

Industrial and New Energy Field

In wind power

Compared with traditional glass fiber blades, it is 30% lighter and more resistant to fatigue. And it can operate stably in strong sea winds for over 20 years, adapting to the development of large-scale and offshore wind power.

In the field of high-pressure containers

Due to its light weight and corrosion resistance, you can use it for natural gas and hydrogen storage tanks. You can also use it in hydrogen fuel cell vehicles’ hydrogen storage tanks, which can reduce weight and improve range.

Conclusion

Carbon composite possesses outstanding performance, which has advantages such as high strength and low density. And it has broad application prospects in fields like aerospace, transportation, sports equipment, and industrial new energy. In addition, it not only drives industrial technological innovation but also provides material solutions for lightweighting and energy conservation.