Knowing every detail about the Production of CFRP material

carbon fibre reinforced plastic

The material carbon fibre-reinforced plastic (CFRP) is rather high-tech. It is continuously introducing new applications because of its qualities, which dwarf those of steel and aluminium, and it is now vital in many fields. We take you on a journey of exploration into the world of carbon fibres so you can understand how minuscule fibres may be made into plastic that is reinforced with carbon fibre.

How do carbon fibres work?

Industrially created fibres that are processed to include practically just carbon are known as carbon fibres. They are eight times thinner than human hair and very tiny.

1000 to 60000 filaments are joined into a multifilament yarn (roving), which is wrapped onto a bobbin, to make them suitable for diverse purposes.

Exactly how are carbon fibres made?

Carbon fibres are created using sophisticated manufacturing techniques. It begins with a base substance like polyacrylonitrile (PAN). The white powder makes up the solid state of polyacrylonitrile. It resists chemicals and solvents and is strong and rigid. The so-called PAN “precursor” has been made by first producing tiny threads from it that are then coiled onto a spool.

These threads are then put in the oven in the following phase. At 200 to 300 degrees Celsius, they are first oxidised, then at 1200 to 1800 degrees Celsius, they are carbonised. What’s left are strong threads with a very high carbon concentration. The carbon fibre is wrapped up and prepared for usage after surface treatment and sizing.

Why does CFRP exist?

Carbon fibre-reinforced plastic is referred to as CFRP. A material known as CFRP is made up of a base or carrier substance also known as matrix and a second reinforcing component known as carbon fibre that is incorporated into the matrix. As a matrix material, synthetic resin is often employed. The type of carbon fibres employed, the matrix, and the manufacturing method all affect the cured composite’s mechanical characteristics.

Exactly how is CFRP made?

Depending on the application, different methods of making CFRP offer distinct benefits in terms of production costs and/or a variety of qualities. But carbon fibre always comes first in the Herstellung von CFK. Using techniques that are common in the textile industry, it is woven, put into a carbon fibre cloth, braided, or wrapped.

Carbon fibres are created using a combination of mechanical and chemical processes. The precursor is gathered into long strands or fibres and cooked to an extremely high temperature without exposing it to oxygen. The fibre cannot burn in the absence of oxygen. Instead, because of the high temperature, the fibre’s atoms bounce erratically until the majority of the non-carbon atoms are ejected. This process, known as carbonization, results in the formation of a fibre made up mostly of long, intricately interwoven chains of carbon atoms.

  • Stabilizing

The fibres must undergo chemical modification before carbonization to change their linear atomic bonding to a more thermally stable ladder bonding. The fibres in the air are heated for 30-120 minutes at a temperature of around 390-590° F (200-300° C) to achieve this. As a result, the fibres absorb oxygen molecules from the atmosphere and change the way their atomic bonds are arranged. The chemical processes that stabilise materials are complex and include several stages, some of which take place concurrently. 

Additionally, Kohlefaserplatten produce heat on their own, which needs to be managed to prevent overheating the fibres. The stabilisation procedure is carried out commercially with a range of tools and methods. The fibres are pulled through a succession of heated chambers in various procedures. In others, hot air is used to suspend beds of loose materials as the fibres travel over hot rollers and through them. Some procedures employ warm air combined with certain gases to hasten the stabilization’s chemical reaction.

  • Carbonizing

After the fibres have been stabilised, they are heated for several minutes in a furnace with a gas mixture devoid of oxygen to a temperature of around 1,830-5,500° F (1,000-3,000° C). The fibres can’t burn in extremely high temperatures because there isn’t enough oxygen there. The locations where the fibres enter and exit the furnace are sealed to prevent oxygen from entering, and the gas pressure inside the furnace is kept higher than the air pressure outside. As the fibres heat up, they start to release various gases such as water vapour, ammonia, carbon monoxide, carbon dioxide, hydrogen, nitrogen, and others in addition to a few carbon atoms. 

The remaining carbon atoms form firmly bound carbon crystals that are oriented roughly parallel to the long axis of the fibre as the non-carbon atoms are removed. To better regulate the pace of heating during carbonization, some techniques employ two furnaces that operate at two distinct temperatures.

  • surface treatment

The fibres’ surface after carbonization makes it difficult for them to adhere to the epoxies and other components used in composite composites. The surface of the fibres is slightly oxidised to improve their bonding abilities. Better chemical and mechanical bonding qualities are produced by the addition of oxygen atoms to the surface, which also etches and roughens the surface. The fibres can be exposed to various gases, such as air, carbon dioxide, or ozone, or various liquids, such as sodium hypochlorite or nitric acid, to oxidise them. 

By making the fibres the positive terminal in a bath of different electrically conductive materials, the fibres can also be coated electrolytically. To prevent the formation of microscopic surface flaws like pits, which might lead to fibre failure, the surface treatment procedure must be carefully managed.

  • Sizing

The fibres are coated after the surface treatment to shield them from abrasion during winding or weaving. This procedure is known as sizing. products for coatings are chosen so that they work well with the glue that is used to create composite products. The usual coating materials include nylon, urethane, polyester, epoxy, and others.

The coated fibres are threaded onto bobbins, which are cylindrical objects. The fibres are twisted into yarns of various sizes by loading the bobbins into a spinning machine.