CARBON–CARBON COMPOSITES

COMPOSITE MANUFACTURING:

 One of the most advanced and promising engineering material is the carbon
fiber reinforced carbon-matrix composite, often termed a carbon–carbon
composite; as the name implies, both reinforcement and matrix are carbon.

 These materials are relatively new and expensive and, therefore, are not
currently being utilized extensively.

 Their desirable properties include high-tensile moduli and tensile strengths that
are retained to temperatures in excess of resistance to creep, and relatively large
fracture toughness values.

 Furthermore, carbon–carbon composites have low coefficients of thermal

expansion and relatively high thermal conductivities; these characteristics,
coupled with high strengths, give rise to a relatively low susceptibility to
thermal shock. Their major drawback is a propensity to high temperature
oxidation.

 The primary reason that these composite materials are so expensive is the
relatively complex processing techniques that are employed. Preliminary
procedures are similar to those used for carbon-fiber, polymer-matrix
composites.

 That is, the continuous carbon fibers are laid down having the desired two-or
three dimensional patterns; these fibers are then impregnated with a liquid
polymer resin, often a phenolic.

 The two general categories of matrix precursors used for carbon-carbon

densification are thermosetting resins, such as phenolic and furfurals, and pitch
based on coal tar and petroleum.

 The work piece is next formed into the final shape, and the resin is allowed to
cure. At this time the matrix resin is “pyrolyzed,” that is, converted into carbon
by heating in an inert atmosphere.

1
 During pyrolysis, molecular components consisting of oxygen, hydrogen, and
nitrogen are driven off, leaving behind large carbon chain molecules.

 Subsequent heat treatments at higher temperatures will cause this carbon matrix
to densify and increase in strength. The resulting composite, then, consists of
the original carbon fibers that remained essentially unaltered, which are
contained in this pyrolyzed carbon matrix.

CARBON FIBRE STRUCTURE:

 Carbon fibers can be used as reinforcements in much different architecture:

random fibers; two directional (2-D) and three directional (3-D) geometries to
increase the off-axis strength.

Fig. 1 Three directional constructions

APPLICATIONS:

 Carbon-carbon composites are attractive for space structure because of their

relatively low density. Typical densities range from 1.4 g/cm3 for flat panel and
tube to 2 g/cm3.

2
 Carbon-carbon composites are biocompatible and can be tailored to be
structurally compatible with bone for application such as integral fixation of
furnace.

 Multi directional carbon-carbon composites are also being studied for potential
use in hip joint replacement.

OXIDATION:

 Oxidation of carbon-carbon composites can begin at temperature as low as

400oC. The rate of oxidation depends on the perfection of the carbon structure
and its purity.

 Highly disordered carbons such as carbonized resins given low temperature

heat treatments will oxidize at appreciable rates at 400oC.

 Highly graphitic structure, such as pitch based carbon fibers, can be heated as
high as 650oC before extensive oxidation occurs. Oxidation at high
temperatures becomes more rapid.

 Adding inhibitors phases to the matrix has become an important part of an

overall oxidation protection system, because inhibitors allows some control of
oxidation that occurs through defects in coatings.

 Inhibitors can also prevent catastrophic oxidation failure due to coating

separation at high temperatures.

 Additions of boron, boron compounds, and phosphorus compounds have been

effective in protecting carbon bodies by true chemical inhibition and formation
of internal and external glass layers that act as diffusion barriers.

PROTECTIVE COATING:

 Coating technology for carbon-carbon has been driven primarily by the

aerospace and defense industries, in applications where the composite is
exposed to high temperature oxidizing environments.

3
 SiC based and Si3N4 based coatings have found broad use at temperature below
1700oC because use at minimum thermal mismatch stresses and low oxide scale
growth.

 In the higher temperature ranges time (1700-2200oC) refractory carbides and

borides also been used.

 Coating deposition techniques that have been used include CVD, Pack
Cementation and Slurry processes.

Properties of refractory materials deposited on carbon-carbon composites

 Chemical vapor deposition attempts to expand carbon-carbon use to turbine

engine hot section and exhaust components fostered the need for protective
coatings that could be applied as thin layers over the structural components.

 The coating developed has been dependent on the application lifetime as well as
on dynamic or static structural requirements.

 The CVD coatings are normally applied in multiple cycles to ensure even
deposition rates over curved surfaces. A substrate pretreatment is normally used
to enhance adherence.