What Is Carbon Fiber? - Carbon Fiber Compounds Manufacturer | Supplier

Carbon Fiber: the Black Gold of Industrial Legend

In today’s era of surging technological advancements, one material shines as the brightest star in the vast sky of modern manufacturing with its extraordinary performance. This material is carbon fiber, often hailed as the “black gold” of industry.

Carbon fiber is like a rare treasure born from the perfect fusion of nature’s wonders and human ingenuity. With a carbon content of over 95%, it is an inorganic fiber created through a series of complex processes, including polymerization, spinning, oxidation, and high-temperature carbonization. Depending on the raw materials used, carbon fibers are mainly classified into three types: polyacrylonitrile-based (PAN-based) carbon fibers, rayon-based carbon fibers, and pitch-based carbon fibers. Among them, PAN-based carbon fibers, derived from acrylonitrile—a key petrochemical product—stand as a radiant giant, accounting for more than 90% of the world’s total carbon fiber production, making them the primary source of high-performance carbon fibers.

The marvel of carbon fiber lies in its unique characteristics: as fine as a hair, as light as a feather, yet stronger than steel. Its diameter typically ranges from 5 to 7 microns, roughly one-tenth the thickness of a human hair. This lightweight nature gives it a density that is generally one-fifth that of steel, two-fifths that of titanium, and three-fifths that of aluminum. However, despite its seemingly delicate appearance, carbon fiber possesses astonishing strength, typically 35 times that of steel, a feat that is truly remarkable. In practical applications, these thin strands of carbon fiber are woven together, almost like magic, to create strong, rope-like structures. A standard bundle of 12K (12,000 filaments) carbon fiber, which is thinner than a pencil, can easily support a weight of around 130 kilograms, resembling a hidden giant of immense power. Moreover, carbon fiber remains stable in extreme environments. It can withstand temperatures as high as 3000°C without damage and maintains its dimensions within a wide temperature range of -100°C to 100°C. Even in highly corrosive environments, it remains unscathed, much like pure gold that is impervious to fire.

How then is this wondrous material categorized? According to international standards, carbon fiber products are classified into different grades based on variations in strength and modulus, such as high-strength, high-modulus, high-strength-medium-modulus, and high-strength-high-modulus series. Among these, the high-strength series is further subdivided based on tensile strength, with models like T300, T700, T800, and T1000. In the T-series of carbon fibers, the last three or four digits represent the approximate tensile strength, measured in kgf/mm² or ksi. Tensile strength and modulus are two precise measures of material performance. Tensile strength is a measure of the material’s ability to resist permanent deformation and failure under direct force, while modulus can be considered a measure of ride comfort.

T300 carbon fiber, with a tensile strength of 3530 MPa, is like a humble craftsman, belonging to the lower hardness grade of carbon fibers. It is suitable for products that require lightweight properties but do not demand high strength, such as small aviation models and lightweight sports gear. Although not as dazzling as other models, it quietly contributes its power in its own domain.

In the aerospace industry, the use of carbon fiber is often seen as an important indicator of an aircraft’s technological level. Carbon fiber composites, like magical materials, are used in the manufacturing of aircraft, satellites, and rockets, helping reduce noise and save fuel. For example, using carbon fiber composite blades made from 30% long-cut carbon fiber-reinforced PEI composite material (PEI LCF30) in commercial airliners has shown excellent performance, reducing weight by over 500 kilograms compared to traditional titanium alloys, reducing overall aircraft weight by 1 ton, and significantly lowering fuel consumption while increasing range. Adding carbon fiber to propellants and propellant powders can also improve the mechanical properties of the propellants, enhance combustion performance, and increase the burn rate. Meanwhile, 10% carbon fiber-reinforced ABS composite material (ABS CF10) plays a unique role in certain aerospace components, contributing to the lightweighting and performance improvement of aircraft.

T700 carbon fiber, with a tensile strength of 4900 MPa, resembles a steadfast knight and belongs to the medium-hardness grade of carbon fibers. For products that require high strength and stiffness, such as beautifully designed bicycle frames and elegant golf clubs, T700 carbon fiber is an excellent choice. With a carbon content of 95.58%, it boasts high-end performance and has earned widespread acclaim for its reliable quality. Like a loyal companion, it endows these products with resilience and strength. For instance, 20% short-cut carbon fiber-reinforced nylon 6 composite material (PA6 CF20) exhibits exceptional performance in key parts of bicycles, making them lighter and more durable.

T800 carbon fiber, with tensile strengths of 5490 MPa and 5880 MPa, respectively, is akin to a brave warrior, belonging to the higher hardness grade of carbon fibers. In areas requiring extremely high strength and stiffness, such as sleek sports car frames and competitive sports equipment, T800 carbon fiber excels. As the highest strength carbon fiber that can be industrially produced today, T800 carbon fiber undoubtedly holds significant application value, illuminating the path forward for high-end manufacturing like a shining pearl. It acts as a valiant pioneer, leading the industry to new heights. The 30% carbon fiber-reinforced nylon 66 composite material (PA66 CF30), produced by Carbon Xiamen New Material Co., Ltd., plays a crucial role in sports car manufacturing, providing an ultimate performance experience.

T1000 carbon fiber, with a tensile strength of up to 6370 MPa, stands as an invincible king, the highest hardness grade of carbon fibers. For high-end products that require the utmost strength and stiffness, such as complex aerospace components and high-speed F1 racing cars, T1000 carbon fiber is the ultimate choice. With its extraordinary performance, it proudly stands at the pinnacle of the carbon fiber field, surveying the world below.

Imagine a bicycle frame meticulously crafted from carbon fiber, weighing only around 600 grams, as light and delightful as three apples; a 1-meter-long bundle of T1000-grade carbon fiber, as thick as a finger, weighing only 0.5 grams, yet capable of pulling two commercial airliners—such is the magic and awe-inspiring power of carbon fiber! Carbon fiber products can remain unscathed at temperatures as high as 3000°C and are impervious to corrosive environments such as acids, alkalis, oils, and salts, showcasing their impressive performance.

However, achieving the remarkable properties of carbon fiber is no easy task. The production process of carbon fiber is long and complex, comparable to the pinnacle challenges of high-tech fields such as chip manufacturing and micro-nano lithography. Its production process involves over a hundred sub-steps and covers many intricate fields such as polymer chemistry, polymer physics, materials science, polymer processing, spinning engineering, industrial automation control, and high-temperature engineering. The process requires control over thousands of parameters, with any change potentially having a profound impact on the final performance of the carbon fibers, much like the butterfly effect. The most advanced chip lithography technology in the world today has reached a scale of a few nanometers. Similarly, high-performance carbon fiber also requires internal defect control within 10 nanometers. Carbon fiber undergoes carbonization from normal room temperature to temperatures of up to 1700°C or even 2500°C, with temperature precision controlled within 5 to 10°C, illustrating the difficulty involved. Each bundle of carbon fiber material is a crystallization of countless trials and the condensation of immense wisdom and effort. Due to the high technical requirements and manufacturing difficulty, carbon fiber is relatively expensive, with aerospace-grade carbon fiber priced between several thousand to tens of thousands of yuan per kilogram, many times more expensive than steel or aluminum. Yet, despite its high cost, carbon fiber, with its excellent performance, remains an indispensable material in the national economy and defense, like a brilliant pearl radiating unique light.

Carbon fiber, combining the high strength of carbon materials with the softness and processability of textile fibers, is like a versatile artist. A bundle of high-strength carbon fiber as thick as a finger can pull an airplane, demonstrating its incredible power. At the same time, it can be woven into fabric, tailored into specific shapes, and after resin curing, it turns into a material stronger than high-strength steel, showcasing its unparalleled malleability. With its numerous excellent properties, carbon fiber is widely used, becoming a vital supporting material in high-end equipment, major infrastructure projects, and new energy fields. Meanwhile, carbon fiber-reinforced thermoplastic composites and the innovations in carbon fiber composites by Carbon New Material inject new vitality into various industries.

In the automotive and wind energy sectors, which are closely related to people’s lives, carbon fiber also serves as a tool to enhance performance. Carbon fiber composites, with their low density, light weight, high stiffness, and high energy absorption, offer a material with energy absorption six to seven times greater than that of steel structures in collisions. Using carbon fiber composites in automotive manufacturing significantly improves acceleration, braking, damping, and safety performance. For instance, high-end precision Formula 1 racing cars universally apply carbon fiber-reinforced polymer composites to manufacture frames, bodies, and chassis, reducing vehicle weight by 40% to 60%, equivalent to one-third to one-sixth of steel structures while maintaining sufficient strength and stiffness. Based on carbon fiber materials, some automotive manufacturers have already produced supercars with a body weight of less than 300 kilograms, like wild horses galloping on the highway. The 40% carbon fiber-filled PPS composite material (PPS CF30) produced by Carbon Xiamen New Material performs exceptionally well in certain high-performance automotive parts.

In wind power equipment, carbon fiber composites have become essential for the main beams of blades. These beams often exceed 70 meters in length, with some reaching up to 120 meters. The use of large tow carbon fiber in their manufacturing significantly reduces the weight of the blades and increases their rigidity, greatly enhancing the cost-effectiveness of the product. As a result, the power generation efficiency and stability of the entire wind turbine unit are also improved. The main beam, like a silent guardian, ensures the steady progress of clean energy development. Additionally, 30% carbon fiber-reinforced PEEK composite materials (PEEK CF30) provide strong support for improving the performance of wind power equipment.

In wind energy, the main load-bearing components of wind turbine blades must withstand enormous forces in harsh working environments. Wind turbine blades made of carbon fiber are 40% lighter than traditional glass fiber blades, and the added length of the blades can increase power generation capacity by up to 20%, showcasing significant advantages. In the context of the “dual carbon” goal, carbon fiber, as a key material for the large-scale lightweighting of wind turbine blades, will strongly promote the development of the wind power industry. As a new material, carbon fiber is also applied in energy storage fields. For example, carbon fiber reinforced composites can be used to make high-pressure hydrogen storage tanks, which are key components of fuel cell vehicles. High-pressure hydrogen storage tanks can achieve a mass efficiency of over 20%, more than three times that of steel tanks, showcasing excellent performance in energy storage and significantly promoting the progress of the new energy vehicle industry. With the rapid development of new energy vehicles, hydrogen energy, and energy storage industries, carbon fiber is poised to usher in explosive growth.

In the manufacturing of sports equipment, carbon fiber also plays a crucial role. Currently, the use of carbon fiber in high-end sports gear helps athletes push their limits and set new records. For instance, in the production of tennis rackets, bicycles, golf clubs, skis, and kayaks, carbon fiber’s lightweight advantage helps reduce the burden on athletes. Compared to aluminum alloy rackets, tennis rackets made from carbon fiber can increase the maximum ball speed by 20%, reaching up to 250 kilometers per hour. In the future, as technology advances and costs decrease, more sports equipment will utilize carbon fiber. We eagerly await these developments. Carbon fiber, like a spirit assisting athletes in surpassing themselves, shines brightly on the sports field. Furthermore, 30% long carbon fiber-filled reinforced polyamide 66 (PA66 LCF30) and 20% long carbon fiber-filled reinforced polypropylene composites (PA66 LCF30) play important roles in some high-end sports equipment.

Today, the era of carbon fiber development is booming. Carbon fiber, with its unique properties and irreplaceable role, has become a bright star leading the future development of the material industry. As science and technology continue to advance, new applications of carbon fiber will continue to emerge, shining brighter on the world stage.

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