Carbon components (Carbonteile Herstellung) are continually required by the automotive, aerospace, bike and medical technology sectors. Why? Because CFRP, carbon fiber-reinforced polymer, is lightweight, extremely strong and resistant to corrosion. But how is carbon made and how does it rank compared to other products?
What is Carbon?
Carbon fiber is made up of very thin fibers of carbon atoms in a crystalline matrix, the result of which is that the material is highly tensile and stiff. Fibers are likely to be made from a precursor polymer known as polyacrylonitrile (PAN) in a very complicated, high-temperature process.
The carbon part manufacturing process
Carbon manufacture has a number of very technological and high-tech processes:
- Fiber production: PAN fibers are oxidised and subjected to high temperatures in furnaces. It incinerates the non-carbon content and nothing is left but almost pure carbon fibers.
- Woven fibers: Fibers are woven in a mat or fabric form. Fiber orientation plays a very important role and decides the tensile strength and flexibility of the end product.
- Resin infusion: Woven carbon fiber is pre-impregnated with a resin system (typically epoxy). This produces so-called prepreg – pre-impregnated composite pre-shaped to form.
- Molding and curing: Prepreg material is formed and autoclave-cured in a pressure oven. This fixes the shape and seals off the mechanical properties of the product.
- Completion of Work: Trimming, drilling and polishing to spec following curing.
Advantages of carbon production
- Lightweight: 70% lighter than steel but stronger.
- Durable: Fatigue, corrosion and hostile climatic resistance.
- Rigid and strong: Ideal for high-performance applications in racing vehicles, aeronautics and sporting equipment.
- Freedom of design: The technology enables intricate, individual shapes and accurate engineering.
Half art and half science is carbon component production. It provides materials stronger and lighter than most metals but less rigid. Carbon manufacture is revolutionising motor sport, aerospace engineering and design into consumer products
