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Shaft Design
Published in Wei Tong, Mechanical Design and Manufacturing of Electric Motors, 2022
Carbon fiber is one of modern materials that has been developed and employed in applications where a large strength-to-weight ratio, high rigidity, and strong corrosion resistance are required, such as in aviation and automotive industries. Carbon fiber has several exceptional advantages over conventional metallic materials, including high tensile strength (five times higher than steel), high stiffness (two times higher than steel), lightweight, corrosion-free, high-temperature tolerance, high thermal conductivity (equivalent to copper), and low thermal expansion. Moreover, as a non-metallic material, the application of carbon fiber as the shaft material can help mitigate shaft voltage and other electrical problems. In practice, carbon fibers are usually composited with other materials (e.g., thermosetting resin such as epoxy, polyester, or vinyl ester) to form composite materials such as carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP). Among all fiber-reinforced materials, CFRP and GFRP are increasingly replacing conventional materials in recent years. Compared to aluminum and steel, CFRP composite structure of equal strength would likely weight 1/5 that of steel structure and 1/2 of aluminum structure. Therefore, they have been extensively used in a wide range of contemporary applications particularly in space and aviation, automotive, civil construction, renewable energy (e.g., wind turbine blades), and sports equipment.
Introduction to Recycling of Polymers and Metal Composites
Published in R.A. Ilyas, S.M. Sapuan, Emin Bayraktar, Recycling of Plastics, Metals, and Their Composites, 2021
R.A. Ilyas, S.M. Sapuan, Abdul Kadir Jailani, Amir Hamzah Mohd Yusof, Mohd Nurazzi Norizan, Mohd Nor Faiz Norrrahim, M.S.N. Atikah, A. Atiqah, Emin Bayraktar
Previous research on recycling carbon fiber composites by Shehab et al. (2020) has established the challenges in cost modeling. Carbon fiber composites are commonly used in various industries because of their superior properties in contrast to traditional materials. Increasing demand in accordance with ecological legislation has encouraged numerous advancements in various carbon fiber composites salvaging strategies, such as thermal, chemical and mechanical recycling processes, where the respective process of reprocessing has its criteria and outputs, along with certain financial effects, and cost modeling is used to validate it. Thanks to their lightweight qualities, carbon fiber composites are commonly used in the aviation industry and contribute to reducing emissions from flights, where up to half of the weight of modern aircraft, such as the Airbus A350, consists of carbon fiber composites. The studies presented that potentially the core issues found may be a beneficial approach to understanding cost drivers by offering an analysis of fundamental conditions that could influence costs (Shehab et al., 2020).
Fibre-reinforced composite materials
Published in William Bolton, R.A. Higgins, Materials for Engineers and Technicians, 2020
The bulk of carbon fibre is manufactured by the heat-treatment of polyacrylonitrile (PAN) filament. The process takes place in three stages in an inert atmosphere: A low-temperature treatment at 220°C. This promotes cross-linking between adjacent molecules so that filaments do not melt during subsequent high-temperature treatments.The temperature is raised to 900°C to ‘carbonise’ the filaments. Decomposition takes place as all single atoms and ‘side groups' are ‘stripped’ from the molecules, leaving a ‘skeleton’ of carbon atoms in a graphite-like structure.The heat-treatment temperature is then raised to produce the desired combination of properties. Lower temperatures (1300–1500°C) produce fibres of high tensile strength and low modulus, whilst higher temperatures (2000–3000°C) provides fibres of low strength but high modulus.
Comparison of failure modes and damage mechanisms of CFRP and C/C composite joints under out-of-plane loading
Published in Mechanics of Advanced Materials and Structures, 2022
Yanfeng Zhang, Zhengong Zhou, Shidong Pan, Zhiyong Tan
Carbon fiber has a series of advantages such as high specific strength, high specific modulus, high temperature resistance, low coefficient of thermal expansion, creep resistance and others. The composites composed of carbon fiber preforms and different matrices indicate excellent physical properties [1]. Structures made of carbon fiber reinforced composites have been widely applied in aerospace, national defense & military industry, construction, automobile and other fields [2, 3], especially to the connection between various components, which reduces the weight of structures compared with metal joints. Meanwhile, the selection of different arrangements of carbon fiber reinforcements and types of matrix can meet the needs of structures in different environments. At present, major matrices of carbon fiber composites include resin, ceramic, carbon, metal and so on [4].
Development of pitch-based carbon fibers: a review
Published in Energy Sources, Part A: Recovery, Utilization, and Environmental Effects, 2020
Jinchang Liu, Xujun Chen, Dingcheng Liang, Qiang Xie
Pitch-based carbon fibers, including isotropic pitch-based and mesophase pitch-based, are indispensable materials for various industries. The development and fabrication of pitch-based carbon fibers with high performance are still key projects in many countries. Furthermore, directional preparation of pitch-based carbon fibers, such as preparing low-cost carbon fibers for lightweighting new energy vehicles, has been a research hotspot in the USA, Japan, and other countries who have possessed advanced technology for carbon fiber industrial production. Carbon fiber production is a time-consuming process covering raw material pretreatment, pitch preparation, melt-spinning, stabilization, carbonization, and graphitization. Each step has a significant influence on the properties and performance of carbon fiber, and each step should be controlled effectively for preparing carbon fiber with targeted performance. The problems of current carbon fiber production and prospects of carbon fiber industrialization are the main challenges for broadening application fields of pitch-based carbon fibers.
Investigation of patch hybridization effect on the composite patch repair of a cracked aluminum plate: A pragmatic approach
Published in Mechanics of Advanced Materials and Structures, 2019
Alpesh H. Makwana, A. A. Shaikh, A. K. Bakare, Saikrishna Chitturi
Parts used in engineering application are not stressed uniformly, due to specific loading in certain areas. Application of a material with throughout the same strength, properties or cross-section does not require every time. Hybrid composites are developed in a logical manner to combine the superior properties of different fibers and matrix in one material. They have been developed without losing functionality to meet the various design requirement in a more economical way. Boron fiber, carbon fiber, kevlar fiber and glass fiber are used as a reinforcement constituent in the composite patch for repair of a cracked structure. Among this boron and carbon fibers are cost prohibitive compared to other materials. Carbon fibers have attractive properties like strength, stiffness, and lightweight. Carbon fiber induces galvanic corrosion of the metal due to a good conductor of electricity. Carbon fiber suffers from lack of energy absorption rate, low toughness and low strain to failure. Repairing of any high stress concentrated regions of damaged location with fiber reinforcement of low toughness provoke premature failure of a structure below design limits [3]. The composite patch prepared from carbon fiber may catastrophically fail after propagation of a crack in the patch.