Carbon fibre, sometimes known as carbon fiber, is a lightweight, highly strong material that is popular in specialized, high-performance applications due to its exceptional properties. It is composed of thin strands of carbon that are tightly bound together in a microcrystalline graphite structure, which gives it its characteristic strength and rigidity while maintaining a very light weight.
The manufacturing of carbon fibre involves several steps:
Polyacrylonitrile (PAN) Production: The majority of carbon fibres are made from a precursor polymer known as polyacrylonitrile, which is an organic polymer with a molecular structure that easily forms sheets of linked carbon atoms.
Stabilization: The PAN is then oxidized at temperatures up to 300°C (572°F) in air, which crosslinks the polymer chains and stabilizes the fibre against melting or fusing during the subsequent carbonization process.
Carbonization: In this step, the stabilized fibres are heated to high temperatures, generally around 1000°C-3000°C (1832°F-5432°F) in an inert atmosphere (like argon or nitrogen), causing the non-carbon atoms to be expelled as gases. This process leaves a filament composed almost entirely of carbon.
Surface Treatment and Sizing: After carbonization, the fibres receive a surface treatment to improve their bonding characteristics, and a sizing or finish is applied, which can protect the fibre and help it adhere to composites.
Properties of Carbon Fibre:
High Strength-to-Weight Ratio: Carbon fibre is known for its rigidity and high tensile strength—it's one of the strongest of all commercial reinforcing fibers, yet it's incredibly lightweight.
Stiffness: The material exhibits high stiffness, meaning it resists deformation under load. This is particularly valuable in applications where the rigidity of the structure is critical.
Low Thermal Expansion: Carbon fibre has a low coefficient of thermal expansion, which means it will only slightly expand or contract in response to temperature changes. This is beneficial for precision engineering applications where dimensional stability is essential.
Chemical Resistance: It is generally resistant to most chemicals, which makes it suitable for use in harsh environments.
Fatigue Resistance: It shows excellent fatigue resistance when compared to many other materials, retaining its features even after many cycles of loading and unloading.
Corrosion Resistance: Unlike metals, carbon fibre does not corrode, which makes it valuable in applications where corrosion is a concern, such as in certain industrial and marine environments.
Because of these qualities, carbon fibre is extensively used in industries where high-strength and low-weight are necessary. These include aerospace, automotive (particularly in racing vehicles), sporting goods (like bicycle frames and tennis rackets), and increasingly in consumer electronics and high-end furniture design.
In furniture, carbon fibre can be used to create sleek, modern pieces that are strong and durable yet light enough to be easily moved. The material's adaptability also allows for innovative designs that might be impossible with traditional materials like wood or metal.
However, there are a few considerations to take into account when working with carbon fibre:
Cost: It's a premium material, and thus, more costly than most other furniture materials.
Manufacturing Complexity: Working with carbon fibre can require specialized knowledge and equipment, which can add to the expense.
Brittleness: While carbon fibre is extremely strong in tension and compression, it can be less impact-resistant and can shatter under certain conditions.
Because of its unique set of properties, carbon fibre remains a material reserved for specific applications where its benefits can be fully realized and justified by the higher costs.
