CARBON FIBER REINFORCED CARBON

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• A Carbon-Carbon composite is a carbon fiber reinforced carbon matrix composite. It is a two-phase composite material and as the name implies, both the matrix and reinforcement fiber are carbon. Carbon-Carbon can be tailor-made to give a wide variety of products by controlling the choice of fiber-type, fiber presentation and the matrix. Carbon-Carbon is primarily used for extreme high temperatures and friction applications.

  Carbon-Carbon combines the desirable properties of the two constituent carbon material. The Carbon matrix (Heat resistance, Chemical resistance, Low thermal expansion coefficient, High-thermal conductivity, Low electric resistance, Low specific gravity) and the Carbon Fiber (High-strength, High elastic modulus) are molded together to form a better combination material. The reinforcing fiber is typically either a continuous (long-fiber) or discontinuous (short-fiber) carbon fiber type.

C/C COMPOSITE MATERIAL COMPARISON

Compared to Metals

• High heat resistance
• Low thermal expansion
• Lightweight (1/5 of metal)
• Does not bond
• Excellent resistance to corrosion and radiation

Compared to Graphite

• High strength and rigidity
• High resistance to fracture

Compared to Ceramics

• High resistance to fracture
• High thermal shock resistance
• Precision machinable

Compared to Plastics

• High heat resistance
• Excellent resistance to corrosion and radiation
• High wear resistance

CFC DESIGN TECHNOLOGY

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  PY Manufacturing

  CFC Design has succeeded in developing a new manufacturing method resulting in reduced production time and cost. This new patented method ensures better penetration of the carbon fiber bundles into the carbon matrix, ensuring uniform properties in the composite and higher strength than conventional C/C composites.

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  Fiber Arrangement

  By controlling the directional arrangement and the length of carbon fiber reinforcement that supports the carbon matrix, we are able to change the characteristics of the C/C Composite so that it can be used for different kinds of application.

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  C/C MC

  One of the unique characteristics of C/C Composite is its porous structure within the carbon matrix. By introducing metal into the carbon matrix, we are able to transform the characteristics of the C/C Composites. With the addition of metal to the main structure of C/C composite, the new material brings out effectively the best functions of each element so that it can be used for different kinds of application.

CAPABILITIES & SOLUTIONS

Since its establishment, CFC Design has been promoting the new technologies of advanced composite materials – including the C/C composite – by introducing innovative manufacturing methods to diverse segments such as the high temperature, friction material, and advanced technology industries. We offer our expertise in the areas of innovation and co-development through a wide range of high-performance composite materials and engineering design to help improve productivity and contribute to energy savings.

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  C/C Manufacturing Raw Material procurement / Blending / Carbon Powder / Carbon Binder / Resin / PY (pre-formed yarn) Bobbin / PY Sheet and Lamination / Hot Press Molding / Carbonization / Graphitization / Primary Machining / Surfacing / Thickness Adjustment / Sizing / Cleaning

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  Engineering Design Customized Product Designs / Material Selection / Overall Layout, Component Shapes, Materials and Dimensions / Load Calculation / Safety & Ergonomics / Quality Control / Assembly, Transport & Operations / FEM Analysis / CAD-CAM / Maintenance, Schedule & Costs

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  C/C Machining Large Capacity Primary & Secondary Precision Machining / Axis machining centers / CNC Horizontal boring and milling machines / Max. Plate size 1000mm X 2000mm / Max. Bar thickness up to 75mm / Cultivated technologies with over 30 year experience in Carbon fiber reinforced carbon machining

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  Purification High Purity C/C Material for Semiconductor and PV applications / Post (secondary) high-purity treatment / Elimination of harmful elements / Halogen Purification can reach ash contents and impurity levels to less than 5ppm

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  Coating Wide range of C/C coating technologies and finishes available for Anti-Dust / Anti-Oxidation / Anti-Carburization / Ceramic Coat (APS, Alumina, BN, Zirconia, Yttria, etc. / Glassy-Carbon Coat / Thermal-Sprayed / Resin-Coat / Nickel-Plate / Infiltration / Slurry

PY MANUFACTURING

Although the C/C composite has excellent performance, the conventional manufacturing method (impregnation method and CVD method) requires complicated steps and requires very long time to manufacture. And as a result it was extremely expensive. CFC have succeeded in a process simplification, shortening delivery time and reducing costs by developing innovative new manufacturing method called preformed yarn method (PY method).

FIBER ARRANGEMENTS

Since the C/C composite is a composite material reinforced with carbon fiber, by controlling the orientation (fiber direction) and length of the fiber, which is the source of its mechanical strength, it is possible to derive various characteristics according to the specific application. Through the accumulation of technology over the years, as shown in the table below, we can realize many product types and can respond to customers’ diverse needs.

Unidirectional Fiber Orientation

Long-fiber

Application: High-strength Rods, etc. Features: Long Rods width maximum bending Strength: Used for Springs & Pins

Bi-directional Fiber (0°/90°) Orientation

Long-fiber

Application: Plates, Large-size boards Features: Heat-treatment trays, etc. Most common use in the heat-resistance field

Multi-directional Fiber Orientation

Short-fiber

Application: Bolts & Nuts, Precision Jigs, etc. Features: Well suited for precision machined parts and complex components

C/C MC [Carbon-Carbon Metal Composite]

One of the unique characteristics of C/C Composite is its porous structure within the carbon matrix. By introducing metal into the carbon matrix, we are able to transform the characteristics of the C/C Composites. With the addition of metal to the main structure of C/C composite, the new material brings out effectively the best functions of each element so that it can be used for different kinds of application. We have defined this as C/CMC, Carbon-Carbon Metal Composite, which is superior in wear resistance, corrosion resistance and sliding property.

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• C/C Composite + Silicon

  Silicon reacts with carbon during sintering and converts to Silicon carbide (SiC), a ceramic compound. We succeeded in remarkably improving the abrasion resistance and oxidation resistance while maintaining the sliding properties of carbon. Applications: Automobile brake pads・Bearing materials

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• C/C Composite + Copper

  The effect of improving the electrical conductivity by copper infiltration, while maintaining the excellent sliding properties and the high-strength, high toughness of reinforcing carbon fibers, makes it possible to use in applications such as sliding boards for current collection on high-speed rails (Pantograph). Applications: Pantograph・Sliding Electrical Parts

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  PLATES/SHEETS

  As one of the main product shapes, many C/C Plates and Sheets are produced at CFC Design factory. There is freedom to cut the Plates/Sheets into various shapes and dimensional accuracy. At CFC, we often have available many different C/C plate size and thickness inventory.

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  COIL SPRINGS

  Carbon springs can function as weights to apply certain amount of force to parts to be processed. Benefits of carbon springs include drastic reduction of energy costs, speed up of thermal processing, and less need of replacements, maintenance or adjustments.

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  THREAD-RODS / NUTS / ROUNDS

  C/C composite bolts, nuts, rods are used as mechanical connectors under extreme high temperature up to 2000˚C (3600˚F), which it is difficult for many ceramics or metals to keep their physical mechanical strengths. CFC material has the advantage in higher heat resistance and superior strength.

STANDARD PLATES

PLATES / BARS / SHEETS

CHARACTERISTIC DATA

*The above data are typical values information only and are not guaranteed.

*FS240 sheet and other product shapes are excluded.

STANDARD COIL SPRINGS

C/C STANDARD COIL SPRING

STANDARD THREADED RODS/NUTS/ROUND RODS

*Inches and special size orders available upon request. For any consultation, please contact us.