Carbon Fibers Filaments and Composites

Transcription

1 Carbon Fibers Filaments and Composites

2 NATO ASI Series Advanced Science Institutes Series A Series presenting the results of activities sponsored by the NA TO Science Committee, which aims at the dissemination of advanced scientific and technological knowledge, with a view to strengthening links between scientific communities. The Series is published by an international board of publishers in conjunction with the NATO Scientific Affairs Division A Life Sciences B Physics C Mathematical and Physical Sciences o Behavioural and Social Sciences E Applied Sciences F Computer and Systems Sciences G Ecological Sciences H Cell Biology Plenum Publishing Corporation London and New York Kluwer Academic Publishers Dordrecht, Boston and London Springer-Verlag Berlin, Heidelberg, New York, London, Paris and Tokyo Series C: Mathematical and Physical Sciences Vol. 177

3 Carbon Fibers Filaments and Composites edited by J. L. Figueiredo University of Porto, Porto, Portugal c. A. Bernardo University of Minho, Minho, Portugal R. T. K. Baker Auburn University, Auburn, Alabama, U.S.A. and K. J. HOttinger University of Karlsruhe, Karlsruhe, F.R.G... Springer-Science+Business Media, BV

4 Proceedings of the NATO Advanced Study Institute on Carbon Fibers and Filaments Alvor, Portugal May 15-27, 1989 Library of Congress Catalog ing in Publication Data NATD Advanced Study InstItute on "Carbon Fibers and Fllaments" (1989 : Alvor, Portugal) Carbon flbers, fl1aments, and composites I edited by J.L. Flguelredo... [et al. J. p. cm. -- (NATD ASI series. Serles E, Applied sciences voi. 177) "Proceedings of the NATD Advanced Study Institute on "Carbon Flbers and Filaments," Alvor, Portugal, May 15-27, 1989." Includes bibl10graphlcal references. ISBN ISBN (ebook) DOI Carbon composites--congresses. 2. Flbrous composites- -Congresses. 1. Flgueiredo, Jose LUiS. II. Title. III. Serles: NATD ASI series. Series E, Applled sciences ; no TA418.9.C6N l' 18--0c ISBN Printed on acid-free paper AII Rights Reserved 1990 by Springer Science+Business Media Dordrecht Originally published by Kluwer Academic Publishers in 1990 No part of the material protected by this copyright notice may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without written permission from the copyright owner.

5 TABLE OF CONTENTS Preface Organizing Committee and Lecturers List of Contributors vii ix xi Part I. Fibres E. Fitzer Carbon fibers - present state and future expectations D.D.Edie Pitch and mesophase fibers G.G. Tibbetts Vapor-grown carbon fibers P. Gade1le The growth of vapor-deposited carbon fibres DJ. Johnson Structure and properties of carbon fibres P. Ehrburger Surface properties of carbon fibres D.D. Edie Critical issues for carbon fibers Part ll. Composites E. Fitzer Carbon fibres and composites W. HUttner, R. Weiss High performance carbon fibre composites with thermoplastic matrices KJ. HUttinger The fundamentals of chemical interactions in composite interfaces W. Weisweiler, K. Schlitter Surface modification of carbon fibres by plasma polymerization W. HUttner Potential of carbon/carbon composites as structural materials 275 KJ. HUttinger Theoretical and practical aspects of liquid-phase pyrolysis as basis of the carbon matrix of CFRC 301

6 vi P. Ehrburger Protective layers for special types of composites 327 W. Hiittner, L.E. Claes Carbon based materials in medical applications 337 B. Rand, R.J. Zeng Fibre reinforced ceramic-matrix composites 367 B. Rand Critical issues concerning carbon fibre reinforced composites 399 Part III. Filaments R.T.K. Baker Electron microscopy studies of the catalytic growth of carbon filaments 405 J.L. Figueiredo, C.A. Bernardo Filamentous carbon formation on metals and alloys 441 A. Sacco, Jf. Carbon deposition and filament initiation and growth mechanisms on iron particles and foils 459 L. Bonnetain, P. OadcIIe, M. Audier Structural characterization of filamentous carbons produced on metal catalysts Tibbetts Physical modeling of carbon filament growth N.M. Rodriguez, M.S. Kim, W.B. Downs, R.T.K. Baker Applications of carbon filaments 0.0. Tibbetts Carbon filaments List of lectures and participants Subject index

7 PREFACE Conventional synthetic materials, like metals, ceramics or glass, are usually isotropic substances, and their suitability for structural applications is achieved by morphological design and combination in the macroscopic scale. However, in modem engineering this is often not acceptable. As an alternative, the use of non-homogeneous, anisotropic materials, with significant stiffness and strength only in the directions these mechanical properties are really needed, can lead to enormous material (and weight) savings. This is the case of multiphase systems called composite materials. In these composites, different material parts are added and arranged geometrically, under clearly designed and controlled conditions. Usually, a structure of fibers provides strength and stiffness and a matrix helds them together, whilst providing the geometric form. Carbon fibers are among the high-performance fibers employed in these advanced structural composites, which are profoundly changing many of today's high technology industries. New research and development challenges in this area include upgrading the manufacturing process of fibers and composites, in order to improve characteristics and reduce costs, and modifying the interfacial properties between fibers and matrix, to guarantee better mechanical properties. The interdisciplinary nature of this "new frontier" is obvious, involving chemistry, materials science, chemical and mechanical engineering. Other topics, which more often are treated separately, are also important for the understanding of the processes of fiber production. Carbon filaments is one such topic, as the study of their mechanisms of nucleation and growth is clearly quite relevant to the production of vapour-grown carbon fibers. For this reason, it was considered appropriate that recognised world experts, actively involved in research, development and design in the field of carbon fibers and filaments, should meet and exchange ideas and experiences. Such a meeting was held at Alvor, Portugal, from 15 to 27 May, 1989, under the sponsorship of the NATO Advanced Study Institutes Programme. This Advanced Study Institute was organized into three main sections, devoted to carbon fibers, composites and filaments, respectively. In each section, the whole field was reviewed from the basic concepts to the frontiers of present knowledge, integrating a vii

8 viii coherent set of lectures. At the end of each section, a general debate was held to systematize the subject and to identify areas of required research. The present book is organized in a similar way. The first part, dedicated to carbon fibers, contains six lectures presenting the state of the art in the production, characterization and applications of PAN- based, pitch and mesophase-based and gasphase grown carbon fibers. In the second part, composites with polymeric (thermoplastic and thermosetting resins), carbon and ceramic matrices are studied. Special attention is given to the fiber-matrix interface, and medical applications of carbon-based materials are also reviewed. The third section deals with the formation of filamentous carbon catalysed by metals such as nickel, iron and alloys. Conflicting views on the mechanism of filament growth are discussed in detail. In addition, novel and potentially interesting applications of these filaments as engineering materials are presented. At the end of each section there is a summary of the debates held during the Institute, written in chapter form by their respective co-ordinators. The editors would like to express their gratitude to all speakers and participants for their active contributions which made the Institute and this book possible, and to the Scientific Affairs Division of NATO for the financial support that was in the basis of it all. Additional support was provided by the Universities of Porto and Minho, Junta Nacional de Investigll lio Cientffica e Tecnol6gica, Instituto Nacional de Investiga9lio Cientffica and the Calouste Gulbenkian Foundation, and is gratefully acknowledged. J.L.Figueiredo C.A.Bernardo K.J.Hiittinger R.T.K.Baker

9 NATO ADVANCED STUDY INSTITUTE FILAMENTS" "CARBON FIBERS AND Alvor, Portugal, May 15-27, 1989 Organizing Committee Director: J.L. Figueiredo Associate Director: C.A. Bernardo Scientific Advisors: R.T.K Baker, KJ. Hiittinger Lecturers R.T.KBaker, Auburn University, Dept.Chemical Eng.,Auburn, AL , USA C.A.Bernardo, Universidade do Minho, 4719 Braga Codex, PORTUGAL D.D.Edie, Clemson University, Dept.Chemical Eng., Clemson, SC , USA P.Ehrburger, Centre de Recherches sur la Physico-Chimie des Surfaces Solides, 24 Av. President Kennedy, Mulhouse, FRANCE J. L.Figueiredo, Faculdade de Engenharia, 4099 Porto Codex, PORTUGAL E.Fitzer,Institut fur Chemische Technik, 7500 Karlsruhe 1, F.R.GERMANY P.Gadelle, ENSEEG, BP75 Domaine Universitaire, St. Martin d'heres, FRANCE KJ.Hiittinger, Institut fur Chemische Technik, 7500 Karlsruhe 1, F.R.GERMANY W.Hiittner, SCHUNK Kohlenstofftechnik, P.O.Box 6420, 6300 Giessen 1, F. R. GERMANY D.J.Johnson, University of Leeds, Dept. Textile Industries, Leeds LS2 9JT, UK B.Rand,Sheffield University, School of Materials, Elmfield, Sheffield S 10 2TZ, UK A.Sacco,Jr.,Worcester Polytechnic Institute,Dept.Chemical Eng., Worcester, Mass ,USA G.G.Tibbetts, General Motors Research Laboratories, Warren, Michigan, , USA ix

10 LIST OF CONTRIBUTORS M.Audier, ENSEEG, BP75 Domaine Universitaire, St. Martin d'heres, FRANCE R.T.KBaker, Auburn University, Dept.Chemical Eng.,Auburn, AL , USA C.A.Bernardo, Universidade do Minho, 4719 Braga Codex, PORTUGAL L.Bonnetain, ENSEEG, BP75 Domaine Universitaire, St. Martin d'heres, FRANCE L.E.Claes, Section fur Unfallchirurgische Forschung Biomechanik, Univ. VIm, D-7900 VIm, F.R.GERMANY W.B.Downs, Auburn University, Dept.Chemical Eng.,Auburn, AL , USA D.D.Edie, Clemson University, Dept.Chemical Eng., Clemson, SC , USA P.Ehrburger, Centre de Recherches sur la Physico-Chimie des Surfaces Solides, 24 Av. President Kennedy, Mulhouse, FRANCE J. L.Figueiredo, Faculdade de Engenharia, 4099 Porto Codex, PORTUGAL E.Fitzer,Institut fur Chemische Technik, 7500 Karlsruhe 1, F.R.GERMANY P.Gadelle, ENSEEG, BP75 Domaine Universitaire, St. Martin d'heres, FRANCE KJ.HUttinger, Institut fur Chemische Technik, 7500 Karlsruhe 1, F.R.GERMANY W.HUttner, SCHUNK Kohlenstofftechnik, P.O.Box 6420, 6300 Giessen 1, F.R.GERMANY DJJohnson, University of Leeds, Dept. Textile Industries, Leeds LS2 9JT, UK M.S.Kim, Auburn University, Dept.Chemical Eng.,Auburn, AL , USA B.Rand,Sheffield University, School of Materials, Elmfield, Sheffield SlO 2TZ, UK N.M.Rodriguez, Auburn University, Dept.Chemical Eng.,Auburn, AL , USA A.Sacco,Jr.,Worcester Polytechnic Institute,Dept.Chemical Eng., Worcester, Mass ,USA KSchlitter, Institut fur Chemische Technik, 7500 Karlsruhe 1, F.R. GERMANY xi

11 xii G.G.Tibbetts, General Motors Research Laboratories, Warren, Michigan, , USA R. Weiss, SCHUNK Kohlenstofftechnik, P.O.Box 6420, 6300 Giessen 1, F.R.GERMANY W.Weisweiler, Institiit fur Chemische Technik, 7500 Karlsruhe 1, F.R. GERMANY R.J. Zeng, Sheffield University, School of Materials, Elrnfield, Sheffield S 10 21Z, UK