Carbon Fibre: Applications, Challenges and Solutions

Reference

Elon Musk recently revealed that SpaceX has chosen stainless steel as an alternative to carbon fiber for building its Starship rocket.

what is carbon fiber

• Carbon fiber is composed of thin and strong crystalline filaments of carbon that are tightly bonded to each other, resulting in a high-strength structure.
• The atoms of carbon fibers are arranged in long strings of crystals, forming a lattice-like structure.
• These fibers are thinner than a human hair (about 5 to 10 micrometers in diameter) and thousands of times stronger.
• Carbon fiber is made of pure carbon with minimal impurities, so it is considered a high-purity material.
• Carbon fiber was first created in the 19th century by Thomas Edison and Joseph Swan for use in light bulbs.

Key Benefits of Carbon Fiber

• High strength-to-weight ratio: Carbon fiber is exceptionally strong and light.
  • Its higher tensile strength and lower weight compared to materials such as steel makes it an ideal choice for applications where minimizing weight is critical.
• Stiffness: Carbon fiber has high stiffness, which means it can resist deformation under applied load.
  • This property allows carbon fiber components to maintain shape and structural integrity even under extreme stress.
• Low density: Carbon fiber has a low density, resulting in lighter structures.
  • This feature is useful in industries such as aerospace and automotive, where reducing weight is crucial to increase fuel efficiency and overall performance.
• Excellent fatigue resistance: Carbon fiber exhibits excellent fatigue resistance, meaning it can withstand repeated loading and unloading cycles without experiencing a significant degradation in performance.
  • This property makes it suitable for applications that involve cyclic loading or vibration, such as sports equipment.
• Corrosion resistance: Carbon fibre is highly resistant to corrosion and does not corrode like metals.
  • This feature makes it beneficial in environments where exposure to moisture or chemicals is a concern.
• Thermal stability: Carbon fiber is an excellent thermal conductor and offers excellent heat resistance, making it ideal for applications such as creating heat shields and exhaust systems in high-performance vehicles and aerospace. 

Applications of Carbon Fiber

• Space industry: In the aerospace and space sectors, carbon fiber is used extensively in aircraft components, including wings and structural elements, because it offers excellent strength and weight savings.
• Automotive industry: The automotive industry uses carbon fiber in high-performance vehicles to increase fuel efficiency and improve structural integrity.
• Marine Industry: Carbon fibre is one of the major materials used in the marine industry, found in superyachts, rescue vessels, etc.
• Sports industry: Sports and recreation equipment, such as bicycles, tennis rackets, and golf clubs, benefit from the lightness, strength, and stiffness of carbon fiber.
• Energy sector: In the renewable energy sector, carbon fibre is used in wind turbine blades to optimise performance.
• Medical Industry: Carbon fiber is used in advanced prosthetics in the medical industry.
• Defence Sector: It can also be used in military and defence sector and can be used for making bulletproof parts as well as for many other purposes.

Challenges Related to Carbon Fiber

• High cost: Carbon fiber production involves complex manufacturing processes and expensive raw materials, making it more expensive than traditional materials such as steel or aluminum.
• Impact damage susceptibility: While carbon fiber is incredibly strong, it can be susceptible to impact damage. A single impact can cause cracks or fractures in the structure, weakening its integrity.
• Difficulty in recycling: Carbon fiber composites are challenging to recycle due to their complex structure. Current recycling methods are limited, leading to environmental concerns and potential accumulation of waste.
• Limited reparability: Unlike metals, repairing damaged carbon fiber components can be a complex and expensive process. Extensive damage may require complete replacement rather than repair, which increases costs.
• Electrical conductivity: Carbon fiber is electrically conductive. While this can be an advantage in some applications, it can cause problems in other applications where electrical conductivity needs to be controlled or varied.
• UV degradation: Carbon fiber composites can experience degradation when exposed to sunlight or UV radiation over long periods of time. Protective coatings or finishing may be required to prevent UV-induced damage and maintain the integrity of the material.
• Limited fire resistance: Carbon fiber is flammable and burns at a higher temperature than metals. Fire retardant treatment or the addition of a fire retardant may be necessary to increase its fire resistance properties.
• Environmental impact during manufacturing: The manufacturing process of carbon fibre involves the use of chemicals and high-energy consumption, which can have an impact on the environment.
• Design limitations: Carbon fibre composites have some design limitations compared to traditional materials. For example, they may not be suitable for applications requiring complex moulding or forming processes.

Ways to make carbon fiber more viable

• Research on cost-effective production methods and alternative precursor materials.
• Advances in recycling technologies to improve sustainability.
• Integration of carbon nanotubes and graphene for enhancing properties.
• Optimizing carbon fiber structures for improved performance.
• Exploring innovative applications in renewable energy, electric vehicles and space exploration.
• At the same time, investments are needed in innovation of alternative solutions,
• For example, SpaceX has used stainless steel instead of carbon fiber in the construction of its Starship rocket.