Unprecedented Material Development
Micro Mechanics – Macro Benefits
Carbon nanotubes (CNT) have amazing material properties which are valuable for a wide field of industrial applications and materials science. Their mechanical properties exceed that of e.g., steel or high-carbon steel by great factors.
With the development of CarboForce FutureCarbon has achieved a break-through to apply the CNT properties to standard composite materials for the CFK and GFK industry.
CFK and GFK components using composites refined with CarboForce are new materials with unprecedented characteristics in a in a large variety of mechanical properties.
Fiber Plastics Reloaded
next generation composites.
Products of the CarboForce series are polymer systems, e.g. epoxy or cyanate ester resins, with specially refined carbon nanotubes form use in CFK & GFK composite materials.
Through the addition of CarboForce these systems are unleashing the material effects of carbon nanomaterials outranging conventional compostite materials in terms of fracture toughness, interlaminar shear strength as well as fatigue properties.
Little Fatigue. Long Lifetime.
Crack bridging is a dominant toughening channel. CarboForce deflects the advancing crack and deviates the crack from the existing fracture plane. Thereby an additional facture surface area is created which requires additional energy to continually drive the crack growth.
CarboForce fosters enhanced fiber matrix bonding and thus, hazard of delamination is reduced…life-time of the CarboForce refined composite material prolonged.
As an example carbon fiber reinforced composites were tested by industry partners for fatigue properties by applying a periodical mechanical load.
The conventional composite failed after approx. 50,000 cycles. CarboForce based composites survived the test objective of 100,000 cycles, showing first signs of fatigue only after 300,000 cycles.
In addition due to the refinement carbon-fiber-reinforced polymer are facing significant lower residual stresses.
In materials science, fracture toughness is a property which describes the ability of a material containing a crack to resist fracture. As such it is one of the most important properties of any material for many design applications.
The general effect of improved fracture toughness through CarboForce composites is demonstrated by an increase of interlaminar energy release of approx. 35% compared to conventional composites.
Strong Bonding. High Safety.
Interlaminar Shear Strength (ILSS)
Interlaminar shear testing is a test on polymer composite that gives a measure of the strength of the bond between fibers and the matrix.
Material test conducted using composite refined with CarboForce resulted in shear strength increase of 48% at room temperature and 38% at 100°C compared to non refined reference material.
The resulting benefit for the end product is less delamination due to improved fiber-matrix adhesion / improved bonding which results in higher safety against material failure for the end product.
Operating at Higher Temperature
From material aspect the overall improved mechanical characteristics also introduces a higher thermal stability of the composite material.
As a result the operating temperature of the end product increases significantly.
Low Concentration. Large Effects.
Commercial viability through material effectiveness.
The dramatic improvement to the mechanical properties shown above are just an example of CarboForce’s effectiveness. In this case the concentration in the applied resin was as little as 0.5 wt.%. CNT were added via CarboForce.
The chemical affinity of the polymer matrix and the CNT can be adjusted by the CNT functionalization.
The CarboForce series is typically developed as high CNT concentration masterbatch which is fully compatible with the tarted resin. Thus, simple combination and most homogenous dispersion of CarboForce into the target polymer system is guaranteed.
CarboForce is a series of carbon nanotube (CNT) refined duroplastic system defined as a vehicle to create new composite material development.
The Automotive industry is constantly challenged for technological developments as right now with the growing popularity of fiber reinforced plastics (FRP) to save up weight and fuel.
CarboForce enhances the mechanical properties of fiber reinforced plastics significantly. This can lower the used CFRP amount while the required strength is being maintained.
As a result the body weight and thus, gas consumption is reduced while overall life-time is enhanced.
In the aerospace industry every gram of weight is directly linked to an enormous amount of cost/saving. Maximizing the mechanical properties of structures by the use of CarboForce reduces the amount of material to be carried, thus, results in significant savings.
Also material used for aerospace structures may spend up to 15 years or more in space and is constantly exposed to cosmic rays and radiation causing a weakening of material stability. CarboForce improves the radiation resistance for an improved lifetime.
Furthermore, the structures are submitted to and exposed to electromagnetic radiation which may cause a safety issue due to potential electrostatic discharges. Due to the conductive particles of CarboForce electrostatic charges can be prevented.
The economic viability of wind power plants is influenced by many factors such as location, electrical power, maintenance / repair and lifetime. The rotor blades are facing high mechanical stress while being exposed to harsh environmental conditions. Improving their mechanical properties via CarboForce directly results in an increased lifetime, less failure, less downtime and less time and effort for reconditioning. The power plants’ commercial effectiveness is significantly boosted by improving the composites material properties through CarboForce.