Browse Topic: Carbon fibers
The intent of this specification is for the procurement of plain weave fabric epoxy prepreg product with 250 °F (121 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3).
The intent of this specification is for the procurement of carbon fiber epoxy prepreg product with 250 °F (121 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (see 4.3).
Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. Auburn University, Auburn, AL In collaboration with Auburn University's Center for Polymers and Advanced Composites (CPAC) and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell - a next-generation 3D carbon fiber composites printer set to define the future of the nation's hypersonic programs. Developed by Idaho-based Continuous Composites, the CF3D system represents a highly specialized advanced manufacturing capability and is the only system of its kind currently operating in Alabama.
Carbon fiber-reinforced polymers (CFRPs) have become essential in modern aerospace structures, from fuselage skins and wing components to nacelles, interior structures, and a growing range of primary load-bearing parts. Their high strength-to-weight ratio delivers major benefits in fuel efficiency, payload capacity, and fatigue performance. Yet achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. The low intrinsic surface energy of composites - particularly under thermal cycling, vibration, and moisture exposure - limits bond durability unless surfaces are properly prepared. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. This is especially important as the aerospace industry transitions from thermoset to thermoplastic composites (TPCs), which enable faster processing, lower
The intent of this specification is for the procurement of carbon fiber and fiberglass epoxy prepreg products with 350 °F (177 °C) cure for aerospace applications; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the production quality assurance section (4.3) of this base specification, AMS6891.
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
The intent of this specification is for the procurement of the material listed on the QPL; therefore, no qualification or equivalency threshold values are provided. Users that intend to conduct a new material qualification or equivalency program must refer to the Quality Assurance section of the base specification, AMS6891.
Oak Ridge National Laboratory (ORNL) researchers have overcome a barrier to using a more affordable, dry process for manufacturing the Li-ion batteries used in vehicles and electronic devices. The resulting batteries provide greater electricity flow and reduced risk of overheating.
A futuristic vehicle chassis rendered in precise detail using state-of-the-art CAD software like Blender, Autodesk Alias. The chassis itself is sleek, low-slung, and aerodynamic, constructed from advanced materials such as high-strength alloys or carbon-fibre composites. Its polished, brushed-metal finish not only exudes performance but also emphasizes the refined form and engineered details. Underneath this visually captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks are situated adjacent to the four shock absorber mounts. These jacks are designed to lift the chassis specifically at the tyre areas, and the total vehicle, ensuring that underbody maintenance is efficient and that, in critical situations, vital adjustments or emergency lifts can be performed quickly and safely. The design also incorporates an intuitive control system where the necessary buttons are strategically placed to optimize driver convenience. Whether
Researchers at the U.S. Department of Energy (DOE)’s Oak Ridge National Laboratory (ORNL) have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites — an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.
Researchers at the U.S. Department of Energy (DOE)’s Oak Ridge National Laboratory (ORNL) have developed an innovative new technique using carbon nanofibers to enhance binding in carbon fiber and other fiber-reinforced polymer composites — an advance likely to improve structural materials for automobiles, airplanes and other applications that require lightweight and strong materials.
Innovators at the NASA Glenn Research Center have developed a toughened hybrid reinforcement material made from carbon fiber and carbon nanotube (CNT) yarn for use in polymer matrix composites (PMCs). The new material improves toughness and damping properties of PMCs, enhancing impact resistance, fatigue life, as well as structural longevity.
The work done in developing stretch broken carbon fiber technology is described. The objectives of the program include the scale up of the process to demonstrate production feasibility, as well as reducing the maximum filament stretch break length to ~50mm/2” or below, less than half of what was achieved on previous programs. The shorter break length is considered to be critical in order to achieve formability into complex geometries. The new stretch break line at Montana State University, BC3, has been commissioned to achieve the required material characteristics and throughput. To date, 6 tows have been successfully stretch broken simultaneously, representing a significant improvement compared with what was achieved on previous programs. Possible geometries and forming evaluation methods are described. Mechanical testing is to be conducted, including both equivalency testing of continuous vs stretch broken carbon fiber and a later minimal level allowables program. It is expected that
The demand for carbon fiber reinforced polymers (CFRPs) is growing, especially for use in high-performance applications. Components manufactured of CFRP are made by layering sheets of carbon fibers within a resin matrix. Due to the fibers’ brittle nature, CFRPs are difficult to shape into complex forms, limiting adoption of the material in applications such as vertical lift systems. To address this limitation, researchers at Montana State University, Bozeman (MSU) are developing a new form of carbon fiber called stretch broken carbon fiber (SBCF). SBCF maintains the strength of continuous carbon fibers, while allowing for fiber slip that is used to create a pseudo-plastic strain response needed in most forming processes. Dome and bulge tests were used for comparing the formability response of IM7 MSU SBCF/977-3 with continuous Hexcel IM7 12K/977-3. Results showed increased formability of the MSU SBCF ones due to their ability to stretch under an applied load.
With performance advances proposed for the Future Vertical Lift suite of aircraft and advancements in the electronic battlefield, it is imperative that advanced materials and concepts be included in the vehicle designs to meet the aggressive weight reduction objectives, structural requirements, and operational environment capabilities. Integrating electromagnetic (EM) shielding during the design process offers an opportunity to make progress towards the performance goals. To this end, efforts must be made to minimize the impact of this shielding to platform weight and structural performance. This article presents work to develop a hybrid multifunctional composite material technology that incorporates copper mesh into a carbon fiber and thermoplastic matrix structural composite material to achieve required levels of EM shielding and high levels of structural efficiency while reducing the overall weight of the system. This article focuses on the design of a representative helicopter
Stretch broken carbon fiber (SBCF) offers enhanced formability as compared to continuous carbon fiber (CCF). However, robust, quantitative evaluation of forming defects remains a challenge. This study introduces a unified formability index (UFI) that integrates multiple defect types, including texture anomalies, bridging, wrinkling, thickness variation, spring-back, and resin distribution variation (RDV), into a single weighted score. Each defect is ranked on a scale of 0-5 using normalized metrics with a tunable parameter, α, allowing users to balance defect magnitude and frequency as desired. The full scoring pipeline is demonstrated for texture defects using measured data, while normalized legacy scores from previous work are used for non-texture defects to enable complete formability index computation. Case studies on three laminates illustrate how variations in α affect both texture scoring and the overall formability index and demonstrate the geometry-agnostic nature of the
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. Its efficiency could be further increased by integration of joining processes, which would otherwise be separate processes requiring additional time and equipment. In this work, an integrative two-step thermoforming process for hollow box structures is presented. The starting point are two organosheets, i.e. fiber-reinforced thermoplastic sheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and
The segment manipulator machine, a large custom-built apparatus, is used for assembling and disassembling heavy tooling, specifically carbon fiber forms. This complex yet slow-moving machine had been in service for nineteen years, with many control components becoming obsolete and difficult to replace. The customer engaged Electroimpact to upgrade the machine using the latest state-of-the-art controls, aiming to extend the system's operational life by at least another two decades. The program from the previous control system could not be reused, necessitating a complete overhaul.
This SAE Aerospace Recommended Practice (ARP) provides methods and guidelines for isolating dissimilar repair patch materials from carbon fiber reinforced plastic (herein also referred to as carbon composite) structure during a repair operation.
Fused deposition modeling (FDM) is a rapidly growing additive manufacturing method employed for printing fiber-reinforced polymer composites. Nonetheless, the performance of printed parts is often constrained by inherent defects. This study investigates how the varying annealing parameter affects the tribological properties of FDM-produced polypropylene carbon fiber composites. The composite pin specimens were created in a standard size of 35 mm height and 12 mm diameter, based on the specifications of the tribometer pin holder. The impact of high-temperature annealing process parameters are explored, specifically annealing temperature and duration, while maintaining a fixed cooling rate. Two set of printed samples were taken for post-annealing at temperature of 85°C for 60 and 90 min, respectively. The tribological properties were evaluated using a dry pin-on-disc setup and examined both pre- (as-built) and post-annealing at temperature of 85°C for 60 and 90 min printed samples
Carbon-fiber structural batteries are not entirely new, but now Sinonus, a company spun out of Chalmers Technical University in Gothenburg, Sweden, is further developing the technology with carbon fibers that double as battery electrodes. The technology has already been demonstrated in low-power applications, and Sinonus will now develop it for use in a range of larger applications including, first, IoT devices and then drones, computers, electric vehicles and airplanes. By integrating the battery into carbon-fiber structures, Sinonus believes that an EV's weight could be reduced while the driving range could increase by as much as 70%. The carbon-fiber technology used by Sinonus originated at Oxeon, another Chalmers spin-off.
This white paper discusses the application of carbon fiber roving for rotor magnet retention in high-performance Brushless DC (BLDC) motors, focusing on sectors like Advanced Air Mobility and motorsports. Highlighting the benefits of carbon fiber's tensile strength, thermal characteristics, and electrical resistivity, it compares thermoset and thermoplastic matrices, analyzing their trade-offs. It delves into manufacturing methods, particularly the advantages of in-situ winding of Hexcel® HexTow® IM7 12k carbon fiber directly onto rotors, versus pre-wound sleeves, emphasizing controlled processes for even stress distribution and preventing failure. Key design factors such as operating speed, temperature, and air gap dimensions are considered to optimize carbon fiber's application. Windings' expertise in fabricating high-tolerance carbon fiber wound rotors is showcased, highlighting its potential to enhance motor power output and offering collaboration for innovative retention solutions
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