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Understanding CFRP Composites
The Amazing Capabilities of Carbon Fiber Reinforced
Polymers
By Todd Johnson
Carbon Fiber Reinforced
Polymer Composites (CFRP) are lightweight, strong materials used in the
manufacturing of numerous products used in our daily life.
It is a
term used to describe a fiber-reinforced composite
material that uses carbon fiber as the primary structural
component.
It
should be noted that the "P" in CFRP can also stand for "plastic"
instead of "polymer."
In
general, CFRP composites use thermosetting resins such as epoxy, polyester, or
vinyl ester.
Although thermoplastic
resins are used in CFRP Composites, "Carbon Fiber
Reinforced Thermoplastic Composites" often go by their own acronym, CFRTP
composites.
When
working with composites or within the composites industry, it is important to
understand the terms and acronyms.
More
importantly, it is necessary to understand the properties of
FRP composites and capabilities of the various reinforcements
such as carbon fiber.
Properties of CFRP Composites
Composite
materials, reinforced with carbon fiber, are different than other FRP
composites using traditional materials such as fiberglass or aramid fiber.
The properties of CFRP composites that are advantageous include:
Light Weight: A traditional fiberglass
reinforced composite using continuous glass fiber with a fiber
of 70% glass (weight of glass / total weight), will commonly have a density of
.065 pounds per cubic inch.
Meanwhile, a CFRP
composite, with the same 70% fiber weight, might typically have a density of
.055 pounds per cubic inch.
Increased Strength: Not only are carbon fiber composites lighter weight, but
CFRP composites are much stronger and stiffer per unit of weight. This is true
when comparing carbon fiber composites to glass fiber, but even more so when
compared to metals.
For example, a decent
rule of thumb when comparing steel to CFRP composites is that a carbon fiber
structure of equal strength will often weigh 1/5th that of steel.
You can imagine why
automotive companies are investigating using carbon fiber instead of steel.
When comparing CFRP
composites to aluminum, one of the lightest metals used, a standard assumption
is that an aluminum structure of equal strength would likely weigh 1.5 times
that of the carbon fiber structure.
Of course, there are
many variables that could change this comparison.
The grade and quality of
materials can be different, and with composites, the manufacturing
process, fiber architecture, and the quality need to be taken into
account.
Disadvantages of CFRP Composites
Cost: Although
amazing material, there is a reason why carbon fiber is not used in every
single application.
At the moment, CFRP
composites are cost-prohibitive in many instances.
Depending on the current
market conditions (supply and demand), the type of carbon fiber (aerospace vs.
commercial grade), and the fiber tow size, the price of carbon fiber can vary
dramatically.
Raw carbon fiber on a
price-per-pound basis can be anywhere between 5-times to 25-times more
expensive than fiberglass.
This disparity is even
greater when comparing steel to CFRP composites.
Conductivity: This
can be both an advantage to carbon fiber composites, or a disadvantage
depending on the application.
Carbon fiber is
extremely conductive, while glass fiber is insulative. Many applications use
glass fiber, and cannot use carbon fiber or metal, strictly because
of the conductivity.
For example, in the
utility industry, many products are required to use glass fibers. It is also
one of the reasons why ladders use glass fiber as the ladder rails.
If a fiberglass ladder
were to come in contact with a power line, the chances of electrocution are
much lower. This would not be the case with a CFRP ladder.
Although the cost of
CFRP composites still remains high, new technological advancements in
manufacturing are continuing to allow for more cost-effective products.
Hopefully, in our
lifetime, we will be able to see cost-effective carbon fiber used in a wide
range of consumer, industrial, and automotive applications.
Todd Johnson
Science Expert
Education
B.S., Business Management, University of
Colorado Boulder
Introduction
Regional Sales Manager for Composites
One, a distributor of composite materials.
B.S. in Business Management
from University of Colorado Boulder's Leeds School of Business
Business Development Manager for Ebert
Composites Corporation
Experience
Todd Johnson is a former writer for
ThoughtCo, who wrote about plastics and composite materials for 2-1/2 years
between 2010 and 2013. He is a Regional Sales Manager at Composites One, a
composite materials distributor in San Diego, CA. Johnson provides support to
the Greater San Diego manufacturers of fiber reinforced and polymer products.
He regularly attends composite industry trade shows including JEC, ACMA, SME,
and SAMPE. In 2008 he presented at the Global Pultrusion Conference in
Baltimore, MD. Previously, Todd spent six years as the Business Development
Manager for Ebert Composites Corporation.
Education
B.S., Business, Management, Marketing,
and Related Support Services - the University of Colorado-Boulder's Leeds
School of Business; attended Griffith University in Queensland,
Australia.
A Message from Todd Johnson
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