CARBON FIBERS AND THEIR USAGE IN RACING CAR INDUSTRY

Two Parts Science part Science part  Will deal with the production and properties of Carbon Fibers Engineering part Engineering part  Will deal with the way in which the fibers are actually used to make the cars.

SCIENCE PART

DISCOVERY Dates back to the early 1800’s Dates back to the early 1800’s Discovery was an accident as most good ones are Discovery was an accident as most good ones are Thomas Edison while testing different materials for the filament of a light bulb repeatedly superheated a piece of plain cotton thread to produce a pure carbon fiber. Thomas Edison while testing different materials for the filament of a light bulb repeatedly superheated a piece of plain cotton thread to produce a pure carbon fiber.

WHAT ARE CARBON FIBERS? It is a synthetic fiber. It is a synthetic fiber. Formed by heating oxidizing and carbonizing of polyacrylonitrile fibers. Formed by heating oxidizing and carbonizing of polyacrylonitrile fibers. Polyacrylonitrile is polymeric compound with long connecting chains of carbon molecules. Polyacrylonitrile is polymeric compound with long connecting chains of carbon molecules.

MANUFACTURING CARBON FIBERS  TWO TYPES OF CARBON FIBERS 1) PAN (polyacrylonitrile) TYPE 2) PITCH type  In most cases PAN type Carbon Fiber is used.

MANUFACTURING STEPS 1) Fibers are stretched and heated to just less than 400 degree Celsius 2) They are then heated in an oxygen free environment 3) The fibers are then graphitised which stretches the fibers more and then is heated between 1100 and 3000 degree Celsius

MANUFACTURING STEPS contd… 4) Finally the fibers undergo surface treatment and epoxy sizing. 5) Finally we obtain the carbon fiber which is wound on a spool for usage for usage

What actually happens?

Contd.. Then the molecules are heated again to around 700 degrees Celsius at this point the carbon atoms release their hydrogen units. Then the molecules are heated again to around 700 degrees Celsius at this point the carbon atoms release their hydrogen units.

Contd… Later, additional slow roasting frees hydrogen gases and these ringed polymers begin fusing together like ribbon. Later, additional slow roasting frees hydrogen gases and these ringed polymers begin fusing together like ribbon.

Reinforcing The obtained fibers are reinforced with epoxy resin to obtain additional durability and strength. The obtained fibers are reinforced with epoxy resin to obtain additional durability and strength.

What you finally get is

Features of Carbon Fibers Light in weight, Strong and Durable. Light in weight, Strong and Durable. Exquisite mechanical properties (high specific tensile strength, high specific elastic modulus, etc.) Exquisite mechanical properties (high specific tensile strength, high specific elastic modulus, etc.)

Some Facts Carbon fiber composites are ten times stronger than steel, yet are still five times lighter. Carbon fiber composites are ten times stronger than steel, yet are still five times lighter. In comparison to aluminum, carbon fiber composites are eight times stronger, two times stiffer, yet still 1.5 times lighter. In comparison to aluminum, carbon fiber composites are eight times stronger, two times stiffer, yet still 1.5 times lighter.

Few graphs to illustrate previous points

Comparison of thermal characteristics

Electromagnetic Wave Shielding Property

Engineering Part

Requirements for a good racing car There are three important factors when searching for F1 car materials: There are three important factors when searching for F1 car materials: Materials must be light to guarantee ideal weight distribution. Materials must be light to guarantee ideal weight distribution. Components must be able to withstand extreme forces during a race to avoid any defects occurring. Components must be able to withstand extreme forces during a race to avoid any defects occurring. The race car has to comply with both the Federation Internationale de l'Automobile (FIA) safety standards and crash tests guidelines The race car has to comply with both the Federation Internationale de l'Automobile (FIA) safety standards and crash tests guidelines

High load-bearing capabilities, fast availability and reliability at low weight – all necessary characteristics of a F1 car - can only be achieved by using hi-tech materials. One such material is Composite Material Carbon. High load-bearing capabilities, fast availability and reliability at low weight – all necessary characteristics of a F1 car - can only be achieved by using hi-tech materials. One such material is Composite Material Carbon.

Roughly 60 percent of a F1 car consists of carbon fibers, embedded in epoxy resin (also known as CFRP). The following car parts are all composed of CFRP: Roughly 60 percent of a F1 car consists of carbon fibers, embedded in epoxy resin (also known as CFRP). The following car parts are all composed of CFRP: The monocoque The monocoque Nose assembly Nose assembly Wings Wings Parts of the suspension Parts of the suspension Clutch and brake disks Clutch and brake disks

How is it used? Firstly the fibers Firstly the fibers are woven are woven into a sheet,just into a sheet,just like textiles. like textiles.

This is the mould of the part to be made

The mold is made of fiberglass. A large sheet of woven carbon fiber is cut and laid over the mould so that a few inches of fabric drape over each corner.

Here are buckets of the epoxy resin being mixed with the reactive catalyst to help harden the material. Here are buckets of the epoxy resin being mixed with the reactive catalyst to help harden the material.

The dreamy, smelly resin is then laid over the woven mat using paintbrushes to thoroughly saturate the weave. The dreamy, smelly resin is then laid over the woven mat using paintbrushes to thoroughly saturate the weave.

A large section of fiberglass mat is then laid over the back of the wet carbon fiber, and covered with additional helpings of epoxy resin. A large section of fiberglass mat is then laid over the back of the wet carbon fiber, and covered with additional helpings of epoxy resin.

Once moistened, this fabric does not stay intact. Adding structure to this fiberglass back in a fiberglass fabric that aids as reinforcement and facilitates the removal of trapped air bubbles.

The backside of the structure gets the “squeegee” treatment, as more imperfections and air pockets are removed and the saturation of the epoxy resin and woven materials is made more thorough. The backside of the structure gets the “squeegee” treatment, as more imperfections and air pockets are removed and the saturation of the epoxy resin and woven materials is made more thorough.

After hardening, the hood is separated from the mould. After hardening, the hood is separated from the mould.

And Finally.. The part is polished according to requirements. The part is polished according to requirements. And putting together all such parts we get this And putting together all such parts we get this

Future Projects Carbon Fibers are not cheap,So major research is going on to find out new methods of production. Carbon Fibers are not cheap,So major research is going on to find out new methods of production. The research team at the Paul Pascal Research Center (Bordeaux) has patented a process for producing fibers and strips from carbon nanotubes produced by an electric arc technique. The research team at the Paul Pascal Research Center (Bordeaux) has patented a process for producing fibers and strips from carbon nanotubes produced by an electric arc technique.

A study is being done on the way in which the parts fly off during a crash so that the projectiles do not injure the driver and also research is being done to control the direction. A study is being done on the way in which the parts fly off during a crash so that the projectiles do not injure the driver and also research is being done to control the direction.