Advanced Structural Carbon Products: Fibers, Foams & Composites

Publication Date	January 2009
Publisher	BCC Research
Product Type	Report
Pages	213
ISBN Number	not applicable
Product Code	BCC00288

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Summary

Study Goals and Objectives

The goal of this study is to provide a comprehensive understanding of advances in structural carbon materials manufacturing, its commercial applications, and its worldwide markets. for the purposes of this report, these materials will include all types of carbon fibers, carbon foams, monolithic structural graphite, and carbon-reinforced carbon composites.

to attain this goal, several objectives will be met. The major types of structural carbon materials will be described, including key physical and chemical properties, raw materials, and manufacturing processes. Commercial applications in which these materials are used will be discussed.

Present consumption and future demand for these materials will be evaluated for the United States and other major geographical markets. Trends in technology will be analyzed and forecasted. The impact of governmental regulations will be ascertained. The dynamics of the structural carbons industry will be outlined along with profiles of key manufacturers.

Reasons for Doing The Study

This study is an update of an earlier BCC report that was published in 2005. The structural carbon materials industry and markets have continued to develop in the 3 years since the previous edition was published.

The structural carbon materials industry serves mature industries such as defense and aerospace, with a wide variety of products satisfying the requirements of well-established applications. These sectors are heavily regulated. However, continuous technical innovations and attempts to make its technologies available to civil markets (at affordable prices) are leading to new application segments.

Corporations engaged in the structural carbons industry must understand the significance of these trends to manage their enterprise and its resources effectively. Stakeholders in these competitive technologies and products must understand the impact of these trends upon their operations. End users of structural carbons must consider the effect of these changes to select the most cost-effective option among newly available products and technologies prior to committing significant capital resources.

Intended Audience

over the next half-decade significant change will take place in global structural carbon products and applications. Technological advances in improving structure-property relationships of advanced carbon materials and breakthroughs in the manufacturing processes-resulting in lower costs-will lead to novel applications. This study analyzes the driving forces that will shape the structural carbons industry over next few years.

Consequently, the information presented in this study is very important to:

Members of the financial community who must understand, assess, and rate the effect of forthcoming changes in the structural carbons industry based upon the financial performance of the companies active in this market segment
Chief executive officers who must effectively manage the assets of their company so as to benefit from forthcoming changes in the structural carbons industry
Directors of planning who must incorporate anticipated changes in the structural carbons industry into corporate planning documents
Directors of manufacturing who must implement new structural carbons technology and products into their operations
Directors of engineering, research, and development who must incorporate the latest in structural carbons technology and products into their designs and projects
Decision makers at major structural carbons consumers, such as the Department of Defense contractors involved in aerospace and aircraft manufacturing
Executives at companies engaged in developing competitive materials and technologies such as other reinforcement fibers like Kevlar or composites manufactured with other matrix materials such as ceramics or metal.

Scope of Report

This report covers technological, economic, and business conditions in the structural carbons industry. Although this report is primarily a study of the U.S. market, analysis and forecasts are also provided for global markets. Included in this report are descriptions of market forces relevant to the structural carbons industry and their areas of application.

The U.S. market is presented by type of structural carbons along with growth forecasts through 2013. The driving forces in the industry and the structure of the industry are also examined.

International aspects of the structural carbons industry are discussed with respect to all the geographic regions and type of structural carbon material. Lastly, brief profiles of the major manufacturers are presented.

Content

Chapter One: Introduction
- Study Goals and Objectives
- Reasons for Doing The Study
- Intended Audience
- Scope of Report
- Methodology and Information Sources
- Analyst's Credentials
- Related BCC Reports
- BCC Research Online Services
- Disclaimer
Chapter Two: Summary
Chapter Three: Industry and Markets Overview
- United States Market
  - Global Markets
- Research and Technology Trends
- Industry Structure
Chapter Four: Technical Overview
- Introduction to Advanced Structural Carbon Products
- Importance of Mechanical Properties
- Carbon Fibers
  - Raw Materials for Carbon Fibers
    - Types of Raw Materials
    - Rayon
    - Pan
    - Pitch
    - Raw Material and Fiber Properties Relationship
    - Pan-Based Fibers
    - Pitch-Based Fibers
    - Rayon-Based Fibers
  - Manufacturing Process
    - Pan Carbon Fiber Process
    - Precursor Preparation
    - Polymerization
    - Spinning and Stretching
    - Stabilization
    - Carbonization
    - Surface Treatment
    - Sizing
    - Pitch Carbon Fiber Process
    - Precursor Preparation
      - Pitch Refining
      - Isotropic Pitch
      - Aniostropic or Mesophase Pitch
      - Thermal Modifications
      - Solvent Modification
      - Chemical Modification
      - Catalytic Modification
    - Melt Spinning
    - Stabilization
    - Carbonization
    - Viscose Rayon Carbon Fiber Process
    - Vapor-Grown Carbon Fibers
  - Chemical and Physical Properties
    - Structural Property Relationship for Carbon Fibers
    - Density
    - Modulus
    - Impact of Fiber Diameter
    - Electrical and Thermal Conductivity
    - Thermal Stability
  - Carbon Fiber Product Forms
    - Carbon Fiber Product Grades
    - Pan-Derived Fibers
    - Pitch-Derived Fibers
    - Tow
    - Carbon Fiber Cloth
    - Prepreg
  - Emerging Manufacturing Technologies
    - Microwave-Assisted Plasma (Map) Process
    - Ultraviolet (Uv) Stabilization of Pan-Based Carbon Fibers
    - Rapid Oxidation Step
    - Advances in Spinneret Design
    - Surface Modification of Carbon Fibers
    - Advances in Pitch-Based Fiber Technology
    - Carbon Nanotubes Reinforcement of Carbon Fibers
    - Continuous Carbon Fiber Produced from Carbon Nanotubes
    - High-Thermal-Conductivity Carbon Fibers
    - Hollow Carbon Fibers
    - Carbon Nanofibers
    - Activated Carbon Fibers
    - Vapor-Grown Carbon Fibers (Vgcf)
    - Three-Dimensional Carbon Fibers
  - Manufacturers of Pan-Based Fibers
    - Small-Tow Manufacturers
    - Cytec's Carbon Fiber Production
    - Hexcel's Carbon Fiber Production
    - Other Manufacturers
    - Large-Tow Carbon Fiber Manufacturers
    - Zoltek Companies, Inc
    - Toho Tenax America
    - Sgl Carbon Fibers and Composites
  - Manufacturers of Pitch-Based Carbon Fibers
  - Carbon Fiber Composites
    - Carbon-Fiber-Reinforced Polymer Composites (Cfrp)
    - Manufacturing Processes
      - Molding Process
      - Roving Process
    - Mechanical Properties
    - Carbon-Fiber-Reinforced Metal Composites (Cfrm)
    - Manufacturing Processes
    - Mechanical Properties
- Carbon Foams
  - Raw Materials
  - Manufacturing Process
    - Flash Process
    - Blowing Gases
    - Sol-Gel Process
  - Chemical and Physical Properties
  - Emerging Technological Trends
    - Uniform-Density-Gradient Carbon Foams
    - Reinforced Carbon Foams
    - High-Strength Carbon Foams by Chemical Vapor Infiltration
    - Carbon Foams by Template Approach
    - Pitch-Based Carbon Foam
    - Carbon Foams for Pistons
    - High-Thermal-Conductivity Carbon Foams
    - Magnetic Carbon Nanofoams
    - Low-Cost Carbon Foams
  - Manufacturers of Carbon Foams
    - Honeywell
    - Poco Graphite
    - Touchstone Research Laboratory
    - University of Dayton and Wright U S. Air Force Laboratory Alliance
- Structural Graphite
  - Types and Manufacturing of Graphite Materials62
    - Natural Graphite
    - Synthetic Graphite
  - Physical and Chemical Properties
    - Crystalline Structure
    - Lubrication
    - Thermal Properties
    - Oxidation Resistance
    - Chemical Resistance
    - Mechanical Properties
  - Emerging Technologies
    - Porous Graphite
    - High-Temperature Graphite Process
    - Flexible Graphite Sheets with Reduced Anisotropy
    - Expandable Graphite
    - Nanographite
- Carbon-Carbon Structural Composites
  - Types of Structural Composite Materials
  - Carbon-Reinforced Carbon Matrix Composites
  - Differences between Graphite and Carbon- Carbon Composites
  - Chemical and Physical Properties
  - Reinforcement Architecture
    - One-Dimensional Architecture
    - Two-Dimensional Architecture
    - Three-Dimensional Architecture
    - Multidimensional Architecture
    - Foams for Reinforcement
  - Manufacturing Processes
    - Architecture of Reinforcement Phase
    - Infiltration of Matrix Phase
    - Raw Materials for Matrix Phase
    - Chemical Vapor Infiltration Process
      - Temperature Gradient Process
      - Isothermal Process
      - Pressure Gradient Process
    - Liquid Pitch Infiltration Process
      - Raw Materials
      - Manufacturing Process
      - Low-Pressure Process
      - High-Pressure Process
    - Thermosetting Resins as Matrix Precursors
  - Structure and Property Relationships
    - Microstructural Features
    - Mechanical Properties
    - Young's Modulus
    - Strength
    - Fatigue and Creep
    - Effect of Temperature on Mechanical Properties
    - Effect of Oxidation on Mechanical Properties
    - Thermal Properties
    - Friction and Wear Properties
  - Oxidation Protection for Carbon-Carbon Composites
  - Emerging Technologies
    - Oxidation Inhibition of Carbon-Carbon Composites
    - Rapid-Oxidative-Stabilization Composites
    - High-Purity Carbon-Carbon Composites
    - High-Density Carbon-Carbon Composites
    - Elimination of Need for Oxidative Stabilization of Carbon Composites
    - Novel Methods of Making Carbon-Carbon Composites
    - Sequential Deposit of Carbon Matrix and in Situ Polymerization
    - Rapid Processing of Carbon-Carbon Composites
    - Protective Coatings
    - Detecting Flaws in The Carbon Composites
    - Carbon-Carbon Composites from Densified Carbon Foam
    - Low-Temperature Densification Using Sugar Pyrolysis
    - Thick Three Dimensional Preforms for Carbon-Carbon Composites
    - High-Strength Composites Developed by Nasa and Jpl
    - Carbon-Carbon Frictional Composites for Elevator Brakes96
    - Joining Carbon-Carbon Composites
    - Nanotubes in Carbon-Carbon Composites
Chapter Five: Commercial Applications
- Carbon Fiber Applications
  - Aerospace and Defense Industry
    - Space Vehicles
    - Unmanned Spacecraft
    - Manned Spacecraft
    - Launch Vehicles
    - Total U S. Space Market
    - Defense Market
    - Defense Aviation
    - Missiles
    - Commercial Aviation
    - Large Aircraft
    - Carbon Fiber Consumption
  - Ground Transport
    - Trains and Locomotives
    - Motor Vehicles
  - Industrial Applications
  - Wind Energy
  - Sporting Goods
    - Golf Clubs
    - Bicycles
    - Recreational Boating
    - Sport Fishing
    - Other Applications
  - Infrastructure
    - New Bridge Construction
    - Bridge Repairs
    - Column Repairs
    - Seismic Retrofit
    - High-Strength Building Construction
    - Engineered Wood Products
    - Tension Leg Platform Tethers from Carbon Composites
    - Smarter and Stronger Concrete
    - New Manufacturing Process for Reinforced Concrete
  - Thermal Management
    - Conductive Plastics
  - Other Applications
    - Biocompatibility Applications
    - Electrochemical Applications
    - Static Dissipation Applications
    - Lightweight Telescope Mirrors
    - Hollow Carbon Fibers in Molecular Sieve Applications
    - Emerging Energy Systems
    - Turtle Airship Uses Carbon Composites
  - Carbon Fibers Market Growth
- Carbon Foam Applications
  - Aerospace and Defense
    - Radiators
    - Fire Barrier Applications
    - Brakes
  - Ground Transportation
    - Automotive Radiators
    - Shock Absorbers and Bumpers
    - Other Automotive Applications
  - Industrial Applications
    - Sandwich Panels
    - Electronic Heat Sinks
    - Phase-Change Materials
  - Energy
    - Batteries
    - Fuel Cells
    - Radiators
    - Humidifiers
    - Supercapacitors
    - Nuclear Reactor Cores
    - Gas Storage
  - Other Applications
    - Personal Cooling Devices
    - Health Care Applications
    - Acoustic Absorber Materials
  - Carbon Foam Market Growth
- Structural Graphite Applicatons
  - Aerospace and Defense
  - Ground Transportation
  - Industrial Applications
    - Chemical Industry Applications
    - Mechanical Applications
    - Bearings and Brushes
    - Seals
    - Friction Materials
    - Metallurgy
    - Glassware
    - Refractory Applications
  - Energy
    - Fuel Cells
    - Nuclear Industry Applications
    - Hydrogen Storage
  - Structural Graphite Market Growth
- Carbon-Carbon Composites Applications
  - Aerospace
    - Space Vehicle Thermal Protection Systems
    - Aircraft Engine Components
    - Aircraft Brakes
    - Other Aerospace Applications
  - Ground Transportation
  - Industrial Applications
    - Refractory Structures
    - Glass Industry
    - Corrosion-Resistant Structures
    - Thermal-Management Solutions
  - Energy
  - Other Applications
    - Biocompatible Structures
  - Carbon-Carbon Composites Market Growth
  - Markets for Advanced Structural Carbons
Chapter Six: Industry Structure and Market Drivers
- Markets for Structural Carbon Materials
  - Manufacturers of Structural Carbons
    - Carbon Fibers
    - Carbon Foams
    - Structural Graphite
    - Carbon-Carbon Composites
  - SWOT Analysis of Structural Carbons Industry
    - Strengths
    - Weaknesses
    - Opportunities
    - Threats
- Market Drivers
  - Economic Factors
  - Legal and Regulatory Factors
    - Price-Fixing in The Carbon Fibers and Composites Industry
    - Price-Fixing in The Graphite Industry
  - Industry Factors
    - Capacity Trends
    - Price Trends
    - New Technologies and New Entrants to The Business
    - Influence and Leverage
    - Buyers' Influence and Leverage
    - Suppliers' Influence and Leverage
    - Substitute Products
- Competitive Strategies in The Structural Carbons Industry
  - New Business Development
  - Competitive Pricing
  - Vertical Integration
  - Global Strategic Alliances
    - Mitsubishi Rayon's Expansion Plans and Alliance with Sgl
    - Zoltek and Bmw Automotive Group
    - Zoltek and Techfab
    - Graftech and Ballard Power Systems
    - Zoltek and Ballard Power Systems
    - Zoltek and Leggett & Pratt
    - Hexcel and Airbus Industries
    - Hexcel and Boeing
Chapter Seven: Intellectual Property and Technology Trends Analysis
- Intellectual Property Analysis
- Technology Development Trends
Chapter Eight: International Aspects of Structural Carbons Business
Chapter Nine: Profile of Manufacturers
- U S. Manufacturers
  - Aar Composites
  - Advanced Carbon Technologies, Inc
  - Advanced Composites, Inc
  - Aerospace Composite Products Co
  - Albany Engineered Composites
  - Applied Sciences, Inc
  - Asbury Carbons
  - Goodrich Corp
  - Boeing Co
  - Btg Composites, Inc
  - Carbon-Carbon Advanced Technologies, Inc
  - Carbon Composites Co
  - Cytec Corp
  - Fiber Innovations, Inc
  - Fiber Materials, Inc
  - Fiberspar Corp
  - Foresee Orthopedic Products
  - Frontiers Materials Corp
  - Grafil, Inc
  - Graphite Metallizing Corp
  - Graphite Sales, Inc
  - Graftech International, Ltd
  - Graphtek, Llc
  - Helwig Carbon Products, Inc
  - Hexcel Corp
  - Hitco Carbon Composites, Inc
  - Honeywell International, Inc
  - Kirkwood Industries, Inc
  - Mer Corp
  - Minerals Technology, Inc
  - Morgan Advanced Materials and Technology
  - Poco Graphite, Inc
  - Polese Co
  - Roc Carbon Co
  - Schunk Graphite Technology, Llc
  - Sgl Carbon Group
  - Shamokin Filler Co
  - Sioux Manufacturing Corp
  - Spaulding Composites Co
  - Spencer Composite Corp
  - St. Marys Carbon Co
  - Superior Graphite Co
  - Techfab Llc
  - Toho Tenax America, Inc
  - Toray Carbon Fibers America, Inc
  - Touchstone Research Laboratory, Ltd
  - Tpi Composites, Inc
  - Ultramet, Inc
  - V2 Composite, Inc
  - Yla, Inc
  - Zoltek Companies, Inc
- International Manufacturers
  - Anaori Carbon Co , Ltd
  - Anshan East Asian Carbon Fibers Co , Ltd
  - Atlas Composites, Ltd
  - Branwell Graphite, Ltd
  - C2 Composites
  - Carbone Lorraine Worldwide
  - Ederena Concept
  - Grupo Antolin Ingenieria S A
  - Mitsubishi Chemical Corp
  - Mitsubishi Rayon Co , Ltd
  - Nippon Graphite Fiber Corp
  - Nippon Sheet Glass Co , Ltd
  - Taiwan Carbon Technology Co , Ltd
  - Toho Tenax Co , Ltd
  - Toray Industries, Inc
List of Summaries
- Summary Table U S. Market for Structural Carbon Materials by User Segment, through 2013 ($ Millions)
- Summary Figure U S. Market for Structural Carbon Materials by User Segment, 2007-2013 ($ Millions)
List of Tables
- Table 1 Dependence of Carbon Fiber Properties on Raw Materials
- Table 2 Structural Property Relationships for Carbon Fibers Derived from Various Precursors
- Table 3 Typical Mechanical Properties of Carbon-Fiber- Reinforced Polymer Composites
- Table 4 Typical Mechanical Properties of Carbon-Fiber- Reinforced Metal Composites
- Table 5 Properties of Pitch Raw Materials Used for Carbon Foam Manufacturing
- Table 6 Physical Properties of Pitch-Derived Carbon Foams
- Table 7 Physical Properties of Graphite Materials
- Table 8 Advantages and Disadvantages of Carbon- Carbon Composites
- Table 9 Comparison of Physical Properties of Graphite and Carbon-Carbon Composites
- Table 10 Comparison of Carbon-Carbon Composites Properties Manufactured by Various Processing Routes
- Table 11 Properties and Applications of Carbon Fibers
- Table 12 U S. Space Vehicle Market, through 2013 ($ Billions)
- Table 13 Sales of U S. Military Aircraft, through 2013 ($ Billions)
- Table 14 U S. Missile Shipments, through- 2013 ($ Billions)
- Table 15 Deliveries of Large U S -Made Commercial Aircraft by Type, through 2013 (Units)
- Table 16 Consumption of Carbon-Fiber-Reinforced Composites in U S -Made Commercial Airliners
- Table 17 Trends in U S. Wind Power Capacity, through 2013 (Mw)
- Table 18 U S. Market for Wind Turbine Rotor Blades, through 2013 ($ Millions)
- Table 19 U S. Market for Carbon Fiber Composite Golf Clubs, through 2013 ($ Millions)
- Table 20 U S. Shipments of Carbon Fiber Fishing Rods, through-2013 ($ Millions)
- Table 21 U S. Consumption of Carbon Fibers, through 2013 (Thousand Lbs )
- Table 22 U S. Market for Carbon Fibers, through 2013 ($ Millions)
- Table 23 U S. Consumption of Carbon Foam, through 2013 (Thousand Lbs )
- Table 24 U S. Carbon Foam Market Growth by Industry, through 2013 ($ Millions)
- Table 25 Typical Applications for Graphite Bearings
- Table 26 U S. Consumption of Structural Graphite by Industry, through 2013 (Thousand Lbs )
- Table 27 U S. Market for Structural Graphite by Industry Segment, through 2013 ($ Millions)
- Table 28 U S. Consumption of Carbon-Carbon Composites by Industry, through 2013 (Thousand Lbs )
- Table 29 U S. Market for Carbon-Carbon Composites by Industry, through 2013 ($ Millions)
- Table 30 U S. Consumption of Structural Carbons by Type of Material, through 2013 (Thousand Lbs )
- Table 31 U S. Market for Structural Carbon Materials by Type of Material, through 2013 ($ Millions)
- Table 32 Patents Issued to Leading Manufactures in Structural Carbon Materials Technology, 1996-2008
- Table 33 Global Market for Structural Carbon by Type of Material, 2007 ($ Millions)
- Table 34 Global Structural Carbons Market Growth by Region, through 2013 ($ Millions)
List of Figures
- Figure 1 United States Market for Advanced Structural Carbons by Type, 2007 (Total = $1 7 Billion)
- Figure 2 Projected Growth Rate in U S. Structural Carbons Market, 2008-2013 (Cagr%)
- Figure 3 Global Advanced Structural Carbons Market by Type, 2007 (Total = $4 3 Billion)
- Figure 4 Global Structural Carbons Consumption by World Region, 2007 (%)
- Figure 5 Types of Structural Carbon Products
- Figure 6 Schematic of Manufacturing Process for Synthetic Graphite
- Figure 7 Crystalline Structure of Graphite
- Figure 8 Representation of Carbon-Carbon Composite Manufacturing Process
- Figure 9 U S. Carbon Fiber Consumption by Industry Segment, 2008 vs. 2013 (%)
- Figure 10 U S. Carbon Fiber Market by Industry, 2008 vs 2013 (% of Total Market Value)
- Figure 11 U S. Consumption of Carbon Foam by Industry Sector, 2008 vs. 2013 (% Total Consumption)
- Figure 12 U S. Consumption of Structural Graphite by Industry Segment, 2007 vs. 2013 (% of Total Lbs Consumed)
- Figure 13 U S. Carbon-Carbon Composites Consumption by Industry Type, 2007 vs. 2013 (%)
- Figure 14 U S. Carbon-Carbon Composites Market Shares by Industry, 2007 vs. 2013 (%)
- Figure 15 Structural Carbon Product Shares of Total U S. Structural Carbon Consumption, 2007 vs. 2013 (%)
- Figure 16 Structural Carbon Product Shares of Total U S. Structural Carbon Consumption, 2007 vs. 2013 (%)
- Figure 17 Leading U S. Carbon Fiber Suppliers' Share of Total U S. Consumption, 2007 (%)
- Figure 18 Leading U S. Carbon Foam Suppliers' Share of Total U S. Consumption, 2007 (%)
- Figure 19 Leading U S. Structural Graphite Suppliers' Share of Total U S. Consumption, 2007 (%)
- Figure 20 Leading U S. Carbon-Carbon Composite Suppliers' Share of Total U S. Consumption, 2007 (%)
- Figure 21 Comparison of Advanced Structural Carbons Consumption in World Regions by Type of Material, 2006 (%)