DowAksa Advances Next-Generation Composite Solutions

What is Carbon Fiber?

Carbon fiber is an extremely fine fiber composed of more than 95% carbon atoms, with a filament thickness of 5-7 μ. This thickness makes it approximately 1/10 the diameter of human hair. It is produced commercially in the form of yarns called tow, consisting of varying numbers of filaments such as 1k, 3k, 6k, 12k, 24k, and 50k. Carbon fiber holds strategic importance because it provides innovative solutions to some of the most pressing problems facing the world and our country, particularly through efficient resource utilization. Its lightweight nature is critical for increasing energy production from wind turbines, reducing fuel consumption in automobiles, and reinforcing infrastructure and structures against earthquakes while extending their economic lifespan. Carbon fiber holds strategic importance because it provides innovative solutions to some of the most pressing problems facing the world and our country, particularly through efficient resource utilization. Its lightweight nature is critical for increasing energy production from wind turbines, reducing fuel consumption in automobiles, and reinforcing infrastructure and structures against earthquakes while extending their economic lifespan.

Carbon fiber is a key component of advanced composite materials containing high technology that can replace metals such as steel and aluminum used in defense, aerospace, and aviation sectors. The following reasons underlie the global demand for carbon fiber material use:

• 4 times lighter than steel, 2 times lighter than aluminum and fiberglass, • 5 times more durable than steel, with rigidity at least 2 times higher than steel, aluminum, and fiberglass, • Resistant to corrosion and fatigue, • Electrically conductive and thermally insulating. Raw materials used in carbon fiber production are based on polyacrylonitrile (PAN), pitch, and rayon. However, more than 80% of produced carbon fiber is PAN (polyacrylonitrile) based. The first use of carbon fiber is credited to Thomas Edison, who carbonized cotton and bamboo fibers for use in incandescent light bulb filaments. However, practical use began in the late 1950s, resulting from the search for materials for space vehicles. Raw materials used in carbon fiber production are, in order of usage, polyacrylonitrile (PAN), pitch, and artificial silk (rayon). The high strength of carbon fiber material stems from strong bonds between atoms and molecules in the material. The precursor, which is the raw material of the carbon fiber process, follows polymerization and fiber spinning processes and enters the production process consisting of four main stages. These four processes are: oxidation, carbonization, surface preparation, and surface coating.

About DowAksa

DowAksa was established in 2012 as a joint venture between Dow Chemical and Aksa Akrilik, combining the strength of two global leaders in the field. DowAksa aims to provide a wide range of products and technical service solutions to the composite industry with carbon fiber as its raw material. One of DowAksa's significant initiatives in the defense and aviation sectors has been the Silk Project. The Silk Project, launched in 2014 as a joint initiative of DowAksa, Turkish Aerospace Industries (TAI), and the Defense Industries Presidency, aimed to develop and produce thermoset resin prepreg materials used in the aerospace industry in Turkey.

Use of Carbon Fiber in Defense and Aerospace

The relentless drive of the aerospace industry to enhance the performance of commercial and military aircraft continuously triggers the development of high-performance structural materials. Composite materials are materials that play an important role in current and future aerospace components. Composite materials hold special importance for space and aerospace applications due to their superior physical properties, exceptional strength, and strength-to-density ratios. Considering 2018 data, global carbon fiber consumption, which grew 10% annually to reach 92,600 tons, reached a market size of USD 2.6 billion. The aerospace and defense industry represents only 23% of the total quantity and half of the total market size. Fiberglass composite use in commercial aviation began in the 1980s and transitioned to carbon fiber composites in the mid-1990s. Currently, approximately 21,000 tons of carbon fiber is consumed annually in the aerospace sector, with a growth rate of approximately 10% per year. Aviation, defense, and space industries represent the largest and most profitable market for carbon fiber and are dominated by two major aircraft manufacturers. To provide an example, Boeing's 787 platform and Airbus's A350-380 platforms account for approximately 80% of aviation carbon fiber demand. Current designs using carbon fiber composites provide 3-5% operational savings due to lower fuel and maintenance costs, offsetting the high initial costs of composite materials. An aircraft manufactured with 50% CFRP is approximately 20% lighter compared to an aircraft containing 3% CFRP. Designs utilizing carbon fiber properties can achieve savings of up to 20%. Each kilogram of carbon fiber used generates operational savings between USD 600–1,500. The greatest advantage of carbon fiber over other composite materials is its high strength-to-weight ratio and high fatigue resistance. In defense and aerospace, the classification of fibers based on modulus and tensile strength according to their applications of use is given below.

Applications of Carbon Fiber Composites in Commercial Aviation

• Primary Structural Components: Medium and high modulus carbon fibers are predominantly used in primary structural components such as wings, fuselage, tail cone, and engine fan blades. Carbon composite materials used in these structures comprise approximately 75-85% of total demand. • Secondary Structural Components: High strength and standard modulus carbon fibers are generally used in secondary structural components such as ailerons, stringers, drive shafts, and horizontal and vertical stabilizers. Carbon composite materials used in these structures comprise approximately 10-15% of total demand. • Interior Structure and Floor Panels: High strength and standard modulus carbon fibers are also used in components such as overhead bins, dividing panels, and floor panels.

Carbon Fiber Composites in Military Applications

Composite materials used to enhance the performance of military aircraft are also used in many other military applications. The mechanical properties offered by carbon fiber make this material ideal for manned and unmanned aircraft and missile systems. Carbon composite materials are preferred particularly in the aerospace and defense industries due to their many superior properties, including long service life, lightweight characteristics, high chemical and mechanical resistance, and flexible design opportunities. However, the advantages that composite materials bring to the aerospace and defense sectors and their development in these sectors are still in a growth phase. The penetration of composite materials in these sectors will develop in parallel with increased material variety and improvements in product mechanical properties. While the fundamental motivation for this development is the mechanical properties of the material, prevailing environmental regulations and the trend toward reducing CO2 emissions play an important role in this development. Considering the effects mentioned above, the use of composite materials will continue to grow in the aerospace and defense industries. It should be noted that these developments will create challenges in the supply of carbon fiber composites and in the field of recycling. Finally, it should be stated that the aerospace, defense, and space industries represent the largest and most profitable market for carbon fiber. Mustafa Koray Özatay / Sales and Business Development Manager - Sales and Business Development Manager - DowAksa References / References https://www.gminsights.com/industry-reports/aerospace-anddefense https://www.gminsights.com/industry-analysis/aerospace-avionicsmarket https://swiss-aerospace-cluster.ch/composites-in-aerospace/ https://www.appropedia.org/File:Composites01.jpg https://ihsmarkit.com/pdf/Composites-Aerospace-Applications-whitepaper_264558110913046532.pdfMcKinsey&Company Lightweighting strategy report https://link.springer.com/chapter/10.1007/978-4-431-55203-1_22 https://www.materialstoday.com/composite-applications/features/hexcels-composites-ready-to-fly-on-the-a350-xwb/ https://www.gurit.com/-/media/Gurit/Datasheets/guide-tocomposites.pdf