A microstructural study of carbon–carbon composites impregnated with SiC filaments

Porous multidirectional carbon/carbon composite obtained by pulse chemical vapour infiltration (PCVI) was impregnated with silicon carbide (SiC) derived from pyrolysis of polymethylsiloxane resin (PMS). The impregnation process was made to improve oxidation resistance and mechanical properties of MD C/C composite. The resin was used as a source of silicon carbide component of the composite forming after heat treatment above 1000 °C. During this process SiC thin filaments were formed inside the porous carbon phase. The aim of this work was to investigate the structure and microstructure of the constituents of carbon composite obtained after pyrolysis of SiC PMS precursor. Microscopic observations revealed that during careful heat treatment of crosslinked polymethylsiloxane resin up to 1700 °C, the filaments (diameter 200–400 nm) crystallized within porous carbon phase. The filaments were randomly oriented on the composite surface and inside the pores. FTIR spectra and XRD analysis of the modified C/C composite showed that filaments had silicon carbide structure with the crystallite size of silicon carbide phase of about 45 nm. The Raman spectra revealed that the composite contains two carbon components distinctly differing in their structural order, and SiC filaments present nanocrystalline structure.     

Production of carbon molecular sieves by plasma treated activated carbon fibers☆

Carbon molecular sieves (CMS) are valuable materials for the separation and purification of gas mixtures. In this work, plasma deposition was used aiming to the formation of pore constrictions, by narrowing the surface pore system of commercial activated carbon fibers (ACF). For this reason propylene/nitrogen or ethylene/nitrogen discharges of 80 and 120 W were used. The molecular sieving properties of the plasma treated ACF were evaluated by measuring the adsorption of CO₂ and CH₄. The CO₂/CH₄ selectivity was significantly improved and depended on plasma treatment conditions (discharge gas and power). The optimum CO₂/CH₄ selectivity (26) was observed for C₂H₄/N₂ plasma treated ACF at 80 W. Sample scanning electron microscopy (SEM) analysis after plasma treatment revealed an external film formation and X-ray photoelectron spectroscopy (XPS) analysis showed the incorporation of nitrogen functional groups in the film, which probably interact with CO₂, thereby altering CO₂/CH₄ selectivity.     

Diamond-like carbon — present status

Hydrogen free diamond-like carbon (DLC) films have been the subject of investigation all over the world during the past 25 years due to the unique combination of their properties that can be found between those of diamond and those of graphite. Intensive work throughout the world in the past 10 years has led to a much better understanding of the complicated mechanisms involved in the deposition of these films. This led to a significant improvement in the deposition processes in the variety of systems employed, enabling fabrication of films with better properties. The present work gives the author's assessment of the current status of DLC film deposition. Topics addressed include: deposition systems; characterization methods; film properties; and possible applications.     

Ablation behavior of ZrB2–SiC protective coating for carbon/carbon composites

Ablation behavior of ZrB₂–SiC protective coating for carbon/carbon composites during oxyacetylene flame test at 2500 °C was investigated by analyzing the microstructure differentiation caused by the increasing intensity of ablation from the border to the center of the surface. After ablation, a continuous SiO₂ scale, a porous SiO₂ layer inlaid with fine ZrO₂ nuclei, and a continuous ZrO₂ scale respectively emerged in the border region, the transitional region, and the center region. In order to investigate the ablation microstructure in the initial stage, the sub-layer microstructure was characterized and found to be mainly formed by coral-like structures of ZrO₂, which showed huge difference with the continuous structure of ZrO₂ on the surface layer. A kinetic model concerning the thickness change induced by volatilization and oxidation during ablation was built to explain the different growth mechanisms of the continuous ZrO₂ scale and the coral-like ZrO₂ structure.     

Bigger blades — the carbon option

As the booming wind energy industry turns to bigger, more powerful turbines, blade manufacturers must develop the composite materials and processing technology to keep pace. George Marsh reports.     

Carbonization of pitches in geometrically restricted spaces. Application to granular carbon–carbon composites

During granular carbon–carbon composites manufacturing, the binder (a pitch) is carbonized while surrounded by solid filler particles. This geometrical limitation imposed on the carbonization medium results in constraints responsible for textural modifications of the pitch-based coke. We studied the consequences of geometrical limitation on pitch carbonization, and also the influence of the as-formed composites multiscale organization on their mechanical properties and carboxyreactivity behavior. The micrometer scale is relevant to understand composite reactivity while the submillimeter scale enables a better comprehension of the mechanical properties.     

ZrB2–SiC gradient oxidation protective coating for carbon/carbon composites

To improve the oxidation protective ability of carbon/carbon composites, ZrB₂–SiC gradient coating was prepared on the surface of C/C composites by an in-situ reaction method. The ZrB₂–SiC gradient coating consisted of an inner ZrB₂–SiC layer and an outer ZrB₂–SiC–Si coating. The phase composition and microstructures of the multiphase coating were characterized by XRD, EDS and SEM. Results showed that the inner coating is mainly composed of ZrB₂ and SiC, while the outer multiphase coating is composed of ZrB₂, SiC and Si. The multilayer coating is about 200 μm in thickness, which has no penetration crack or big hole. The oxidation behavior of the coated C/C composites at 1773 K in air was investigated. Results show that the gradient ZrB₂–SiC oxidation protective coating could protect C/C from oxidation for 207 h with only (4.56±1.2)×10⁻³ g/cm² weight loss, owing to the compound silicate glass layer with the existence of thermally stable phase ZrSiO₄.     

A ZrB2–SiC/SiC oxidation protective dual-layer coating for carbon/carbon composites

In order to improve the oxidation resistance of C/C composites, a ZrB₂–SiC/SiC oxidation protective dual-layer coating was prepared by a pack cementation combined with the slurry paste method. The phase and microstructure of the coating were characterised by X-ray diffraction, scanning electron microscope and energy-dispersive spectrometer analyses. The anti-oxidation and thermal shock resistance of the coating were also investigated. It was found that the ZrB₂–SiC/SiC coating could effectively improve the oxidation resistance of the C/C composites. The weight loss of the coated samples was only 1.8% after oxidation at 1773?K for 18?h in air. The coating endured 20 thermal shock cycles between 1773?K and room temperature with only 4.6% weight loss.     

Hot pressed hydroxyapatite–carbon fibre composites

Composite samples were obtained from hydroxyapatite powder and carbon fibres by hot pressing at 1100°C and 25 MPa for 15 min in argon atmosphere. Two types of cut carbon fibres produced in a carbonisation process of polyacrylonitrile (PAN) precursor were used both in non-coated or coated form. The coatings of calcium phosphate were applied by sol–gel technique. The highly sintered composite with the best strength properties was obtained from coated carbon fibres with basic character of the surface. The existence of hydroxyl groups on fibre surface makes possible formation of bonds with the calcium phosphate layer formed as a result of polycondensation following the sol–gel procedure.     

Furfural hydrogenation over carbon‐supported copper

Furfural hydrogenation over copper dispersed on three forms of carbon – activated carbon, diamond and graphitized fibers – were studied. Only hydrogenation of the C=O bond to form either furfuryl alcohol or 2‐methyl furan occurred at temperatures from 473 to 573 K. Reduction at 573 K gave the most active catalysts, all three catalysts had activation energies of 16 kcal/mol, and turnover frequencies were 0.018–0.032 s^-1 based on the number of Cu⁰ + Cu⁺ sites, which were counted by N₂O adsorption at 363 K and CO adsorption at 300 K, respectively. The Cu/activated carbon catalyst showed no deactivation during 10 h on stream, in contrast to the other two catalysts. A simple Langmuir–Hinshelwood model invoking two types of sites was able to fit all kinetic data quite satisfactorily, thus it was consistent with the presence of both Cu⁰ and Cu⁺ sites. This revised version was published online in July 2006 with corrections to the Cover Date.     

Immobilization of β-Glucosidase on carbon nanotubes

Carbon nanotubes are demonstrated as a good support for the immobilization of -Glucosidase. This is an enzyme with high molecular weight (ca. 135 kDa). A high enzyme loading of 630 mg per gram of support was achieved in 12 h. The link between the enzyme and the carbon nanotubes surface was by electrostatic interactions due to the different charges of the enzyme and the support at the pH of the immobilization. Immobilized -Glucosidase showed a catalytic activity above 400 U/g on the hydrolysis of 4-nitrophenyl--D-glucopyranoside (p-NPG).     

A Si–SiC oxidation protective coating for carbon/carbon composites prepared by a two-step pack cementation

To prevent carbon/carbon (C/C) composites from oxidation, a Si–SiC coating has been prepared by a two-step pack cementation technique. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analysis show that the coating obtained by the first step pack cementation is a porous β-SiC structure, and a dense structure consisting α-SiC, β-SiC and Si is obtained after heat-treatment by the second step pack cementation. By energy dispersive spectroscopy (EDS) analysis, a gradient C–SiC transition layer can be formed at the C/C-coating interface. The as-received coating has excellent oxidation protection ability and can protect C/C composites from oxidation for 166 h at 1773 K in air. The weigh loss of the coated C/C is due to the formation of bubble holes on the coating surface and through-coating cracks in the coating.