June 2022
The term carbon fiber refers to organic materials that have been heat-treated at temperatures of 1,000–3,000°C and generally contain 92–99.99+% carbon. Graphite fiber refers to carbon fiber precursors that have been processed at temperatures exceeding 2,500°C for an extended period of time; for the purposes of this report, however, graphite fibers will not be distinguished from carbon fibers. Carbon fibers are noted for their high strength and stiffness. These properties are quantitatively measured by tensile-strength and tensile-modulus tests. The tensile strength of a material is the rupture strength per unit area as the material is subjected to a specified dynamic load. Tensile modulus is the ratio of stress to strain of the material as it is deformed under a specified dynamic load.
Carbon fibers are used primarily as reinforcing agents in high-performance composites with synthetic resin matrices such as epoxies, polyimides, vinyl esters, phenolics, and certain thermoplastics. High-performance composites, also referred to as advanced composites, are generally defined as very strong fiber-reinforced matrices having at least 60% fiber loading; composites having a fiber loading of 12–35% are used more frequently in industrial applications such as construction panels, pipes, or boats. Carbon fibers are used mainly in applications requiring high stiffness properties exceeding the tensile modulus of glass or aramid fibers. In recent years, the price of carbon fiber–reinforced composites has dropped, making them more attractive for use in more applications.
The following pie chart shows world consumption of carbon fibers:
Across the world, carbon fiber use will expand for industrial applications because of its importance as a lightweight and high-strength material. The growing pressure vessel market, including gas transport, compressed natural gas (CNG) vehicles, and hydrogen fuel cells, will continue to be supported with carbon fiber use. In wind energy, renewable energy targets, longer wind blades, larger wind turbines, and the increase in offshore wind installations will lead to more carbon fiber use in this market. For higher-value markets, carbon fibers are increasingly being used in commercial and military aircraft manufacture. Carbon fiber composites are used in the main body, wings, engines, etc., and can result in less aircraft weight, lower fuel consumption and lower emissions, as well as higher speeds, longer distance ranges, and easier maintenance.
Major advances in technology and processing have expanded the demand for high-performance carbon fibers. The introduction of higher-volume and lower-cost fibers, coupled with gains in productivity, has reduced the manufacturing costs of carbon fibers. Since cost is a major factor affecting demand, continued improvements in performance, along with increased availability, are expected to support growing consumption in all regions and applications. However, cost will remain a challenge in applications such as widespread automotive use.
In the United States, industrial use in pressure vessels will benefit from alternative fuels usage such as natural gas, gas transport, and the growing use of fuel-cell and electric vehicles. Use in wind energy will continue because of lower costs, longer turbine blades, larger wind turbines, and the growing number of offshore installations supporting this market. Carbon fiber composite use in mass-produced automobiles will have modest growth, providing lower weight, more fuel efficiency, and lower emissions; however, higher costs and longer production times will continue to limit widespread use.
Mainland Chinese carbon fiber consumption is expected to experience strong growth. Continued installed capacity of wind power will contribute to this growth, and this market will continue to have the largest consumption in the coming years. In automobiles, carbon fiber composite research will focus on reducing process time and cost. Civil engineering uses will also increase as the reinforcement and maintenance of existing roads and bridges are more frequent.
In Western Europe, future growth will depend on use of carbon composites in mass-produced automobiles as well as meeting renewable energy targets. Carbon fiber use in aircraft will grow strongly because of the increased use of composite structures in civil aircraft in order to reduce fuel consumption.
Japan remains the largest exporter of carbon fibers and production has increased in response to growing global demand. Carbon fiber use in automotive applications has increased to help reduce the weight of cars, increase fuel efficiency, and reduce emissions. Carbon fibers are also used in aircraft for both domestic use and export. In sporting goods/recreation applications, producers have relocated to Other Asian countries; however, in Japan, mostly high-end sporting good products are still produced.
For more detailed information, see the table of contents, shown below.
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