Analysis of carbon fiber reinforced plastic composite material CFRP

Carbon fiber reinforced plastic composite (CFRP) is a lightweight, strong material used to manufacture many products used in everyday life. It is a term used to describe fiber-reinforced composite materials with carbon fiber as the main structural component. It should be noted that the "P" in CFRP can also stand for "plastic" instead of "polymer".

Typically, CFRP composites use thermosetting resins such as epoxy, polyester or vinyl ester. Although thermoplastic resins are used in CFRP composites, "carbon fiber reinforced thermoplastic composites" often uses its own acronym CFRTP composites.

Knowing terminology and acronyms is important when working with composites or working in the composites industry. More importantly, it is necessary to understand the performance of FRP composites and the performance of various reinforcement materials such as carbon fibers.

Properties of CFRP Composites

Composites reinforced with carbon fibers differ from other FRP composites that use traditional materials such as glass fibers or aramid fibers. Advantages of CFRP composites include:

Lightweight: Traditional fiberglass reinforced composites using continuous glass fibers and 70% glass fibers (glass weight/total weight) typically have a density of 0.065 lb/in3. A CFRP composite with the same 70% fiber weight might typically have a density of 0.055 lb/in3.

Increased Strength: Not only are carbon fiber composites lighter, but CFRP composites are stronger and stiffer per unit weight. This is true when comparing carbon fiber composites to fiberglass, and even more so when compared to metals.

For example, when comparing steel to CFRP composites, a good rule of thumb is that a carbon fiber structure of the same strength is typically 1/5 the weight of steel. You can imagine why car companies are looking into using carbon fiber instead of steel.

When comparing CFRP composites to aluminum (one of the lightest metals used), the standard assumption is that an aluminum structure of the same strength could weigh 1.5 times as much as a carbon fiber structure.

Of course, there are many variables that can change this comparison. Materials may vary in grade and quality, and for composites, manufacturing process, fiber structure and quality need to be considered.

Disadvantages of CFRP Composites

Cost: As amazing as the material is, there's a reason carbon fiber can't be used in every situation. Currently, CFRP composites are cost-prohibitive in many cases. The price of carbon fiber can vary significantly depending on current market conditions (supply and demand), the type of carbon fiber (aerospace versus commercial), and fiber tow size.

On a per-pound basis, carbon fiber materials can be 5 to 25 times more expensive than fiberglass materials. This difference is even greater when comparing steel to CFRP composites.

Electrical conductivity: This can be an advantage or a disadvantage for carbon fiber composites, depending on the application. Carbon fibers are extremely conductive, while glass fibers are insulating. Many applications use fiberglass and cannot use carbon fiber or metal, strictly because of conductivity.

For example, in the utilities industry, many products require the use of glass fibers. This is one of the reasons why ladders use fiberglass as the ladder rails. The chances of getting an electric shock are much lower if the fiberglass ladder comes into contact with the power lines. The situation is different with CFRP ladders.

Although the cost of CFRP composites remains high, new technological advances in manufacturing are continuing to provide more cost-effective products. Hopefully, within our lifetimes, we'll see cost-effective carbon fiber widely used in consumer, industrial, and automotive applications.

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