Elsevier

Reinforced Plastics

Volume 60, Issue 6, November–December 2016, Pages 396-400
Reinforced Plastics

Feature
Carbon Nexus at Deakin University: a globally unique carbon fiber and composite research facility in Australia

https://doi.org/10.1016/j.repl.2015.03.013Get rights and content

Abstract

Carbon Nexus, the new cutting-edge open-access carbon fiber and composites research facility at Deakin University, recently commenced operations. The two carbon fiber processing lines are allowing researchers to investigate new methods for manufacturing carbon fiber which can lower energy inputs, maximise output, and increase fiber performance. The lines are also enabling industrial partners to validate new technologies at industrial scale. With a focused research program driven by a cross-functional research team, Carbon Nexus aims to reduce the cost of producing carbon fiber and increase the rate of manufacturing composite parts.

Introduction

Carbon fiber is a new generation engineered material that is increasingly being positioned to meet the demand for lighter and stronger structural components. Carbon fiber reinforced composites have significantly contributed to the weight reduction and fuel efficiency of current aircraft and have enabled the development of light-weight wind turbine blades. Carbon fibers are currently more costly than steel, however the global demand for carbon fiber is expected to reach 89,000 tons in 2020 with annual growth rates of around 10%. Many research organizations and production facilities around the world are targeting low cost precursors or manufacturing processes with the goal of reducing carbon fiber prices to $10 per kilogram or less. This is significant when considering the uptake of these materials into high volume applications for the automotive and consumer electronics markets. Many countries and companies have recently invested in carbon fiber production and research capabilities, foreseeing the increased future demand of carbon fiber reinforced composites in a range of areas where the high performance and weight reduction benefits of carbon fiber will see its adoption.

Poly acrylonitrile (PAN) is the most common carbon fiber precursor and more than 90% of world's carbon fiber production is based on PAN. In a typical process, PAN polymer is converted into a micron sized continuous white fiber in a solution spinning process. The PAN precursor fibers are heat treated during an oxidation process where the fibers are stabilized to withstand the very high temperature in the carbonization process. The fibers undergo both low temperature and high temperature carbonization passes in an inert atmosphere. The carbonized fibers are then passed though surface treatment and sizing processes and finally wound onto bobbins ready for the next step in the production process.

Section snippets

Carbon Nexus

Carbon Nexus is a globally unique carbon fiber and composite research facility located at Deakin University's Geelong Waurn Ponds Campus, near Melbourne. Opened in May 2014, Carbon Nexus aims to be a world-leading center in providing research solutions for the global carbon fiber industry. The $34 m Carbon Nexus facility is an integral component of the Australian Future Fibers Research and Innovation Centre (AFFRIC) jointly funded by Deakin University, the Victorian state government and the

The carbon fiber manufacturing facility

Carbon Nexus houses two fully functional production lines capable of processing industrially relevant quantities of high quality carbon fibers from PAN precursors. The larger of the two lines is the Industrial Pilot-Scale Line with an annual capacity of up to 100 tons. The 90 m long pilot line is able to manufacture fibers in tow sizes from 3 k to 320 k and facilitates the thermal, chemical and mechanical optimization of the carbon fiber manufacturing process. The Pilot Line is equipped with a wide

Carbon Nexus research strategies

Research activities at Carbon Nexus are focused on original and cutting-edge research on various aspects of carbon fiber production and composite manufacturing. Four key research themes have been developed over several years of consultation with key players from industry and academia. This important feedback which sets the research directions has been informed by the academic and industry representatives participating in the biennial ‘Carbon Fiber Future Directions’ conferences organized by

Carbon Nexus partners

Carbon Nexus at Deakin University operates globally with a number of key strategic partners in industry and other universities. Many of our research projects are conducted with the Commonwealth Scientific and Industrial Research Organisation (CSIRO) is Australia's national science agency. Deakin University's industry engagement in the field of carbon fiber and composite materials has been enhanced by a strong partnership with the Victorian Centre for Advanced Materials Manufacturing (VCAMM) for

Summary

Carbon fiber manufacturers around world are in search of innovative, low cost and energy efficient carbon fiber and composite production technologies. The open access approach of Carbon Nexus at Deakin University can reveal these carbon fiber secrets and bring exciting findings relevant to the production as well as the science and technology of precursor, carbon fiber and composite production. Through its ability to produce customized carbon fibers in industrially relevant production

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