Effect of impregnation pressure and time on the porosity, structure and properties of polyacrylonitrile-fiber based carbon composites

Carbon–carbon composites may find applications in critical parts of advanced nuclear reactors. A series of carbon–carbon composites were prepared using polyacrylonitrile (PAN) based carbon fibers. The materials were densified by impregnating two-dimensional (2D) preforms with liquid phenol formaldehyde resin at different pressures and for different periods of time and then carbonizing those by slowly heating at 1000 °C. Effects of the processing parameters on the structure of the composites were extensively studied. The study showed conclusively that open porosity decreased with increasing impregnation pressure, whereas impregnation time had lesser effect. Matrix–resin bonding also improved at higher pressure. d002 spacing decreased and ordering along c-axis increased with concomitant increase in sp2-carbon fraction at higher impregnation pressures. The fiber reinforced composites exhibited short range ordering of carbon atoms and satisfied structural conditions (d002 values) of amorphous carbon according to the turbostratic model for non-graphitic carbon materials. The composites had pellet-density of ∼85% of the theoretical value, low thermal expansion and negligible neutron-poisoning. They maintained structural integrity and retained disordered nature even on heat-treatment at ca. 1800 °C.