Advanced Structural Carbon Products: Fibers, Foams and Composites

Advanced Structural Carbon Products: Fibers, Foams & Composites

BCC, Date of Publication: Feb 17, 2016, 193 Pages
US$6,650.00
GB-AVM038E

The overall goal of this study is to provide a comprehensive understanding of advances in structural carbon materials manufacturing, their commercial applications, and worldwide markets.  For the purposes of this report, these materials are defined to include all types of carbon fibers, carbon foams, monolithic structural graphite, carbon-reinforced carbon composites, and certain graphene materials.

Specific objectives of the study include describing the major types of structural carbon materials, including key physical and chemical properties, raw materials, and manufacturing processes.  Commercial applications in which these materials are used will be discussed.

Present consumption and future demand for these materials will be evaluated for the United States and other major geographical markets.  Trends in technology will be analyzed and forecasted.  The impact of governmental regulations will be assessed.  The dynamics of the structural carbons industry will be outlined along with profiles of key manufacturers.

REASONS FOR DOING THE STUDY

This study is an update of an earlier report that was published in 2011.  The structural carbon materials industry and markets have continued to develop in the two years since the previous edition was published.

The structural carbon materials industry serves mature markets such as defense and aerospace, with a wide variety of products satisfying the requirements of well-established applications.  However, continuous technical innovations and efforts to make structural carbon technologies available for new applications (at affordable prices) are leading to the development of new markets.

Corporations in the structural carbons industry need to understand the significance of these trends to manage their enterprise and resources effectively.  Users of structural carbons must also understand the effect of these changes in order to select the most cost-effective option among newly available products and technologies prior to committing significant capital resources.

INTENDED AUDIENCE

Over the next half-decade, significant change will take place in global structural carbon products and applications.  Technological advances in improving structure-property relationships of advanced carbon materials and breakthroughs in the manufacturing processes, resulting in lower costs, will lead to novel applications.  This study analyzes the driving forces that will shape the structural carbons industry over next few years.

Consequently, the information presented in this study should be useful to:

  • Members of the financial community who must understand, assess, and rate the effect of forthcoming changes in the structural carbons industry based upon the financial performance of the companies active in this market segment.
  • Chief executive officers who must effectively manage the assets of their company so as to benefit from forthcoming changes in the structural carbons industry.
  • Directors of planning who must incorporate anticipated changes in the structural carbons industry into corporate planning documents.
  • Directors of manufacturing who must implement new structural carbons technology and products into their operations.
  • Directors of engineering, research, and development who must incorporate the latest in structural carbons technology and products into their designs and projects.
  • Decision makers at major structural carbons consumers, such as the Department of Defense contractors involved in aerospace and aircraft manufacturing.
  • Executives at companies engaged in developing competitive materials and technologies such as other reinforcement fibers like Kevlar or composites manufactured with other matrix materials such as ceramics or metal.

 
SCOPE OF REPORT

This report covers technological, economic, and business conditions in the structural carbons industry.  Although this report is primarily a study of the U.S. market, analysis and forecasts are also provided for global markets.  Included in this report are descriptions of market forces relevant to the structural carbons industry and their areas of application.

The U.S. market is presented by type of structural carbons along with growth forecasts through 2018.  The driving forces in the industry and the structure of the industry are also examined.

International aspects of the structural carbons industry are discussed with respect to all the geographic regions and type of structural carbon material.  Lastly, brief profiles of the major manufacturers are presented.

This report provides:

  • An overview of the market for advanced structural carbon products, defined in this report to include all types of carbon fibers, carbon foams, monolithic structural graphite, carbon-reinforced carbon composites, and certain graphene materials
  • Analyses of market trends, with data from 2012, estimates for 2013, and projections of compound annual growth rates (CAGRs) through 2018
  • Descriptions of the major types of structural carbon materials, including key physical and chemical properties, raw materials, and manufacturing processes
  • Evaluations of current consumption and future demand for these materials for the United States and other major geographic markets
  • Discussion of trends in technology and the impact of governmental regulations
  • Comprehensive company profiles of major players in the market segment.


This report will be updated in February 2016, please contact us to arrange updates and best price for your purchase.

 

TABLE OF CONTENTS

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Chapter 1: INTRODUCTION

    STUDY GOALS AND OBJECTIVES
    REASONS FOR DOING THE STUDY
    INTENDED AUDIENCE
    SCOPE OF REPORT
    METHODOLOGY AND INFORMATION SOURCES
    ANALYST'S CREDENTIALS
    DISCLAIMER

Chapter 2: SUMMARY  $250   

        Table Summary : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, THROUGH 2018
        Figure Summary : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, 2012-2018

Chapter 3: INDUSTRY AND MARKETS OVERVIEW       $212   

    UNITED STATES MARKET
            Figure 1 : UNITED STATES MARKET FOR ADVANCED STRUCTURAL CARBONS BY TYPE, 2012
            Figure 2 : PROJECTED GROWTH RATE IN U.S. STRUCTURAL CARBONS MARKET, 2013-2018
    GLOBAL MARKETS
            Figure 3 : GLOBAL ADVANCED STRUCTURAL CARBONS MARKET BY TYPE, 2012
            Figure 4 : GLOBAL STRUCTURAL CARBONS CONSUMPTION BY WORLD REGION, 2012
    RESEARCH AND TECHNOLOGY TRENDS
    INDUSTRY STRUCTURE

Chapter 4: TECHNICAL OVERVIEW  $3134   

    INTRODUCTION TO ADVANCED STRUCTURAL CARBON PRODUCTS
    IMPORTANCE OF MECHANICAL PROPERTIES
    CARBON FIBERS
        RAW MATERIALS FOR CARBON FIBERS
            Types of Raw Materials
            Raw Material and Fiber Properties Relationship
        MANUFACTURING PROCESS
            PAN Carbon Fiber Process
            Pitch Carbon Fiber Process
                Precursor Preparation
                Melt Spinning
                Stabilization
                Carbonization
                Graphitization
            Viscose Rayon Carbon Fiber Process
            Vapor-Grown Carbon Fibers
        CHEMICAL AND PHYSICAL PROPERTIES
            Structural Property Relationship for Carbon Fibers
        CARBON FIBER PRODUCT FORMS
            Carbon Fiber Product Grades
            Tow
            Carbon Fiber Cloth
            Prepreg
        RECENT DEVELOPMENTS IN MANUFACTURING TECHNOLOGIES
            Microwave-Assisted Plasma (MAP) Process
            Low Cost Carbon Fiber from Renewable Resources
            Low Cost Carbon Fiber from Polyolefin
            Converting Polyethylene into Carbon Fiber
            Ultraviolet (UV) Stabilization of PAN-based Carbon Fibers
            Rapid Oxidation Step
            Surface Modification of Carbon Fibers
            Carbon Nanotube Reinforcement of Carbon Fibers
            Continuous Carbon Fiber Produced from Carbon Nanotubes
            Carbon Nanofibers
            Activated Carbon Fibers
        MANUFACTURERS OF PAN-BASED FIBERS
            Small-tow Manufacturers
            Large-Tow Carbon Fiber Manufacturers
        MANUFACTURERS OF PITCH-BASED CARBON FIBERS
        CARBON FIBER COMPOSITES
            Carbon-Fiber-Reinforced Polymer Composites (CFRP)
            Carbon-Fiber-Reinforced Metal Composites (CFRM)
    CARBON FOAMS
        RAW MATERIALS
        MANUFACTURING PROCESS
            Flash Process
            Blowing Gases
            Sol-Gel Process
        CHEMICAL AND PHYSICAL PROPERTIES
                Table 6 : PHYSICAL PROPERTIES OF PITCH-DERIVED CARBON FOAMS
        RECENT TRENDS IN CARBON FOAM TECHNOLOGY
            Uniform-Density-Gradient Carbon Foams
            Reinforced Carbon Foams
            High-Thermal-Conductivity Carbon Foams
            Magnetic Carbon Nanofoams
            Low-Cost Carbon Foams
        MANUFACTURERS OF CARBON FOAMS
            Honeywell
            POCO Graphite
            Touchstone Research Laboratory
            University of Dayton and Wright U.S. Air Force Laboratory Alliance
    STRUCTURAL GRAPHITE
        TYPES AND MANUFACTURING OF GRAPHITE MATERIALS
            Natural Graphite
            Synthetic Graphite
        PHYSICAL AND CHEMICAL PROPERTIES
            Crystalline Structure
            Lubrication
            Thermal Properties
            Oxidation Resistance
            Chemical Resistance
            Mechanical Properties
        EMERGING TECHNOLOGIES
            Porous Graphite
            High-Temperature Graphite Process
            Expandable Graphite
    CARBON-CARBON STRUCTURAL COMPOSITES
        TYPES OF STRUCTURAL COMPOSITE MATERIALS
        CARBON-REINFORCED CARBON MATRIX COMPOSITES
                Table 8 : ADVANTAGES AND DISADVANTAGES OF CARBON-CARBON COMPOSITES
        DIFFERENCES BETWEEN GRAPHITE AND CARBON-CARBON COMPOSITES
                Table 9 : COMPARISON OF PHYSICAL PROPERTIES OF GRAPHITE AND CARBON-CARBON COMPOSITES
        CHEMICAL AND PHYSICAL PROPERTIES
        REINFORCEMENT ARCHITECTURE
            One-Dimensional Architecture
            Two-Dimensional Architecture
            Three-Dimensional Architecture
            Multidimensional Architecture
            Foam Reinforcement
        MANUFACTURING PROCESSES
            Infiltration of Matrix Phase
        STRUCTURE AND PROPERTY RELATIONSHIPS
            Microstructural Features
            Mechanical Properties
            Thermal Properties
            Friction and Wear Properties
        OXIDATION PROTECTION FOR CARBON-CARBON COMPOSITES
        TECHNOLOGY TRENDS
            Oxidation Inhibition of Carbon-Carbon Composites
            Rapid-Oxidative-Stabilization Composites
            High-Purity Carbon-Carbon Composites
            High-Density Carbon-Carbon Composites
            Elimination of Need for Oxidative Stabilization of Carbon Composites
            High Thermal Conductivity Carbon-Carbon Composites
            Sequential Deposit of Carbon Matrix and In Situ Polymerization
            Rapid Processing of Carbon-Carbon Composites
            Protective Coatings
            Detecting Flaws in the Carbon Composites
            Carbon-Carbon Composites from Densified Carbon Foam
            Low-Temperature Densification Using Sugar Pyrolysis
            Thick Three Dimensional Preforms for Carbon-Carbon Composites
            High-Strength Composites Developed by NASA and JPL
            Carbon-Carbon Frictional Composites for Elevator Brakes
            Joining Carbon-Carbon Composites
            Nanotubes in Carbon-Carbon Composites
            Low Cost Production of Carbon-Carbon Composites
    GRAPHENE
        PROPERTIES
        RAW MATERIALS AND PRODUCTION PROCESSES
            Established Technologies
            Experimental Approaches
        COMPANIES DEVELOPING GRAPHENE STRUCTURAL MATERIALS
            General Motors
            Graftech
            Graphenea

Chapter 5: COMMERCIAL APPLICATIONS  $2796    

    CARBON FIBER APPLICATIONS
    CARBON FOAM APPLICATIONS
        AEROSPACE AND DEFENSE
            Radiators
            Fire Barrier Applications
            Brakes
        GROUND TRANSPORTATION
            Automotive Radiators
            Shock Absorbers and Bumpers
            Other Automotive Applications
        INDUSTRIAL APPLICATIONS
            Sandwich Panels
            Electronic Heat Sinks
            Phase-Change Materials
        ENERGY
            Batteries
            Fuel Cells
            Supercapacitors
            Nuclear Reactor Cores
            Gas Storage
        OTHER APPLICATIONS
            Air Filtration Devices
            Personal Cooling Devices
            Health Care Applications
            Acoustic Absorber Materials
        CARBON FOAM MARKET GROWTH
                Table 23 : U.S. CONSUMPTION OF CARBON FOAM, THROUGH 2018
                Figure 10 : U.S. CONSUMPTION OF CARBON FOAM BY INDUSTRY SECTOR, 2012 VS. 2018
                Table 24 : U.S. CARBON FOAM MARKET GROWTH BY INDUSTRY, THROUGH 2018
    STRUCTURAL GRAPHITE APPLICATIONS
        AEROSPACE AND DEFENSE
        GROUND TRANSPORTATION
        INDUSTRIAL APPLICATIONS
            Chemical Industry Applications
            Mechanical Applications
            Metallurgy
            Glassware
            Refractory Applications
        ENERGY
            Fuel Cells
            Nuclear Industry Applications
            Hydrogen Storage
        STRUCTURAL GRAPHITE MARKET GROWTH
    CARBON-CARBON COMPOSITES APPLICATIONS
        AEROSPACE
            Space Vehicle Thermal Protection Systems
            Aircraft Engine Components
            Aircraft Brakes
            Other Aerospace Applications
        GROUND TRANSPORTATION
        INDUSTRIAL APPLICATIONS
        ENERGY
        OTHER APPLICATIONS
            Biocompatible Structures
        CARBON-CARBON COMPOSITES MARKET GROWTH
                Table 28 : U.S. CONSUMPTION OF CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2018
                Figure 12 : U.S. CARBON-CARBON COMPOSITES CONSUMPTION BY INDUSTRY TYPE, 2012 VS. 2018
                Table 29 : U.S. MARKET FOR CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2018
    STRUCTURAL GRAPHENE APPLICATIONS
        INDUSTRIAL APPLICATIONS
            Thermal Management Solutions
        ENERGY
            Hydrogen Storage
        MARKET GROWTH
                Table 30 : U.S. CONSUMPTION OF STRUCTURAL GRAPHENE BY INDUSTRY, THROUGH 2018
    MARKETS FOR ADVANCED STRUCTURAL CARBONS
            Table 31 : U.S. CONSUMPTION OF STRUCTURAL CARBONS BY TYPE OF MATERIAL, THROUGH 2018
            Figure 13 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2012 VS. 2018
            Table 32 : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE OF MATERIAL, THROUGH 2018
            Figure 14 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2012 VS. 2018

Chapter 6: INDUSTRY STRUCTURE AND MARKET DRIVERS     $593    

    MARKETS FOR STRUCTURAL CARBON MATERIALS
        MANUFACTURERS OF STRUCTURAL CARBONS
            Carbon Fibers
            Carbon Foams
            Structural Graphite
            Carbon-Carbon Composites
        SWOT ANALYSIS OF STRUCTURAL CARBONS INDUSTRY
            Strengths
            Weaknesses
            Opportunities
            Threats
    MARKET DRIVERS
        ECONOMIC FACTORS
        LEGAL AND REGULATORY FACTORS
            Price-Fixing in the Carbon Fibers and Composites Industry
            Price-Fixing in the Graphite Industry
        INDUSTRY FACTORS
            Capacity Trends
            Price Trends
            New Technologies and New Entrants to the Business
            Influence and Leverage
            Substitute Products
    COMPETITIVE STRATEGIES IN THE STRUCTURAL CARBONS INDUSTRY
        NEW BUSINESS DEVELOPMENT
        COMPETITIVE PRICING
        VERTICAL INTEGRATION
        GLOBAL STRATEGIC ALLIANCES
            SGL - BMW Joint Venture
            SGL-Mitsubishi Joint Venture
            Mitsubishi Rayon's Expansion Plans and Alliance with SGL
            Zoltek and Chomarat
            GrafTech and Ballard Power Systems
            Zoltek and Leggett & Pratt
            Hexcel and Airbus Industries
            Hexcel and Boeing

Chapter 7: INTELLECTUAL PROPERTY AND TECHNOLOGY TRENDS ANALYSIS     $127    

    INTELLECTUAL PROPERTY ANALYSIS
            Table 33 : PATENTS ISSUED TO LEADING MANUFACTURES IN STRUCTURAL CARBON MATERIALS TECHNOLOGY, 1996-MAY 2013
    TECHNOLOGY DEVELOPMENT TRENDS

Chapter 8: INTERNATIONAL ASPECTS OF STRUCTURAL CARBONS BUSINESS     $127   
       
    Figure 19 : COMPARISON OF ADVANCED STRUCTURAL CARBONS CONSUMPTION IN WORLD REGIONS BY TYPE OF MATERIAL, 2012

Chapter 9: PROFILES OF MANUFACTURERS  $932   

    U.S. MANUFACTURERS
    INTERNATIONAL MANUFACTURERS
 
List of Tables

    Summary Table : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, THROUGH 2018
    Table 1 : DEPENDENCE OF CARBON FIBER PROPERTIES ON RAW MATERIALS
    Table 2 : STRUCTURAL PROPERTY RELATIONSHIPS FOR CARBON FIBERS DERIVED FROM VARIOUS PRECURSORS
    Table 3 : TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBER-REINFORCED POLYMER COMPOSITES
    Table 4 : TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBER-REINFORCED METAL COMPOSITES
    Table 5 : PROPERTIES OF PITCH RAW MATERIALS USED FOR CARBON FOAM MANUFACTURING
    Table 6 : PHYSICAL PROPERTIES OF PITCH-DERIVED CARBON FOAMS
    Table 7 : PHYSICAL PROPERTIES OF GRAPHITE MATERIALS
    Table 8 : ADVANTAGES AND DISADVANTAGES OF CARBON-CARBON COMPOSITES
    Table 9 : COMPARISON OF PHYSICAL PROPERTIES OF GRAPHITE AND CARBON-CARBON COMPOSITES
    Table 10 : COMPARISON OF CARBON-CARBON COMPOSITES PROPERTIES MANUFACTURED BY VARIOUS PROCESSING ROUTES
    Table 11 : PROPERTIES AND APPLICATIONS OF CARBON FIBERS
    Table 12 : U.S. SPACE VEHICLE MARKET, THROUGH 2018
    Table 13 : SALES OF U.S. MILITARY AIRCRAFT, THROUGH 2018
    Table 14 : U.S. MISSILE SHIPMENTS, THROUGH- 2018
    Table 15 : DELIVERIES OF LARGE U.S.-MADE COMMERCIAL AIRCRAFT BY TYPE, THROUGH 2018
    Table 16 : CONSUMPTION OF CARBON-FIBER-REINFORCED COMPOSITES IN U.S.-MADE COMMERCIAL AIRLINERS
    Table 17 : TRENDS IN U.S. WIND POWER CAPACITY, THROUGH 2018
    Table 18 : U.S. PRODUCTION OF WIND TURBINE ROTOR BLADES, THROUGH 2018
    Table 19 : U.S. MARKET FOR CARBON FIBER COMPOSITE GOLF CLUBS, THROUGH 2018
    Table 20 : U.S. SHIPMENTS OF CARBON FIBER FISHING RODS, THROUGH-2018
    Table 21 : U.S. CONSUMPTION OF CARBON FIBERS, THROUGH 2018
    Table 22 : U.S. MARKET FOR CARBON FIBERS, THROUGH 2018
    Table 23 : U.S. CONSUMPTION OF CARBON FOAM, THROUGH 2018
    Table 24 : U.S. CARBON FOAM MARKET GROWTH BY INDUSTRY, THROUGH 2018
    Table 25 : TYPICAL APPLICATIONS FOR GRAPHITE BEARINGS
    Table 26 : U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY, THROUGH 2018
    Table 27 : U.S. MARKET FOR STRUCTURAL GRAPHITE BY INDUSTRY SEGMENT, THROUGH 2018
    Table 28 : U.S. CONSUMPTION OF CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2018
    Table 29 : U.S. MARKET FOR CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2018
    Table 30 : U.S. CONSUMPTION OF STRUCTURAL GRAPHENE BY INDUSTRY, THROUGH 2018
    Table 31 : U.S. CONSUMPTION OF STRUCTURAL CARBONS BY TYPE OF MATERIAL, THROUGH 2018
    Table 32 : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE OF MATERIAL, THROUGH 2018
    Table 33 : PATENTS ISSUED TO LEADING MANUFACTURES IN STRUCTURAL CARBON MATERIALS TECHNOLOGY, 1996-MAY 2013
    Table 34 : GLOBAL MARKET FOR STRUCTURAL CARBON BY TYPE OF MATERIAL, 2012
    Table 35 : GLOBAL STRUCTURAL CARBONS MARKET GROWTH BY REGION, THROUGH 2018

List of Figures

    Summary Figure : U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, 2012-2018
    Figure 1 : UNITED STATES MARKET FOR ADVANCED STRUCTURAL CARBONS BY TYPE, 2012
    Figure 2 : PROJECTED GROWTH RATE IN U.S. STRUCTURAL CARBONS MARKET, 2013-2018
    Figure 3 : GLOBAL ADVANCED STRUCTURAL CARBONS MARKET BY TYPE, 2012
    Figure 4 : GLOBAL STRUCTURAL CARBONS CONSUMPTION BY WORLD REGION, 2012
    Figure 5 : SCHEMATIC OF MANUFACTURING PROCESS FOR SYNTHETIC GRAPHITE
    Figure 6 : CRYSTALLINE STRUCTURE OF GRAPHITE
    Figure 7 : REPRESENTATION OF CARBON-CARBON COMPOSITE MANUFACTURING PROCESS
    Figure 8 : U.S. CARBON FIBER CONSUMPTION BY INDUSTRY SEGMENT, 2012 VS. 2018
    Figure 9 : U.S. CARBON FIBER MARKET BY INDUSTRY, 2012 VS. 2018
    Figure 10 : U.S. CONSUMPTION OF CARBON FOAM BY INDUSTRY SECTOR, 2012 VS. 2018
    Figure 11 : U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY SEGMENT, 2012 VS. 2018
    Figure 12 : U.S. CARBON-CARBON COMPOSITES CONSUMPTION BY INDUSTRY TYPE, 2012 VS. 2018
    Figure 13 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2012 VS. 2018
    Figure 14 : STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2012 VS. 2018
    Figure 15 : LEADING U.S. CARBON FIBER SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2012
    Figure 16 : LEADING U.S. CARBON FOAM SUPPLIERS' SHARE OF TOTAL U.S. CONSUMPTION, 2012
    Figure 17 : LEADING U.S. STRUCTURAL GRAPHITE SUPPLIERS' SHARE OF TOTAL U.S. CONSUMPTION, 2012
    Figure 18 : LEADING U.S. CARBON-CARBON COMPOSITE SUPPLIERS' SHARE OF TOTAL U.S. CONSUMPTION, 2012
    Figure 19 : COMPARISON OF ADVANCED STRUCTURAL CARBONS CONSUMPTION IN WORLD REGIONS BY TYPE OF MATERIAL, 2012

 

Date of Publication:
Feb 17, 2016
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