Carbon Fiber Technology Course

Lesson 1 • Carbon Fiber Composition and Structure

Explains the atomic and molecular structure of carbon fiber at the microstructural level. Links crystalline alignment to mechanical performance outcomes.

Lesson 2 • Carbon Fiber Grades and Classifications

Differentiates standard, intermediate, high, and ultra-high modulus fiber grades. Connects grade selection to cost, weight, and structural performance trade-offs.

Lesson 3 • History and Industry Overview

Traces carbon fiber development from early rayon-based fibers to modern aerospace-grade materials. Provides context for understanding current manufacturing standards and market drivers.

Lesson 4 • Comparison with Competing Materials

Benchmarks carbon fiber against aluminum, steel, fiberglass, and aramid fibers. Supports engineering decisions by clarifying performance and cost trade-offs.

Lesson 1 • Polyacrylonitrile Precursor Processing

Covers PAN polymerization, spinning, and drawing to produce precursor tow. Establishes how precursor quality directly determines fiber mechanical performance.

Lesson 2 • Stabilization and Oxidation

Explains the oxidative stabilization step that converts PAN to a thermally stable ladder polymer. Identifies critical temperature profiles and atmospheric conditions.

Lesson 3 • Graphitization for Ultra-High Modulus Fiber

Covers optional graphitization above 2000°C to maximize crystalline alignment and stiffness. Explains trade-offs between modulus gain and reduced tensile strength.

Lesson 4 • Low and High Temperature Carbonization

Describes the two-stage carbonization process that removes non-carbon elements and builds graphitic structure. Links furnace atmosphere and temperature to fiber modulus.

Lesson 1 • Unidirectional and Multiaxial Fabrics

Explains unidirectional tape and non-crimp fabric construction for maximum fiber efficiency. Links fiber orientation to anisotropic stiffness and strength behavior.

Lesson 2 • Braided and Filament-Wound Preforms

Describes 2D and 3D braiding and filament winding as continuous fiber preform methods. Highlights their suitability for tubular and complex-geometry structures.

Lesson 3 • Prepreg and Dry Preform Handling

Covers storage, cutting, kitting, and handling of prepreg and dry fiber preforms. Prevents defects caused by improper handling before layup.

Lesson 4 • Woven Fabric Architectures

Covers plain, twill, satin, and harness weave patterns and their mechanical implications. Connects weave geometry to drapability, surface finish, and in-plane stiffness.

Lesson 1 • Epoxy Resin Systems

Covers epoxy chemistry, curing agents, and cure cycle design for structural composites. Epoxy is the dominant aerospace and sporting goods matrix system.

Lesson 2 • Resin Infusion and Prepreg Resin Systems

Differentiates low-viscosity infusion resins from prepreg resin systems optimized for out-of-autoclave processing. Connects resin viscosity to fiber wet-out quality.

Lesson 3 • Bismaleimide, Cyanate Ester, and Polyimide Resins

Introduces high-temperature thermoset resins for applications exceeding epoxy service limits. Compares processing complexity and thermal performance across resin families.

Lesson 4 • Role of the Matrix in Composites

Defines the matrix function in load transfer, fiber protection, and environmental resistance. Establishes why matrix selection is as critical as fiber selection.

Lesson 1 • Filament Winding and Pultrusion

Covers continuous fiber processes for tubular and constant-cross-section structural profiles. Connects winding angle and pull speed to part mechanical properties.

Lesson 2 • Vacuum Bagging and Autoclave Processing

Explains vacuum bag assembly, debulking, and autoclave cure cycle management. Connects applied pressure and temperature to fiber volume fraction and void content.

Lesson 3 • Automated Fiber Placement and Tape Laying

Introduces AFP and ATL machines for high-rate, precise fiber deposition on complex surfaces. Highlights programming, steering limits, and defect types unique to automated processes.

Lesson 4 • Out-of-Autoclave Cure Methods

Examines oven cure, press cure, and heated tooling as alternatives to autoclave processing. Evaluates mechanical property trade-offs and cost benefits of each method.

Lesson 5 • Resin Transfer Molding and Infusion

Covers RTM, VARTM, and SCRIMP processes for closed-mold, high-fiber-volume parts. Links infusion strategy to fill time, fiber wet-out, and part quality.

Lesson 1 • Buckling and Stability Analysis

Applies plate and column buckling theory to thin-walled carbon fiber structures under compression. Identifies stiffener configurations that improve buckling resistance.

Lesson 2 • Failure Criteria for Composites

Covers maximum stress, maximum strain, Tsai-Wu, and Hashin failure criteria for ply-level analysis. Enables prediction of first-ply failure and progressive damage onset.

Lesson 3 • Classical Laminate Theory

Derives the ABD stiffness matrix for symmetric and unsymmetric laminates under in-plane and bending loads. Provides the analytical foundation for all subsequent design calculations.

Lesson 4 • Ply Orientation and Stacking Sequence

Explains how ply angles and stacking order affect bending-extension coupling and damage tolerance. Establishes design rules for balanced, symmetric, and quasi-isotropic laminates.

Lesson 1 • Process Control and Acceptance Standards

Establishes in-process inspection checkpoints and acceptance criteria aligned with industry quality standards. Links defect acceptance limits to structural allowables and certification requirements.

Lesson 2 • X-Ray and Computed Tomography

Explains radiographic and CT scanning for internal fiber architecture and void characterization. Addresses radiation safety and data interpretation for complex geometries.

Lesson 3 • Ultrasonic Inspection Methods

Covers pulse-echo, through-transmission, and phased-array ultrasonic techniques for composite inspection. Explains signal interpretation for delamination and porosity detection.

Lesson 4 • Thermography and Shearography

Introduces flash thermography and laser shearography as full-field, rapid inspection methods. Highlights their advantages for large-area delamination and disbond detection.

Lesson 1 • Wet Layup and Prepreg Patch Repairs

Covers scarfing, ply replacement, and bonded patch repair procedures for structural composite parts. Connects repair ply schedule and taper ratio to restored structural strength.

Lesson 2 • Injection and Resin Infusion Repairs

Explains resin injection for delamination repair and vacuum-assisted infusion for large disbonds. Addresses resin selection and injection pressure for effective void filling.

Lesson 3 • Sustainability Metrics and Circular Economy

Quantifies embodied energy, carbon footprint, and waste reduction potential across the composite life cycle. Connects sustainability metrics to design-for-disassembly and material recovery strategies.

Lesson 4 • Carbon Fiber Recycling Technologies

Compares pyrolysis, solvolysis, and mechanical grinding as recycling routes for carbon fiber composites. Evaluates recovered fiber quality and viable secondary applications.