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The term carbon fiber refers to organic materials that have been heat-treated
at temperatures of 1,000–3,000°C and generally contain 92–99.99+%
carbon. Graphite fiber refers to carbon fiber precursors that have been processed
at temperatures in excess of 2,500°C for an extended period of time.
Carbon fibers are noted for their high strength and stiffness. They are used
primarily as reinforcing agents in high-performance composites with synthetic
resin matrices such as epoxies, polyimides, vinyl esters, phenolics and certain
thermoplastics. Small quantities of carbon fiber are consumed in composites
with carbon matrices; in addition, developmental work is being performed with
metal, ceramic and glass matrices. The carbon fiber serves to provide the strength
and stiffness of the composite, while the matrix material maintains fiber alignment
and transfers structural load among the fibers. Compared with conventional
construction materials such as aluminum or steel, carbon fiber composites have
some highly desirable properties. Structural members made from these composites
can be designed to have twice the strength and more than twice the fatigue resistance
of steel; in addition, they can be twice as stiff as aluminum at half the weight.
In 2002, the value of the worldwide carbon fiber industry was over $1 billion.
Of the total fibers produced globally, Japan and the United States combined
provided 78%. With more capacity than the United States, Japan consumes approximately
one-third of its domestic carbon fiber production, with the remaining 67% of
carbon fibers made by major Japanese producers going to exports.
In 2002, Japan provided 47% and the United States 31% of the world’s carbon
fiber supply; the remainder was produced in Western Europe, Taiwan and the Republic
of Korea. A minor amount was produced in Hungary.
World consumption of carbon fibers increased at an average annual rate of 5.8%
between 1997 and 2002. The United States is the world’s primary market
for carbon fiber, followed closely by Western Europe. In 2002, the United States
consumed 30% of the world’s supply of carbon fibers. Japan, Taiwan, the
Republic of Korea and China combined accounted for about 29%, and Western Europe
for 27%; the remainder was used by various end-use manufacturers located predominantly
in the other Asian countries.
Demand for carbon fiber is forecast to increase at nearly 8% annually over
the next five years, with greater-than-average growth occurring in Western Europe
and selected other Asian countries (particularly China).
While aircraft and aerospace applications are the largest end-use area in the
United States, industrial applications are second. This category, which includes
applications from electronic shielding through offshore oil drilling platforms,
is projected to be the fastest growing area in the United States over the next
five years.
Western European consumption of carbon fibers in industrial applications (over
half of total demand in 2002) grew at a 24% annual rate from 1997 to 2002. The
aircraft/aerospace sector consumed 33% of the total in 2002, while sporting
goods accounted for the remainder. Total Western European consumption is expected
to grow at an average annual rate of almost 11% from 2002 to 2007.
The No. 1 end use for carbon fibers in Japan is in industrial applications,
followed by sporting equipment; a minimal amount is used in aircraft/aerospace
applications. Demand for carbon fiber in industrial applications increased at
a rate of over 11% per year between 1997 and 2002 and is expected to grow at
5% per year over the next five years.
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