Email Us

Call Us

Uses of Carbon Fiber Reinforcement Polymers -CFRP, in Automotive Industry

CFRP Carbon Fiber in AUTOMOTIVE INDUSTRY

CFRP Carbon Fiber in AUTOMOTIVE INDUSTRY

 

Overview

As the need to enhance fuel efficiency and improve overall vehicle performance gains more momentum, auto makers are increasingly looking for alternative materials that have higher strength-to-weight ratio, corrosion resistance and flexibility.

Carbon fiber fits the bill perfectly. Carbon Fiber Reinforced Polymers (CFRP), to be precise, are finding wide acceptance in the auto making sector. To demonstrate the growing obsession with CFRP, here is a quick comparison: Carbon fiber has 5X more strength than steel and 2X more stiffness, but  is lighter than steel, making it the ideal manufacturing material for several car components. No wonder automobile designers and engineers simply love carbon fiber!

 

Key characteristics

Greater stiffness, high tensile strength, low weight-to-strength ratio, high chemical resistance, superb temperature tolerance and low thermal expansion are some of the many physical-chemical properties of carbon fibers that make them ideal for use in automotive manufacturing.

 

 

Scope and applicability  

Drive Shafts, Suspension Control Arms, Structural Braces, Crash Structures, Seat Structures are the components/parts that are primarily manufactured using CFRP.

 

Benefits of CFRP in auto manufacturing

  • Lower weight
  • Greater fuel efficacy
  • Reduced vibrations
  • Better corrosion resistance
  • Sleek look with superior finishes

 

Expanding horizon

Though the use of CFRP is primarily limited to hi-end luxury cars and racing cars, the day is not far when these magic materials will be used in mainstream passenger car production. As per an industry report, the average car will now incorporate nearly 350 kilograms of plastics – which is an appreciable increase from the average of 200 kg in 2014.

 

Catering to car makers with the right composite

Bhor Industries has put in place hi-end processes for making carbon composites, backed by the capability to quickly scale fiber production as well as uphold long-term price and supply commitments. To know more about how we can assist and support you in your automotive production program, please call 9822298222 for details.

Use of Carbon Fiber Reinforcement Fabrics in Aerospace and Defence Industry

AEROSPACE AND DEFENCE INDUSTRY

Overview

Conventionally, aluminum constituted almost 65% of the weight of an aeroplane, which resulted in lower fuel efficacy, lesser load bearing capacity and higher cost.

Enterprises in the aerospace and defence production industry then started seeking out ways for reducing weight, increasing fuel efficiency and improving overall system performance. While metal and metal alloys are still integral to aerospace design, the quest for innovative, lightweight materials eventually led to carbon composites. In this context, carbon fiber-reinforced fabrics are rapidly emerging as the material of choice for the Aerospace and Defence production sector.

 

Properties of carbon fabrics

There are several reasons why carbon fabrics are finding wide spread acceptance in mission-critical applications in the Aerospace and Defence production sector:

  • High Strength to weight ratio
  • Rigidity
  • Corrosion Resistance
  • Electrical Conductivity
  • Fatigue Resistance
  • Good tensile strength yet brittle
  • Fire Resistance
  • Low coefficient of thermal expansion
  • Non-toxic
  • Biologically inactive

 

The physical strength, toughness and lightweight of carbon fiber make it an appropriate raw material in making parts or components for aircraft, satellites, defence equipment, etc. But perhaps the most important property is its low coefficient of thermal expansion resulting in high dimensional stability; this means that the fabric doesn’t shrink or extend easily. It has low tendency to expand when heated and to contract when cooled.

 

Bhor – a leading supplier of carbon reinforced fabrics to the Aerospace and Defence industry

At Bhor, we have the techno-commercial capability to produce Carbon Fibers and Carbon Composites required to make structural applications as well as components for aircraft, satellites and advanced military systems. We supply composite prepregs and high-performance liquid resin systems for the manufacture of complex Aero structures such as the fuselage sections, Satellite structures, engine nacelles, wing spars, fan blades etc.

 

Brand folio

BhorForce® is our range of woven Reinforcement Fabric Products. Woven fabric based reinforcement materials are lightweight yet sturdy, with excellent good fatigue and impact resistance. They provide good drape, excellent handling characteristics and superior strength and stiffness. A wide range of reinforcement fiber options is available ranging from Carbon fiber to Aramid to Quartz fibers.

BhorPreg® – is our range of Prepreg resin systems. We can formulate a wide variety of systems, which essentially include Epoxy Prepreg and Cynate Ester. A range of Aerospace prepreg systems tailored for your highly demanding application requirements are available under our BhorPreg brand.

 

Solutions successfully delivered to the Aerospace market

  • Quartz Cyanate Ester Prepregs for Radome manufacturing.
  • High Tg Epoxy prepreg with High modulus Carbon fibre for satellite structures
  • Low Aerial weight UD Prepreg’s for Spacecrafts support structures
  • Out of Autoclave Epoxy Prepreg’s for mini, micro and large UAV’s

 

Connect with us for the right composite

As the market leader in carbon composites, we are uniquely positioned to meet your carbon fiber-reinforced fabric needs by proposing the right solution. Please email at contact@bhor.com for more details.

‘Carbon Fiber Properties’, which makes them special!

Carbon fiber Car -Carbon fiber Fabrics

Carbon fiber’ also called sometimes as ‘Graphite fiber’. In today’s era manufactures are looking for material that has more strength and is lighter in weight to achieve greater safety and efficiency.

Carbon-fiber-composites are the solution to these manufacturer’s requirements. Carbon-fiber’s have not only the highest compressive strength properties of all the reinforcing materials, but at the same time, it has a low coefficient of thermal expansion. and also high strength to weight ratio.

As compared to steel which is mainly used in manufacturing, carbon fibers have lower density and more strength. Its density is very less as compared to Steel and other metals used in manufacturing. They are is composed of mostly carbon atoms that are in the form of several thousand long, thin strands of material.

 

‘Carbon Fiber’ Special Properties:

 

• Lower in Weight and Density

Carbon fiber composites have lower mass and density as compared to other metals. It has a density of 1.6 g/ cm3 whereas other metals such as aluminum are 2.7g/cm3 and steels density is 8 g/cm3.

Hence if we compare the weight of other metals such as steel which weights 8kg for 1mmx 1mx1m sheet, aluminum weighs around 2.7kg. On the other hand, these fiber panel weighs only 1.6kg, which compared is 5 times lower than the steel’s weight.

Hence, the major weight to strength advantage makes it the first choice in Precision Machines. Machines such as Formula 1 cars, Racing Bikes, Robotic arms Gripping parts, Aircraft, Spaceships and many more are such examples.

• Electrical Conductivity is high

There are both, advantages and disadvantages of this property of Carbon-fibers. In Industries such as Shipbuilding due to this property at most care has to be taken off while installation; as Carbon-fibers conductivity can facilitate galvanic corrosion in the fittings.

• It has Resistant to Corrosion and are Stable Chemically.

By Itself, These fibers do not deteriorate. But other matrices such as Epoxy are sensitive to sunlight and need to be protected. Any other matrices might also be reactive.

• They have Resistance to Fire.

If we compare with existing materials that are very difficult to use in producing fire-resistant clothes. Carbon-fiber can be the best solution as they are very delicate and can be used in defensive clothes for firefighting. Such a very good example is a Nickel covered fiber.

Since carbon fiber is otherwise artificially inactive, it very well may be utilized where there is fire joined with destructive substances.

• The Tensile Strength of Carbon-Fiber is very good.

Tensile strength or ultimate strength is the maximum stress that any material can withstand while in tension or pull before necking or breaking. Due to Internal flaws, Brittle materials such as carbon fibers do not always fail at the same stress level but, tend to fail at minimal strains.

Testing involves taking a sample with a fixed cross-section area and then pulling it gradually by increasing the force until the sample changes shape or break. These Fibers, being only 1/200th of an mm in diameter, are made into composites of appropriate shapes.

• Specific strength: These Fibers are known for High Strength to Weight Ratio.

Strength to weight ratio- as to suggest is measured by how strong and lightweight the material is. The strength of a material is the force per unit area at failure, divided by its density. Any material that is strong and also light in weight has a favorable Strength/weight ratio.

The specific strength of Carbon-fiber is very high. It is 5 times lighter than steel and has more strength than Steel.

Carbon fiber wheel

• Rigidity: It is a very rigid material.

Young Modulus is used to find out the Rigidity or stiffness of any material. This is tested by how much the material deflects under the stress applied. As per the lab tests it is found that Carbon-fiber reinforced polymer is twenty(20x) times stiffer than pine and 2.5 times stiffer than Aluminum and double stiffer than Glass reinforced plastic or polymers.

• It has good resistance properties to Fatigue.

Carbon-Fiber Composites have very good resistance to fatigue property. Carbon-fibers are superior to E glass fibers in fatigue, static strength as well as in stiffness. When carbon fiber fails it usually fails catastrophically.

Damage in tensile fatigue can be seen due to a reduction in its stiffness, with numbers of stress cycles in large numbers (unless the temperature is high). It is also seen that failure is unlikely to be a problem when cyclic stresses coincide with the fiber orientation.

• These fibers are X-Ray Permeable, Biologically inert, and Non-Poisonous.

These properties of Carbon fiber make it very useful in Medical applications. Carbon-fibers use in Prosthesis parts, tendon repair and implants, surgical instruments and x-ray Machines are in making and Researched. Though carbon fibers are not poisonous, they can be quite irritating and it’s long term exposure which is unprotected needs to be limited. The matrix either with epoxy or polyester can, however, be toxic or proper care is required.

• Properties of Thermal Conductivity.

Under steady conditions, Thermal conductivity is the amount of the heat transferred through a unit of thickness, in the normal direction of a surface of unit area. Due to the gradual increase in temperature. In other words, it’s measured by how easily heat flows through a material.

As there are many combinations on the design of carbon fiber, it is not possible to point out the exact thermal conductivity. Special types of Carbon Fiber are specially designed for high or low thermal conductivity.

Carbon fiber fabric texture

• They are a Low Coefficient of Thermal Expansion.

The coefficient of expansion is a measure of how much a material expands and contracts when the temperature changes low or high. In a sufficiently high mast contrasts in Coefficients of thermal expansion of different materials can marginally adjust the apparatus pressures.

It is suitable for applications wherein case if small motions or movements are critical, due to its Low Coefficient of Thermal Expansion. Telescopes and other optical machinery are other such applications.

• Are Relatively Expensive.

Carbon-fibers have all the advantages such as strength, Rigidity, Lighter in Weight, but one of the disadvantages for its popularity in use is its cost. Buy, as Specific Strength is critically important in applications such as Spaceships, Aircraft, Racing cars and Bikes to name a few, it is worth an extra cost. Also, they are low in maintenance and are an added advantage of the materials used.

• These Fibers are brittle in Nature.

In case if the fibers bend, they have a property of failure at a minimal strain. Layers in carbon fibers are formed by strong covalent bonds. Its Sheet-like gathering allows the proliferation of cracks.

 

 

Applications of Carbon-Fiber Composites in Industrial Products

Sr. No

Use by Industry or Product

Properties Of Carbon Fiber

1

Aerospace

·         High Physical Strength

·         Good Specific Toughness

·         Lightweight, Lower density

2

Road And Marine Transport

3

Racing, Sporting Goods

4

Defence Equipment’s, Missiles, Fighter Planes

·         High Dimensional Stability,

·         Low Coefficient Of Thermal Expansion,

·         Low Abrasion value

5

Aircraft Brake

Aerospace Antenna And Support Structure

6

Large Telescopes, Optical Benches

7

Waveguides For Stable High-Frequency (GHz) Precision Measurement Frames

8

Audio Equipment, Loudspeakers For Hi-Fi Equipment,

·         Good Vibration Damping,

·         Higher Strength

·         High Toughness

9

Pickup Arms, Robot Arms

10

Automobile Hoods

·         Good Electrical Conductivity

11

Novel Tooling, Panel Casings, And Bases For Electronic Equipment’s

12

EMI And RF Shielding, Brushes

13

Medical Applications In Prostheses, Surgery And X-Ray Equipment, Implants, Tendon/Ligament Repair

·         Biological Inertness

·         X-Ray Permeability

14

Textile Machinery

General Engineering

·         High Fatigue Resistance,

·         self-lubrication property,

·         High Damping Property

15

Chemical Industry;

Nuclear Field

·         Good Chemical Inertness,

·         High Corrosion Resistance

16

Valves, Seals, And Pump Components In Process Plants

17

Large Generator Retaining Rings

·         Good Electromagnetic Properties

18

Radiological Equipment

Ask our Team about Products, Applications or our Services

Get in Touch! We will be happy to Answer !

Types Of Fiber Reinforcement

Types Of Fiber Reinforcement

  19 Apr 2019          Bhor Chemicals

There are many different types of fibers which can be used to reinforce polymer matrix composites. However the most common are carbon fibers and fiberglass.

Read on to know more about the different types of fiber reinforcement.

1. Carbon (Graphite) Fiber Reinforcement

Carbon fibers are much conductive, but have an excellent combination of high modulus and high tensile strength. Also they have a meagre CTE and thus they offer good resistance to high temperatures.

Carbon fibers are mostly categorised using tensile modulus. There are five categories in carbon fibers which are generally used in composites:

  • Low modulus
  • Standard modulus
  • Intermediate modulus
  • High modulus
  • Ultra-high modulus

The exact cut-off in these categories may vary depending on the reference but generally, low modulus fibers have a tensile modulus of lesser than 30Msi. Also the ultra-high modulus fibers have tensile modulus greater than 75Msi. For comparison, the steel has a tensile modulus of 29Msi.

As the modulus increases, fibers tend to get more and more brittle, more expensive and much harder to handle.

Furthermore, the tensile strength of the fibers generally increases with the modulus increases from low to intermediate, but then falls off in the high and ultra-high modulus fibers. Thus it can be said that the tensile strength of carbon fibers tends to be the greatest for the intermediate modulus fibers. For such reasons, standard and intermediate modulus fibers are considered to have great performance unless the application is very stiffness oriented.

2. Fiberglass Fiber Reinforcement

Fiberglass is a glass which has been spun into the form of fibers. Fiberglass is comparatively less strong and stiff but has the characteristics which make it desirable in many applications. Fiberglass is non-conductive and is an insulator. It is usually invisible to most types of transmissions. This makes it a great choice while dealing with the electrical or broadcast applications.

There are five major types of fiberglass:

  • A-glass (alkali glass)- Good chemical resistance
  • C-glass (chemical glass)- Very high chemical resistance
  • E-glass (electrical glass)- Excellent insulator and resists attacks from water.
  • S-Glass (structural glass)- Optimised for mechanical properties.
  • D-glass (dielectric glass)- Has the best electrical properties but lacks in mechanical properties as compared to E and S glass

These types are great combinations of chemical resistance, mechanical properties and insulating properties.

3. Other Fiber Reinforcements

Even though carbon fibers and fiberglass are the most popular fiber reinforcements in thermoplastic composites, there are other alternatives like Aramid fibers like Kevlar, Twaron and boron fibers which are previously used in composites and offer some beneficial properties like amazing toughness and compressive strength. However, they have characteristics which have limited use. These fibers include ceramic fibers, including SiC or aluminum oxide. These fibers may be useful for their compression, insulating, and high-temperature properties.

Automated Dynamics’ staff can also assist with the selection of the best fiber for your application based on program needs, availability, economics, and other factors as well.

Want to know more about Fiber reinforcements? Explore our exclusive range of products Hexacure Fiber Reinforcement Polymer. Don’t hesitate to call us for more information!

Ask our Team about Products, Applications or our Services

Get in Touch! We will be happy to Answer !

What are “Prepreg’s ” ? Advantages and Disadvantages of “Prepreg’s “

What are Prepegs? Their Advantages and Disadvantages

  9 Apr 2019          Bhor Chemicals

“Prepreg” is a popular term for reinforcing a fabric which has been pre-impregnated with a resin system. This resin system already includes a proper curing agent. Resultantly, a Prepreg is ready to get moulded without adding any more resin. In order for the laminate and cure, it is necessary to use a combination of pressure and heat.

Here we discuss the advantages and disadvantages of prepregs.

Advantages of Prepregs

There are many certainly many advantages of prepregs. Here are a few:

Prepregs have maximum strength properties. 

In a hand layup, it is tedious to achieve 50% resin content. It means that the completed laminate weight is 50% fabric and the rest is 50% resin. The typical hand laminates, even when they are vacuum bagged, end up with a efficient amount of excess resin. Excess resin adds up to the brittleness and reduces the overall properties. On the other hand, mostly the prepregs contain about 35% of resin. This is perfect for maximum cured properties and is generally impossible to achieve in normal lamination.

Prepregs give uniformity and repeatability. 

If there would be no pitfalls of human lamination techniques, then there will neither be resin-rich areas nor dry spots. The thickness of the ingredients will be uniform and each part that comes out of the mold has a likelihood of being identical. Although there is still a margin of error in the vacuum, bagging techniques, handling, etc., yet prepregs reduce these problems to a significant amount.

Prepregs make less mess and less waste. 

Prepregs will excrete excess resin during the curing process but those excesses of hand layup, high amount of resin, messy rollers, and drips – are no more a problem. Additionally, if prepregs are handled at room temperature you need not have to take much effort to prevent your resin from setting up before you are ready.

Prepregs need reduced curing time.

After the heat curing cycle is finished, it is ready for service. You do not have to wait for 48 hours to allow a full cure like in a typical hand lamination.

Prepregs are better cosmetics.

As mold preparation and mold release is still needed and will directly affect the cosmetics of the part just like a hand laminate. However, the prepregs eliminate air bubbles and give a smooth, glossy surface.

Disadvantages of Prepregs

  1. Cost. Prepregs are a bit more pricey. Even when you sum up the cost of the resin, cure and fabric, prepregs tend to cost a bit more.
  2. Shelf life. This is a small problem because the prepregs can be stored up to six months at room temperature. However, storage at warm temperatures will reduce the shelf life of the product. Keeping the material cooler will extend life to a significant extent though.
  3. Necessary heat cure. You need to have a heat source and vacuum bagging at a minimum temperature. You must be able to achieve a minimum temperature of 270°F and sustain at that temperature for a minimum of four hours. A number of advanced fabricators use autoclaves but any source of heat can be useful.

Now that you know the advantages and disadvantages of prepregs it’s time to get in touch with us to discuss your requirements. Bhor Chemical is a reputed manufacturer of prepregs in India and is ready to serve your needs!

Ask our Team about Products, Applications or our Services

Get in Touch! We will be happy to Answer !

The Basics of Using Carbon Fiber Laminates

The Basics of Using Carbon Fiber Laminates

 

  22 Mar 2019          Bhor Chemicals

If using carbon fiber composites was simple, it would have been more popular. But using carbon fiber materials takes much science and mechanical skill.

Hence, to make things easier for you, today we are discussing the basics of using Carbon Fiber Laminates.

The Basics

Whether you are working for a hobby project or trying to trick out your car, then first consider the reason you want to use carbon fiber for. Although carbon composite is quite versatile, still it can be comparatively expensive to work with and may not be the ideal material for the job.

Carbon fiber has many benefits though. This material is amazingly lightweight, yet incredibly strong, and it has excellent mechanical properties.

Carbon fiber is also quite trendy, this means that people may use it for the sake of using it. For instance, if all you actually want is the surface finish of a carbon fiber weave, then you can save yourself the hassle and simply apply a carbon-fiber adhesive film!

Carbon Fiber Film

You can get the carbon fiber vinyl film in rolls or sheets. This film has a look and texture of actual carbon fiber. It also comes with a adhesive-backed film which is as easy to apply as a sticker. You simply need to cut it to size, peel, and stick.

Many distributors sell this film, which is extremely affordable compared to the actual carbon fiber. The carbon fiber film has higher UV resistance and provides some impact resistance too. It is used in everything from cell phones to sports cars and much more.

How to Use Carbon Fiber Film

It isn’t much difficult to learn how to use the carbon fiber film.

First, you have to be clear about the purpose why you are using the carbon fiber or carbon fiber film. If it is only for aesthetics, then the single layer of inexpensive carbon fiber will probably do the trick. This layer can cover a thick laminate of fiberglass. However, if you are planning a structural component or something which needs to be stronger, or more robust then using the carbon fiber may be warranted.

In case you are building a snowboard in your garage or designing an aircraft part by using carbon fiber, then you will have to do some planning before you begin. This can help you to avoid manufacturing which will fail, and also prevent you from wasting this expensive material. Also, by using the composite material software program, you can design a specific carbon fiber item which you need. You can also consult with a professional engineer while designing a critical part or piece, so that the failure can be avoided.

 

Laminating carbon fiber is nothing different than fiberglass or other reinforcements. You need to practice how to use the resin carefully. If it is a part intended for its look and feel and free of gel coat, use a better quality polyester or epoxy resin. Most epoxies and polyester resins have a yellowish or brownish color, but a clear resin will be your best choice. Any resin utilized in surfboard manufacturing is usually as clear and transparent as water.

 

We hope the basics of Carbon Fiber Laminates listed in this blog will aid in your research. If you are looking for more information, don’t hesitate to contact us. We’re always happy to help!

Ask our Team about Products, Applications or our Services

Get in Touch! We will be happy to Answer !

How Bhor Chemicals is Helping The Aerospace Industry

  15 Mar 2019          Bhor Chemicals

Bhor Chemicals caters to many industries and markets like Structural RehabilitationProducts EngineeringIndustrial Composites, and Aerospace.

The aerospace industry we serve consists of the commercial aircraft, military rotorcraft and space structures. The significant demands of the structural performance, operating temperatures, and reliability makes composites an ideal foil for manufacturing of the components for these core segments.

The aerospace industry continues to be considered to be on the forefront in the usage of composite prepregs and high performance liquid resin systems for manufacturing of complex aero structures like fuselage sections, satellite structures, engine nacelles, wing spars, fan blades, etc.

At Bhor Chemicals, we offer high-quality and completely utilitarian solutions to the aerospace industry in India.

 Products Offered by Bhor Chemicals

  • Carbon Fibers : HS, IM and HM

  • BhorForce – Carbon, Glass, Aramid, Quartz, Fiber Woven Fabrics, 3D profiles

  • BhorPreg® – High performance hot melt Prepreg systems

  • High performance adhesives and coatings

  • Thermoformed and Thermofixed tape dry carbon reinforcements

  • BhorBond® – Polymer resins for structures made by infusion technologies

  • Coatings Putties, finishing agent, high temperature consumables, etc.

Our team is highly experienced and thus understands the demands of this market and can deliver timely tested results. Being honored with the multiple innovation awards given by the JEC Group, Paris, we are one of the best service providers to aerospace market in India.

 

 Our Prime Qualities 

  • We offer high performance prepregs based on quartz reinforcements, solvent-less cyanate ester matrix resins and cyanate ester base resin film adhesive

  • We offer jute/coir biodegradable pultruded “green composite”

  • We develop high-performance Epoxy prepregs

 

Solutions we offer for several clients in the Aerospace Industry

  • Quartz Cyanate Ester Prepregs for Radome manufacturing

  • High Tg Epoxy prepreg with High modulus Carbon fiber for Satellite Structures

  • Low Aerial weight UD prepreg’s for Spacecrafts support structures

  • Out of Autoclave Epoxy prepreg’s for mini, micro and large UAV’s

Our team is not just a commercial firm but a passionate team which is backed by precise and flawless knowledge, values and dedication to our quality of work. Challenges are something that we handle everyday and are keen to handle them with care.

Not only this, but with an experience so many years, we have an eye to details and thus we take every possible measure to avoid any errors and deliver flawless service.

 

As the aerospace industry needs huge dedication and flawlessness, we provide special attention to every single nuance and are ready to face every hurdle.

To know how we can help you, connect with us at the earliest and get the toughest tasks solved easily!

Ask our Team about Products, Applications or our Services

Get in Touch! We will be happy to Answer !