What is the difference between carbon fiber and Kevlar®?

What is the difference between carbon fiber and Kevlar®?
Here, we discuss the similarities and differences between carbon fiber and Kevlar, how they are made, and the pros and cons of each. We offer carbon fiber in small quantities by the meter on our e-commerce website, as well as carbon fiber and aramid fabrics including Kevlar from our Leeds and Newry warehouses over 10m away.

What is carbon fiber?
Carbon fibers are long, thin threads made primarily of carbon atoms bonded together in the form of microscopic crystals.

The crystals are neatly arranged, which makes them very strong. They are then twisted together, much like the cotton production process, to form yarn. The yarns are then woven together to form carbon fiber cloth. Carbon fiber comes in different types of weaves:

 

Plain Weave: Also known as two-way standard over/under, it is very easy to handle due to its tight weave.
Twill: Diagonal pattern from top to bottom This is the most easily identifiable carbon fiber pattern and offers a looser form than flat designs, making it better suited to more complex shapes.
Satin: Satin has a brick-like resemblance, coming from the number of upper layers (usually four or eight) to the next. This pattern is not the easiest to work with and works best with complex curves.
Unidirectional: As the name suggests, all yarns are unidirectional. There is no weaving, it is usually held together with threads, but this does not change the structure of the carbon fiber. It is best suited for molds where forces act on only one axis

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How is carbon fiber made?
Each carbon fiber manufacturer has its own method of making the material to give it strength or aesthetic selling characteristics. Typically, however, all carbon fibers are derived from organic polymers, which are strings of molecules held together by carbon atoms.

The PAN (polyacrylonitrile) manufacturing process accounts for approximately 90% of all carbon fiber manufacturing and is divided into five steps:

 

Polyacrylonitrile is mixed with other items and spun into fibers, which are then stretched and cleaned.
Chemicals are then added to stabilize
Adding heat, the high temperatures help form tightly bound carbon crystals.
The fibers are oxidized to improve bonding properties.
Finally, the wire is coated and wound into different sized wires. Before carbon fiber becomes a composite, a polymer is added and the threads are bonded to the polymer using heat, pressure, or vacuum to form the composite.
As with any manufacturing process, the materials used will produce specific qualities and effects in the carbon fiber, allowing for grading and application differences.
What are the benefits of carbon fiber?
Carbon fiber is known for its light weight and high strength, making it an ideal advanced composite material for the marine, automotive and aerospace industries. Key benefits include:

 

Excellent strength to weight ratio
High heat resistance
High chemical/corrosion resistance (when used with the correct resin)
Extremely flexible for a variety of applications
Excellent fatigue performance
Suitable for a variety of different materials
Electrical and thermal conductivity
Has low thermal expansion coefficient

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