ACROSS USA: Carbon/Carbon(C/C) Composites brings revolution and innovation to composite technology The Next Material World ACROSS USA 1

Transcription

1 ACROSS USA: Carbon/Carbon(C/C) Composites brings revolution and innovation to composite technology The Next Material World ACROSS USA 1

2 Who We Are ACROSS USA, INC. Established in 2006, ACROSS USA, Inc. (Carson, CA) is the US subsidiary office for CFC Design, Inc. (formerly ACROSS Corporation). For over 25 years, ACROSS/CFC Design has been involved in the development and manufacturing of Carbon-fiber reinforced Carbon matrix (C/C) advanced composite materials. Through intensive research, ACROSS has pioneered, perfected, and patented an innovative processing technique in the development of C/C composites. This revolutionary method has enabled us to overcome various complexities associated with C/C composites and greatly reduce its production time and cost. By bringing revolutionary composite technology, we aim to reach out and provide a wide variety of solutions to the industries and applications around the world. ACROSS USA, INC Beachey Place Carson, CA, USA Manufacturing Plant CFC Design FUKUI Factory ISO 9001:2000 Certified Phone: Fax:

3 Carbon/Carbon Composites One of the most advanced and promising engineering material is the Carbon Fiber Reinforced Carbon-Matrix composite (C/C composite). They are designed to exceed temperature capabilities of super-alloys and can withstand temperatures of well over 2000ºC (3600ºF) without losing strength and rigidity. Furthermore, they have low coefficients of thermal expansion and relatively high thermal conductivities. These characteristics, coupled with high strength, make them highly resistant to thermal shock. METAL GRAPHITE CERAMICS PLASTICS Compared to Metal: Compared to Graphite: Compared to Ceramic: Compared to Plastics: Carbon/Carbon Composite High heat resistance over 2000ºC(3600ºF) Low thermal expansion Light weight (1/5 of metal) Excellent resistance to corrosion and radiation High strength and rigidity High resistance to fracture High resistance against fracture Does not bond Can be made into complex shape Heat resistance over 2000ºC (3600ºF) Excellent resistance against corrosion and radiation 3

4 Composites Technology Simplified Manufacturing: PY Method ACROSS/CFC Design Carbon/Carbon composites meets and exceeds the mechanical characteristics of standard carbon/carbon composites without the major drawbacks that are associated with conventional manufacturing processes. In conventional procedures, continuous woven fibers are laid down and are then impregnated with a liquid polymer resin, often a phenolic. The resulting matrix resin is converted into carbon by repeated heat treatments. By contrast, we have developed a C/C composite material manufactured by the patented Preformed Yarn Method (PY method). In the PY method, the carbon fiber is mixed with a special type of binder, then heated and hardened in one process. This specific process results in a dramatically reduced production time. The preformed yarn consists of a bundle of carbon fibers in a matrix precursor of coke and pitch binder powders. Better penetration of the binder into the carbon fiber bundle results in a higher strength than found with conventional manufacturing methods. ACROSS/CFC Design PY Method Conventional Method Variety of Carbon Fiber Arrangements ACROSS/CFC Design specializes in manufacturing a variety of carbon fiber arrangements for use in different applications. By controlling the directional arrangement and the length of carbon fiber reinforcement that supports the carbon matrix, the characteristics of the C/C composites can be altered. Some examples are: 1. Unidirectional 2. Bi-directional woven 3. Bi-directional layer 4. Multi-directional 5. Custom/Specialty design 4

5 Business Segments In order to meet and surpass current material and production standards for advanced engineered materials, ACROSS is focused on two fundamental areas of research and development: Heat Resistance Improved performance under high temperature environment Friction Materials Advanced Friction and Thermal shock resistance characteristics ACROSS/CFC Design continues with extensive R&D into advanced materials in order to serve as many industries and customers as we can. If you are interested in our products or have any questions please do not hesitate to contact us. Our Sales and Engineering teams will be delighted to answer any and all questions or discuss any new ideas. 5

6 Heat Resistance Strength of ACROSS C/C composite material in Heat Treatment With its following noteworthy features, ACROSS can help customers in improving productivity and cost reduction for heat treatment operations. 1. Our patented production methods enable much shorter production lead-times compared to its competitors. 2. Parts made from ACROSS C/C parts are thinner and lighter than those made from conventional materials. e.g., Weights of jigs and fixtures can be reduced by as much as 70%. 3. Due to the compactness of C/C designed jigs and fixtures, more material can be loaded into the furnace resulting in increased productivity by as much as 50%. 4. The excellent thermal conductivity also contributes to energy savings. 5. Thinner and lighter parts are advantageous in saving energy during heat treatment. 6. The durability of ACROSS C/C parts offer longer life cycles when compared to parts made from conventional materials. 7. The superb durability and strength, along with uniformity in mechanical properties of ACROSS C/C parts, make them almost maintenance-free Heat-Resistant Steel (63kg/139lbs) Strength decreases at Hightemperatures Warping and deformation with repeated cycles If replaced from steel to Carbon/Carbon (example of 600x900x5mmT, 3 Tiers Tray) Carbon/Carbon (13kg/29lbs) Maintains strength at high temperatures Highly stable, no deformation 6

7 Furnace Bottom Fans Inner Sleeve Coil Springs Conveyer Link Belt & Roller Insulation Protector Sheet Jigs Jigs ACROSS/CFC Carbon/Carbon Composite Furnace Parts Trays Bolts & Nuts Washer 7

8 Graphite Comparison If replaced from Graphite 40% Efficiency Increase per Product Graphite Tray ACROSS/CFC Design C/C Tray Weight of Parts Weight of Trays Total Weight Heat Capacity Effective Heat Available Graphite Base + 4 Tiers 80kg 70kg 150kg 2.0x10 7 cal 41% C/C Base + 5 Tiers 100kg 29.1kg 129.1kg 1.5x10 7 cal 68% Result + 1 Tier +25% 58% weight loss 14% weight loss 24% decrease 25% increase in amount of parts processed, and heat capacity reduction of 24% is also achieved While amount of parts process has increased, the total weight of furnace load has decreased by 14% Better and ease of handling the Trays due to increased strength with using C/C material 8

9 Applications Automotive Heat treatment of automotive components is one of the most popular applications for ACROSS jigs and fixtures. Our jigs and fixtures are used to treat parts of automotive transmissions, radiators, oil coolers and EGRs while reducing the overall production cost. Every type of heat treatment furnace has its limit of total loading weight for one cycle of operation. This is due to the heating capacity that the furnace can generate and maximum weight which the furnace structure can sustain. By switching the jig material from conventional metals to C/C, the density becomes 1/5 that of stainless steel resulting in a considerable weight reduction. Customers may then increase the number of components that can be processed in one cycle of operation. Aerospace In addition to improving heat treatment requirements for the automobile industries, ACROSS C/C jigs and fixtures can also be used to accommodate many other customer s needs. Our composites are expanding their market into the Aircraft industries. Not only can we design jigs and fixtures be tailor-made for heat-treating existing aircraft components, we can also produce custom C/C parts for various aerospace components themselves. The excellent strength-to-weight ratio of our C/C composites makes them optimal for these applications. Brazing Jig for Oil Cooler In cases of jigs made from conventional metals, customers require top-weights in order to achieve a consistent pressure during the process. With ACROSS/CFC Design C/C composite jigs, a 20kgweight (44lbs-wieght) can be replaced with two pieces of C/C Springs.. Display In growing support of display industry, C/C robotic arm tools exhibit outstanding performance when utilized during the transport operation of glass substrates. The growing demand for larger glass substrates and lightweight robotic grippers makes ACROSS Design C/C an excellent substitute for conventional ceramic material. The significant characteristics of C/C material as relevant to the Display industry are its lightweight structure, excellent strength and high heat resistance. 9

10 Applications Semiconductor The continuous need for improved production and product quality have increased demand for better technology in the manufacturing of semiconductors and silicon materials. Crucibles, heat shields, heaters and sealing components used for pulling process of single crystal silicon ingots are some applications which take advantage of the excellent thermal properties that ACROSS C/C composite possess. As the demand for increased functional capability in industrial robots increases, mechanical grippers used for the transport and control of silicon wafers are more effective when fabricated from C/C materials. Reliability and speed of movement due to weight loss are some of the factors which boost production. Solar/Photovoltaic(PV) Keeping pace with the advancement of solar technology, ACROSS has been providing its products for various photovoltaic applications. C/C Rods, Heat-Shields, Heater Plates provide excellent life and quality in the field or Polysilicon production. Crucible reinforcement parts, heat-shielding, molten silicon sealing components, and individual parts such as bolts and nuts are some of the products offered for Silicon Ingot production. These products can be specifically made for either single crystal pulling process or multicrystalline silicon casting. Other applications include susceptors for CVD equipment and PECVD carrier plates for the transport of glass substrates in solar cell manufacturing.. Other Industries ACROSS C/C composites are vital in various industries. Glass processing requires materials with excellent thermal shock resistance as well as heat resistance. Hard metal tool manufacturing requires robust furnace supplies including sintering trays. ACROSS Design C/C is the optimal material for these demanding processes. 10

11 Friction Material ACROSS C/C composites are optimal for many areas of frictional material applications, from sliding to stopping by means of controlling the frictional coefficient. Characteristics of ACROSS C/C as Sliding Material Extreme Heat Resistance Heat Resistance of 100% carbon They can be used in high temperature environment where resin or metal cannot be used. Greater Stability in Relation to Size It prevents the deformations caused by frictional heat Reduces Friction without Lubricant - The Self-lubricating characteristics of carbon Resistance Against Wear Designs for each Frictional Circumstance The specifically required resistance against wear can be achieved by designing the C/C composites for each circumstance.. Lightweight Density is 1.7 g/cm 3 The weight is only 1/4 to 1/5 of iron (iron s density is 7.8 g/cm 3 ) High Rigidity Reinforced by Carbon Fiber It is 3 to 5 times stronger than ordinary carbon material because it uses carbon fiber as reinforcement. 11

12 Physical Characteristics C/C Plate Material Property/Material Type AC100 FS140 AC200 FS240 FS320 FC500 FS540 Heat treatment ( ) Length of Carbon Fiber Short Long Long Short Carbon Fiber Type Non-woven Non-woven Non-woven Non-woven Directional Arrangement Random direction, chopped fiber layers Unidirectional, 0 /90 alternating layers Unidirectional, 0 /90 alternating layers Random direction, chopped fiber layers Applications Precise process jigs Structural Material Heat resistant jigs Strong structural Material Structural Material Heat resistant jigs Heat resistant jigs Bolts & nuts Product dimensions (mm) x1000x x 1900 x x1000x20 12

13 Physical Characteristics C/C Coil Spring Springs made of C/C composite are characterized by high strength, high modulus of elasticity and lightweight. Springs have high toughness and excellent abrasion resistance and corrosion resistance. They maintain excellent characteristics even at high temperature no less than TYPE -A TYPE-B TYPE-C TYPE-D Outside diameter (mm) φ 31 φ 50 φ 50 φ 50 Inside diameter (mm) φ 19 φ 20 φ 30 φ 20 Length (mm) L40 L25 L27.5 L40 Spring constant(kgf/mm) Max Contraction (mm) C/C Leaf Springs Property AC250 Maximum dimension(mm)

14 Physical Characteristics C/C Rods Standard Rods Strong Rods Sorts X Max Length(mm) φ φ φ φ φ φ φ φ φ C/C Threaded Rods & Nuts Sorts X Max Length(mm) Standard Nuts size(mm). M M M M M M

15 Advanced Materials Rapid advancements are constantly being made in the field of robotics. Mechanical Parts used for industrial robots are being enlarged and thus require faster movement. Materials such as ceramics, aluminum, and CFRP have been the convention within these areas. We develops and produces functional C/C and C/CMC as an alternative in these special applications where lighter weight and greater heat resistance become a key advantage. Carbon/Carbon Metal Composite (C/CMC) One of the unique characteristics of C/C composite is its porous structure within the carbon matrix. After years of research, ACROSS/CFC Design has developed a technology to control the number and size of these pores and have added metal into the carbon matrix., thus creating C/CMC (Carbon/Carbon Metal Composite). As a result, composites with unique characteristics are produced by employing metals such as silicon, aluminum, and copper alloys. This technology is similar but different from CFRM (Carbon Fiber Reinforced Metal) which does not have a carbon matrix structure. In comparison to CFRM,C/CMC is designed to have metallic characteristics in supplement to the principal characteristics of C/C composite such as its rigidity, heat resistance, and lightweight. This makes C/CMC an excellent choice of material for high-technology applications. After carbonization of the carbon matrix and the fiber reinforcements is completed, liquid metal is added to the pores by employing a very special technique. C/C with metal added to the pores = C/CMC Characteristics C/C-AL C/C-Cu C/C-SiC Compounding Metal AL Cu Si Function Example use for Aluminum compounded C/C has light weight, high rigidity and flexibility Robot Materials, Carrier plates Copper Alloy compounded C/C is a frictional material which has electroconductivity Sliding boards for pantographs of train, fictional electrical parts Reaction of Silicon and C/C makes SiC which has greater anti-oxidation and greater resistance to wear Frictional parts for automobile, various bearings 15

16 Development & Support Procedures for Inquiry Please send us an inquiry via Web, or Phone. To enable us to provide you with prompt solution, we will ask you for detailed information of your application. Product Planning Your inquiry will be reviewed for any problem with former products, and question what kind of characteristics you expect of C/C composite. Production/Assembly/Testing We will proceed to production after detailed discussions about the expenses and test schedule in the trial stage. Product Evaluations/Experiment Test Testing and evaluations on the product life and the characteristics of the C/C composite. Our quality control is based on ISO 9001:2001. Ensuring Product Reliability Our support team will work with each customer to exceed performance requirements and to provide outstanding products. Business Solutions ACROSS/CFC Design is an established and respected manufacturer of high quality Carbon/Carbon. composites. We offer many standard sized materials as well as custom design materials. Whether you wish to machine your own parts or not, we are here to support. Our technical team and sales team will work with each customer to find the best solutions for every situation. In today s competitive world, long-term solution is critical. Let us help you in making the right decision for your company s long term success. 16