Grant: CCI Applied Research and Development Grants

Carbon-carbon (C/C) materials are a generic class of composites similar to the graphite/epoxy family of polymer matrix composites. These materials can be made in a wide variety of forms. Because of their multiformity, their mechanical properties can be readily tailored. C/C is a hard material that can be made highly resistant to thermal expansion, temperature gradients, and thermal cycling, depending on how the fibre scaffold is laid up and the quality/density of the matrix filler. The current method of production is not ideal, and many improvements can be made to this process. Paterson Composites Inc. (PCI) hopes to find a process for the production of the composites and acquire the right equipment to produce a sample of material that can be tested and verified. This will then lead to producing the required sample in the dimensions required by the customer and to produce a small amount of C/C composite to develop the large-scale production process. In collaboration, PCI and Lambton College will start with developing a production process and identifying the equipment needed for C/C production. Once this is accomplished, the team will work to develop small pieces that PCI can use to test for their larger applications. The team will utilize high temperature furnaces to accomplish this work and experiment with methods and additives to ensure a quality product at the end of the study. The project's second phase would be to expand the work to produce a workable part that PCI can take to its customers for validation. The success of this project will lead to the creation of a new C/C product that is expected to meet the demands of the current customer, which equates to 20 tonnes of C/C composite per annum. This project will develop a domestic production line with a steady supply chain that can address the issues causing low growth in the C/C composite market. Initial production will aim to produce over 1000 units (10 ft pipe) per year, a pre-order that PCI has already secured based on the success of this project, with increased production through additional sales. Developing this process will allow PCI to expand its business and supply other industries as this project will develop an adaptable process for many different C/C applications.