Fabrication and Characteristics of Carbon Nanofiber-Reinforced Carbon/Carbon Composites by Fast Catalytic Infiltration Processes

The simultaneous in-situ growth of carbon nanofibers (CNFs) and densification of a CNFs/CF hybrid multiscale felt are accomplished in a single step by thermal gradient chemical vapor infiltration using Fe as the catalyst and vaporized kerosene under atmospheric pressure. A three-dimensional CNF network which could bridge dissimilar components of composites is formed on carbon fibers (CFs). The length of CNFs can reach several micrometers and the diameters are about 80 rim. Smooth and rough surface densified CNFs can be produced after further higher temperature infiltration. CNFs, anchoring to CFs by the adherence of the catalyst nanoparticles, enhance the bonding between CFs and pyrocarbon as well as promoting the formation of a rough laminar pyrocarbon matrix. The deposition mechanisms and physical model are also discussed. This fast catalytic infiltration process can be applied to other ceramic materials and has significant enlargement potential.