One-Step Densification of Carbon/Carbon Composites Impregnated with Pyrolysis Fuel Oil-Derived Mesophase Binder Pitches

Abstract

Carbon/carbon (C/C) composites are conventionally manufactured by liquid-phase impregnation (LPI), in which the binder pitches and phenolic resins are impregnated into the composites, and by chemical vapor infiltration (CVI). However, CVI has certain limitations in that expensive gases, such as methane and propane, are used and a long reaction time is required. Therefore, LPI is more widely used, as it employs economical pitches. In this study, the effects of one-step preparation on mechanical properties of C/C composites impregnated with mesophase binder pitches and phenolic resins have been investigated. The C/C composites containing four types of 20 wt.% mesophase binder pitches had differences in softening point (SP) and quinoline insoluble (QI) contents. After conducting trials on mesophase formation using different heat treatment temperatures and times, the best density and mechanical properties of the C/C composites were achieved using the mesophase binder pitches with 170 °C SP. However, when SP 200 °C was used, the density of the C/C composites was not further improved. This is because the binder pitches were not properly impregnated into the composites due to the high viscosity and QI of the binder pitches. Furthermore, the C/C composites fabricated with 20 wt.% pitch 2 exhibited the highest mechanical properties.