Here we report on how residence time influences the evolution of the structure and properties through each stage of the carbon fibre manufacturing process. The chemical structural transformations and density variations in stabilized fibres were monitored by Fourier Transform Infrared Spectroscopy and density column studies. The microstructural evolution and property variation in subsequent carbon fibres were studied by X-ray diffraction and monofilament tensile testing methods, which indicated that the fibres thermally stabilized at longer residence times showed higher degrees of structural conversion and attained higher densities. Overall, the density of stabilized fibres was maintained in the optimal range of 1.33 to 1.37 g/cm³. Interestingly, carbon fibres manufactured from higher density stabilized fibres possessed lower apparent crystallite size (1.599 nm). Moreover, the tensile strength of carbon fibres obtained from stabilized fibres at the high end of the observed range (density: 1.37 g/cm³) was at least 20% higher than the carbon fibres manufactured from low density (1.33 g/cm³) stabilized fibres. Conversely, the tensile modulus of carbon fibres produced from low density stabilized fibres was at least 17 GPa higher than those from high density stabilized fibres. Finally, it was shown that there is potential to customize the required properties of resultant carbon fibres suiting specific applications via careful control of residence time during the stabilization stage.

Carbon fibre composites are lightweight, high performance materials with outstanding mechanical properties.