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Advanced Structural Carbon Products: Fibers, Foams & Composites

Advanced Structural Carbon Products: Fibers, Foams & Composites

The U.S. market for advanced structural carbon materials totaled $2.3 billion in 2014. The market should reach over $2.4 billion in 2015 and $3.3 billion in 2020, demonstrating a compound annual growth rate (CAGR) of 6.3% from 2015 to 2020.

This report provides:

An overview of the market for advanced structural carbon products, defined in this report to include all types of carbon fibers, carbon foams, monolithic structural graphite, carbon-reinforced carbon composites, and certain graphene materials.

Analyses of market trends, with data from 2014, estimates for 2015, and projections of compound annual growth rates (CAGRs) through 2020.

Evaluations of current consumption and future demand for these materials for the United States and other major geographic markets.

Analysis of the market's dynamics, specifically growth drivers, inhibitors, and opportunities.

Discussion of trends in technology and the impact of governmental regulations.

Profiles of major players in the market.


SCOPE OF REPORT

This report covers technological, economic and business conditions in the structural carbons industry. Although this report is primarily a study of the U.S. market, analysis, forecasts are also provided for global markets. Included in this report are descriptions of market forces relevant to the structural carbons industry and their areas of application.

The U.S. market is presented by type of structural carbons along with growth forecasts through 2020. The driving forces in the industry and the structure of the industry are also examined.

International aspects of the structural carbons industry are discussed with respect to all the geographic regions and type of structural carbon material. Lastly, brief profiles of the major manufacturers are presented.

CHAPTER 1 INTRODUCTION
STUDY GOALS AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE OF REPORT
METHODOLOGY AND INFORMATION SOURCES
ANALYST'S CREDENTIALS
RELATED BCC RESEARCH REPORTS
BCC RESEARCH WEBSITE
DISCLAIMER
CHAPTER 2 SUMMARY
SUMMARY TABLE U.S. MARKET FOR ADVANCED STRUCTURAL CARBON PRODUCTS BY USER SEGMENT, THROUGH 2020 ($ MILLIONS)
SUMMARY FIGURE U.S. MARKET FOR ADVANCED STRUCTURAL CARBON PRODUCTS BY USER SEGMENT, 2014-2020 ($ MILLIONS)
CHAPTER 3 INDUSTRY AND MARKETS OVERVIEW
UNITED STATES MARKET
FIGURE 1 U.S. MARKET FOR ADVANCED STRUCTURAL CARBONS BY TYPE, 2014 (%)
FIGURE 2 PROJECTED GROWTH RATE IN U.S. STRUCTURAL CARBONS MARKET, 2014-2020 (CAGR%)
GLOBAL MARKETS
FIGURE 3 GLOBAL ADVANCED STRUCTURAL CARBON PRODUCTS MARKET BY TYPE, 2014 (%)
FIGURE 4 GLOBAL STRUCTURAL CARBON PRODUCTS MARKET SHARE BY REGION, 2014 (%)
RESEARCH AND TECHNOLOGY TRENDS
INDUSTRY STRUCTURE
CHAPTER 4 TECHNICAL OVERVIEW
INTRODUCTION TO ADVANCED STRUCTURAL CARBON PRODUCTS
IMPORTANCE OF MECHANICAL PROPERTIES
CARBON FIBERS
RAW MATERIALS FOR CARBON FIBERS
Types of Raw Materials
Rayon
PAN
Pitch
Raw Material and Fiber Properties Relationship
TABLE 1 DEPENDENCE OF CARBON FIBER PROPERTIES ON RAW MATERIALS
PAN-Based Fibers
Pitch-Based Fibers
Rayon-Based Fibers
MANUFACTURING PROCESS
PAN Carbon Fiber Process
Precursor Preparation
Polymerization
Spinning and Stretching
Stabilization
Carbonization
Surface Treatment
Sizing
Pitch Carbon Fiber Process
Precursor Preparation
Pitch Refining
Isotropic Pitch
Anisotropic or Mesophase Pitch
Thermal Modifications
Solvent Modification
Chemical Modification
Catalytic Modification
Melt Spinning
Stabilization
Carbonization
Graphitization
Viscose Rayon Carbon Fiber Process
Vapor-Grown Carbon Fibers
CHEMICAL AND PHYSICAL PROPERTIES
Structural Property Relationship for Carbon Fibers
Density
Modulus
Impact of Fiber Diameter
Electrical and Thermal Conductivity
Thermal Stability
TABLE 2 STRUCTURAL PROPERTY RELATIONSHIPS FOR CARBON
FIBERS DERIVED FROM VARIOUS PRECURSORS
CARBON FIBER PRODUCT FORMS
Carbon Fiber Product Grades
PAN-Derived Fibers
Pitch-Derived Fibers
Tow
Carbon Fiber Cloth
Prepreg
RECENT DEVELOPMENTS IN MANUFACTURING TECHNOLOGIES
Microwave-Assisted Plasma (MAP) Process
Low-cost Carbon Fiber from Renewable Resources
Low-cost Carbon Fiber from Polyolefin
Converting Polyethylene into Carbon Fiber
Ultraviolet (UV) Stabilization of PAN-based Carbon Fibers
Rapid Oxidation Step
Surface Modification of Carbon Fibers
Carbon Nanotube Reinforcement of Carbon Fibers
Continuous Carbon Fiber Produced from Carbon Nanotubes
Carbon Nanofibers
Activated Carbon Fibers
Diamond Nanofibers
MANUFACTURERS OF PAN-BASED FIBERS
Small-tow Manufacturers
Cytec's Carbon Fiber Production
Hexcel's Carbon Fiber Production
Other Manufacturers
Large-Tow Carbon Fiber Manufacturers
Zoltek Companies Inc.
Toho Tenax America
SGL Carbon Fibers and Composites
MANUFACTURERS OF PITCH-BASED CARBON FIBERS
CARBON FIBER COMPOSITES
Carbon-Fiber-Reinforced Polymer Composites (CFRP)
Manufacturing Processes
Molding Processes
Roving Processes
Mechanical Properties
TABLE 3 TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBER-REINFORCED POLYMER
COMPOSITES
Carbon-Fiber-Reinforced Metal Composites (CFRM)
Manufacturing Processes
Mechanical Properties
TABLE 4 TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBER-REINFORCED METAL
COMPOSITES
CARBON FOAMS
RAW MATERIALS
TABLE 5 PROPERTIES OF PITCH RAW MATERIALS USED FOR CARBON FOAM MANUFACTURING (°C/%)
MANUFACTURING PROCESS
Flash Process
Blowing Gases
Sol-Gel Process
CHEMICAL AND PHYSICAL PROPERTIES
TABLE 6 PHYSICAL PROPERTIES OF PITCH-DERIVED CARBON FOAMS
RECENT TRENDS IN CARBON FOAM TECHNOLOGY
Uniform-Density-Gradient Carbon Foams
Reinforced Carbon Foams
High-Thermal-Conductivity Carbon Foams
Magnetic Carbon Nanofoams
Low-cost Carbon Foams
MANUFACTURERS OF CARBON FOAMS
Honeywell
POCO Graphite
Touchstone Research Laboratory
University of Dayton and Wright U.S. Air Force Laboratory Alliance
STRUCTURAL GRAPHITE
TYPES AND MANUFACTURING OF GRAPHITE MATERIALS
Natural Graphite
Synthetic Graphite
FIGURE 5 SCHEMATIC OF MANUFACTURING PROCESS FOR SYNTHETIC
GRAPHITE
PHYSICAL AND CHEMICAL PROPERTIES
Crystalline Structure
FIGURE 6 CRYSTALLINE STRUCTURE OF GRAPHITE
Lubrication
Thermal Properties
Oxidation Resistance
Chemical Resistance
Mechanical Properties
TABLE 7 PHYSICAL PROPERTIES OF GRAPHITE MATERIALS
EMERGING TECHNOLOGIES
Porous Graphite
High-Temperature Graphite Process
Expandable Graphite
CARBON-CARBON STRUCTURAL COMPOSITES
TYPES OF STRUCTURAL COMPOSITE MATERIALS
CARBON-REINFORCED CARBON MATRIX COMPOSITES
TABLE 8 ADVANTAGES AND DISADVANTAGES OF CARBON-CARBON
COMPOSITES
DIFFERENCES BETWEEN GRAPHITE AND CARBON-CARBON COMPOSITES
TABLE 9 COMPARISON OF PHYSICAL PROPERTIES OF GRAPHITE AND CARBON-CARBON COMPOSITES
CHEMICAL AND PHYSICAL PROPERTIES
REINFORCEMENT ARCHITECTURE
One-Dimensional Architecture
Two-Dimensional Architecture
Three-Dimensional Architecture
Multidimensional Architecture
Foam Reinforcement
MANUFACTURING PROCESSES
Infiltration of Matrix Phase
Raw Materials for Matrix Phase
Chemical Vapor Infiltration Process
Temperature Gradient Process
Isothermal Process
Pressure Gradient Process
Liquid Pitch Infiltration Process
Raw Materials
Manufacturing Process
Low-Pressure Process
High-Pressure Process
Thermosetting Resins as Matrix Precursors
FIGURE 7 REPRESENTATION OF CARBON-CARBON COMPOSITE
MANUFACTURING PROCESS
STRUCTURE AND PROPERTY RELATIONSHIPS
Microstructural Features
TABLE 10 COMPARISON OF CARBON-CARBON COMPOSITES
PROPERTIES MANUFACTURED BY VARIOUS PROCESSING
ROUTES
Mechanical Properties
Young's Modulus
Strength
Fatigue and Creep
Effect of Temperature on Mechanical Properties
Effect of Oxidation on Mechanical Properties
Thermal Properties
Friction and Wear Properties
OXIDATION PROTECTION FOR CARBON-CARBON COMPOSITES
TECHNOLOGY TRENDS
Oxidation Inhibition of Carbon-Carbon Composites
Rapid-Oxidative-Stabilization Composites
High-purity Carbon-Carbon Composites
High-density Carbon-Carbon Composites
Elimination of Need for Oxidative Stabilization of Carbon Composites
High Thermal Conductivity Carbon-Carbon Composites
Sequential Deposit of Carbon Matrix and In Situ Polymerization
Rapid Processing of Carbon-Carbon Composites
Protective Coatings
Detecting Flaws in the Carbon Composites
Carbon-Carbon Composites from Densified Carbon Foam
Low-Temperature Densification Using Sugar Pyrolysis
Thick Three-dimensional Preforms for Carbon-Carbon Composites
High-Strength Composites Developed by NASA and JPL
Carbon-Carbon Frictional Composites for Elevator Brakes
Joining Carbon-Carbon Composites
Nanotubes in Carbon-Carbon Composites
Low-cost Production of Carbon-Carbon Composites
GRAPHENE
PROPERTIES
RAW MATERIALS AND PRODUCTION PROCESSES
Established Technologies
"Scotch Tape" Method
Epitaxial Method
Graphite Oxide Reduction Method
Experimental Approaches
Metal-Carbon Melt Method
Pyrolysis of Sodium Ethoxide Method
Production of Graphene from Carbon Nanotubes
Production of Graphene from Table Sugar
Dissolving Graphite in Chlorosulphonic Acid
"Molecular Wedge" Method
Radio Frequency Catalytic Chemical Vapor Deposition
Atmospheric Pressure Chemical Vapor Deposition
Carbon Dioxide Reduction
Dry Ice-Based Production Processes
COMPANIES DEVELOPING GRAPHENE STRUCTURAL MATERIALS
Allotropica Technologies
General Motors
Graftech
Graphene Devices Ltd.
Graphenea
CHAPTER 5 COMMERCIAL APPLICATIONS
CARBON FIBER APPLICATIONS
TABLE 11 PROPERTIES AND APPLICATIONS OF CARBON FIBERS
AEROSPACE AND DEFENSE INDUSTRY
Space Vehicles
Unmanned Spacecraft
Manned Spacecraft
Launch Vehicles
Total U.S. Space Market
TABLE 12 U.S. SPACE VEHICLE MARKET, THROUGH 2020 ($ BILLIONS)
Defense Market
Defense Aviation
TABLE 13 U.S. MILITARY AIRCRAFT MARKET, THROUGH 2020 ($ BILLIONS)
Missiles
TABLE 14 U.S. MISSILE SHIPMENTS, THROUGH- 2020 ($ BILLIONS)
Commercial Aviation
Large Aircraft
TABLE 15 DELIVERIES OF LARGE U.S.-MADE COMMERCIAL AIRCRAFT BY TYPE, THROUGH 2020 (UNITS)
Carbon Fiber Consumption
TABLE 16 CONSUMPTION OF CARBON-FIBER-REINFORCED COMPOSITES IN U.S.-MADE COMMERCIAL AIRLINERS (LBS/%)
GROUND TRANSPORT
Trains and Locomotives
Motor Vehicles
INDUSTRIAL APPLICATIONS
WIND ENERGY
TABLE 17 U.S. WIND POWER CAPACITY, THROUGH 2020 (MW)
TABLE 18 U.S. PRODUCTION OF WIND TURBINE ROTOR BLADES, THROUGH 2020 (NUMBER OF BLADES)
SPORTING GOODS
Golf Clubs
TABLE 19 U.S. MARKET FOR CARBON FIBER COMPOSITE GOLF CLUBS, THROUGH 2020 ($ MILLIONS)
Bicycles
Recreational Boating
Sport Fishing
TABLE 20 U.S. SHIPMENTS OF CARBON FIBER FISHING RODS, THROUGH-2020 ($ MILLIONS)
Other Applications
INFRASTRUCTURE
New Bridge Construction
Bridge Repairs
Column Repairs
Seismic Retrofit
High-Strength Building Construction
Engineered Wood Products
Deepwater Oil and Gas Structures Made from Carbon Composites
Smarter and Stronger Concrete
New Manufacturing Process for Reinforced Concrete
THERMAL MANAGEMENT
Conductive Plastics
Carbon Nanotubes
OTHER APPLICATIONS
Biocompatibility Applications
Electrochemical Applications
Static Dissipation Applications
Lightweight Telescope Mirrors
Hollow Carbon Fibers in Molecular Sieve Applications
Emerging Energy Systems
Turtle Airship Uses Carbon Composites
CARBON FIBERS MARKET GROWTH
TABLE 21 U.S. CONSUMPTION OF CARBON FIBERS BY INDUSTRY, THROUGH 2020 (THOUSAND LBS.)
FIGURE 8 U.S. CONSUMPTION SHARE OF CARBON FIBER BY INDUSTRY, 2014 VS. 2020 (%)
TABLE 22 U.S. MARKET FOR CARBON FIBERS BY INDUSTRY, THROUGH 2020 ($ MILLIONS)
FIGURE 9 U.S. MARKET SHARE FOR CARBON FIBER BY INDUSTRY, 2014 VS. 2020 (%)
CARBON FOAM APPLICATIONS
AEROSPACE AND DEFENSE
Radiators
Fire Barrier Applications
Brakes
GROUND TRANSPORTATION
Automotive Radiators
Shock Absorbers and Bumpers
Other Automotive Applications
INDUSTRIAL APPLICATIONS
Sandwich Panels
Electronic Heat Sinks
Phase-Change Materials
ENERGY
Batteries
Fuel Cells
Radiators
Humidifiers
Bipolar Plates
Supercapacitors
Nuclear Reactor Cores
Gas Storage
OTHER APPLICATIONS
Air Filtration Devices
Personal Cooling Devices
Health Care Applications
Acoustic Absorber Materials
CARBON FOAM MARKET GROWTH
TABLE 23 U.S. CONSUMPTION OF CARBON FOAM, THROUGH 2020 (THOUSAND LBS.)
FIGURE 10 U.S. CONSUMPTION SHARE OF CARBON FOAM BY INDUSTRY, 2014 VS. 2020 (%)
TABLE 24 U.S. CARBON FOAM MARKET BY INDUSTRY, THROUGH 2020 ($ MILLIONS)
STRUCTURAL GRAPHITE APPLICATIONS
AEROSPACE AND DEFENSE
GROUND TRANSPORTATION
INDUSTRIAL APPLICATIONS
Chemical Industry Applications
Mechanical Applications
Bearings and Brushes
TABLE 25 TYPICAL APPLICATIONS FOR GRAPHITE BEARINGS
Seals
Friction Materials
Metallurgy
Glassware
Refractory Applications
ENERGY
Fuel Cells
Nuclear Industry Applications
Hydrogen Storage
STRUCTURAL GRAPHITE MARKET GROWTH
TABLE 26 U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY, THROUGH 2020 (THOUSAND LBS.)
FIGURE 11 U.S. CONSUMPTION SHARE OF STRUCTURAL GRAPHITE BY INDUSTRY, 2014 VS. 2020 (%)
TABLE 27 U.S. MARKET FOR STRUCTURAL GRAPHITE BY INDUSTRY, THROUGH 2020 ($ MILLIONS)
CARBON-CARBON COMPOSITES APPLICATIONS
AEROSPACE
Space Vehicle Thermal Protection Systems
Aircraft Engine Components
Aircraft Brakes
Other Aerospace Applications
GROUND TRANSPORTATION
INDUSTRIAL APPLICATIONS
Refractory Structures
Glass Industry
Corrosion-Resistant Structures
Thermal-Management Solutions
ENERGY
OTHER APPLICATIONS
Biocompatible Structures
CARBON-CARBON COMPOSITES MARKET GROWTH
TABLE 28 U.S. CONSUMPTION OF CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2020 (THOUSAND LBS.)
FIGURE 12 U.S. CONSUMPTION SHARE OF CARBON-CARBON COMPOSITES BY INDUSTRY, 2014 VS. 2020 (%)
TABLE 29 U.S. MARKET FOR CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2020 ($ MILLIONS)
STRUCTURAL GRAPHENE APPLICATIONS
INDUSTRIAL APPLICATIONS
Thermal Management Solutions
ENERGY
Hydrogen Storage
Oxidized Graphene Sheets
Corrugated Graphene
Other Developments
Batteries
OTHER APPLICATIONS
TABLE 30 POSSIBLE TYPES OF GRAPHENE COMPOSITES AND THEIR PROPERTIES
MARKET GROWTH
TABLE 31 U.S. CONSUMPTION OF STRUCTURAL GRAPHENE BY INDUSTRY, THROUGH 2020 ($ MILLIONS)
MARKETS FOR ADVANCED STRUCTURAL CARBONS
TABLE 32 U.S. CONSUMPTION OF STRUCTURAL CARBONS BY MATERIAL TYPE, THROUGH 2020 (THOUSAND LBS.)
FIGURE 13 U.S. CONSUMPTION SHARE OF STRUCTURAL CARBONS BY MATERIAL TYPE, 2014 VS. 2020 (%)
TABLE 33 U.S. MARKET FOR STRUCTURAL CARBON PRODUCTS BY TYPE, THROUGH 2020 ($ MILLIONS)
FIGURE 14 U.S. MARKET SHARE FOR STRUCTURAL CARBON PRODUCTS BY TYPE, 2014 VS. 2020 (%)
CHAPTER 6 INDUSTRY STRUCTURE AND MARKET DRIVERS
MARKETS FOR STRUCTURAL CARBON MATERIALS
MANUFACTURERS OF STRUCTURAL CARBONS
Carbon Fibers
FIGURE 15 U.S. CONSUMPTION SHARE OF CARBON FIBER BY LEADING SUPPLIERS, 2014 (%)
Carbon Foams
FIGURE 16 U.S. CONSUMPTION SHARE OF CARBON FOAM BY LEADING SUPPLIERS, 2014 (%)
Structural Graphite
FIGURE 17 U.S. CONSUMPTION SHARE OF STRUCTURAL GRAPHITE BY LEADING SUPPLIERS, 2014 (%)
Carbon-Carbon Composites
FIGURE 18 U.S. CONSUMPTION SHARE OF CARBON-CARBON COMPOSITES BY LEADING SUPPLIERS, 2014 (%)
SWOT ANALYSIS OF STRUCTURAL CARBONS INDUSTRY
Strengths
Weaknesses
Opportunities
Threats
MARKET DRIVERS
ECONOMIC FACTORS
LEGAL AND REGULATORY FACTORS
Price-Fixing in the Carbon Fibers and Composites Industry
Price-Fixing in the Graphite Industry
INDUSTRY FACTORS
Capacity Trends
Price Trends
New Technologies and New Entrants to the Business
Influence and Leverage
Buyers' Influence and Leverage
Suppliers' Influence and Leverage
Substitute Products
COMPETITIVE STRATEGIES IN THE STRUCTURAL CARBONS INDUSTRY
NEW BUSINESS DEVELOPMENT
COMPETITIVE PRICING
VERTICAL INTEGRATION
GLOBAL STRATEGIC ALLIANCES
SGL-BMW Joint Venture
SGL-Mitsubishi Joint Venture
Mitsubishi Rayon's Expansion Plans and Alliance with SGL
Zoltek-DeWind Supply Agreement
Zoltek and Chomarat
GrafTech and Ballard Power Systems
Zoltek and Leggett & Pratt
Hexcel and Airbus Industries
Hexcel and Boeing
Chinese - Russian Alliance
CHAPTER 7 INTELLECTUAL PROPERTY AND TECHNOLOGY TRENDS
ANALYSIS
INTELLECTUAL PROPERTY ANALYSIS
TABLE 34 PATENTS ISSUED TO LEADING MANUFACTURES IN STRUCTURAL
CARBON MATERIALS TECHNOLOGY, 1996-SEPTEMBER, 2015
TECHNOLOGY DEVELOPMENT TRENDS
CHAPTER 8 INTERNATIONAL ASPECTS OF STRUCTURAL CARBONS
BUSINESS
TABLE 35 GLOBAL MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE, 2014 ($ MILLIONS)
FIGURE 19 GLOBAL MARKET SHARE FOR STRUCTURAL CARBON MATERIALS BY TYPE, 2014 (%)
TABLE 36 GLOBAL STRUCTURAL CARBON MATERIALS MARKET BY REGION, THROUGH 2020 ($ MILLIONS)
CHAPTER 9 PROFILES OF MANUFACTURERS
U.S. MANUFACTURERS
ADVANCED CARBON TECHNOLOGIES INC.
ADVANCED COMPOSITES INC.
AEROSPACE COMPOSITE PRODUCTS CO.
ALBANY ENGINEERED COMPOSITES
APPLIED SCIENCES INC.
ASBURY CARBONS
BOEING CO.
CARBON-CARBON ADVANCED TECHNOLOGIES INC.
CHOMARAT NORTH AMERICA
CYTEC CORP.
FIBER MATERIALS INC.
GENERAL MOTORS CO.
GRAPHITE METALLIZING CORP.
GRAPHITE SALES INC.
GRAFTECH INTERNATIONAL LTD.
GRAPHTEK LLC
HELWIG CARBON PRODUCTS INC.
HEXCEL CORP.
HITCO CARBON COMPOSITES INC.
HONEYWELL INTERNATIONAL INC.
KIRKWOOD HOLDING INC.
MER CORP.
MINERALS TECHNOLOGIES INC.
MITSUBISHI RAYON CARBON FIBER AND COMPOSITES.
MORGAN ADVANCED MATERIALS
POCO GRAPHITE INC.
ROC CARBON CO.
SCHUNK GRAPHITE TECHNOLOGY LLC
SGL GROUP - THE CARBON COMPANY
SIOUX MANUFACTURING CORP.
SPENCER COMPOSITE CORP.
ST. MARYS CARBON CO.
SUPERIOR GRAPHITE CO.
TOHO TENAX AMERICA INC.
TORAY CARBON FIBERS AMERICA INC.
TOUCHSTONE RESEARCH LABORATORY LTD.
TPI COMPOSITES INC.
ULTRAMET INC.
UTC AEROSPACE SYSTEMS
V2 COMPOSITE INC.
ZOLTEK COMPANIES INC.
INTERNATIONAL MANUFACTURERS
ANAORI CARBON CO. LTD.
ATLAS COMPOSITES LTD.
GRAPHENEA
GRUPO ANTOLIN INGENIERIA S.A
MERSEN GROUP
MITSUBISHI CHEMICAL CORP.
MITSUBISHI RAYON CO. LTD.
NIPPON GRAPHITE FIBER CORP
TAIWAN CARBON TECHNOLOGY CO. LTD.
TOHO TENAX CO. LTD.
TORAY INDUSTRIES INC.

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