Chemical Vapor Infiltration of Carbon Fiber Felts from Methane: Influence of Surface Area / Volume Ratios

Isothermal, isobaric chemical vapor infiltration of carbon fiber felts with fiber volume fractions of 7.1% and 14.2% were investigated at infiltration times from 20 to 120 hours, using a constant temperature of 1095 oC and a methane pressure of 22.5 kPa. Bulk densities and the density profiles as well as porosity at various densification stages were determined. Inside–outside densification was obtained in the most infiltrations, the gradients of densification along the infiltration depth decrease with increasing of residence time and infiltration times. Outside–inside densification occurs only in the felt with the lower fiber volume fraction at final infiltration stage and at longer residence times. Microstructure of the obtained matrix carbon was analyzed with a polarized light microscopy. Abruptly change from low/medium textured carbon to medium/high textured carbon are observed in both of the carbon fiber felts, whereas the thickness of the first lower textured layer is about 14 micros in the felt with a fiber volume fraction of 7.1%, whereas it is only 2 micros in the felt with a fiber volume fraction of 14.2%, which is caused by an increasing of initial surface area / volume ratio, [A/V], from 33 to 71 mm-1. Results are completely in agreement with the previous simulations studies on the influence of [A/V] ratios.