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Microcellular Carbon/Graphite Foams & Microcellular Carbon/Carbon Composites
Typical microcellular Carbon foam

Unidirectional fiber reinforced Carbon foam

Wovenfabric reinforced Carbon foam

Microcellular carbon graphitic foam is a new foamed material which contains open-celled microcellular/carbon graphitic network created from carbon fiber precursors. Our foaming process aligns the graphene planes along each ligament axis. The morphology of the ligaments resembles that of carbon fibers, and hence, their mechanical characteristics are similar to those of the fibers’. The foams can be used as net shaped preforms for reinforcement of structural composites, sandwich core, and structural components for high temperature applications.

Microcellular carbon/carbon composites are carbon fibers reinforced carbon matrix that have a microcellular morphology. The fibers can be chopped, unidirectional or woven. Wright Materials Research Co. (WMR) has developed two proprietary foaming and post processing technique for this class of ultra-lightweight carbon material.
Sandwich structures with microcellular carbon/graphitic foam core

Features of WMR's C & C/C Foaming Technique

  • Single-Step Process

  • Environmentally friendly

  • Scalable to very large parts

  • Physical and functional properties of parts can be tailored by WMR’s processing technique

  • Foam density can be controlled from a few pcf to over 70 pcf

  • Starting materials include isotropic pitch, mesophase pitch, PAN, and various polymers

  • WMR’s agile foaming technique offers custom made ability

Microcellular Carbon/Graphite Foams

Potential Industrial Applications

  • Heat exchangers
  • High temp tooling
  • Acoustic Insulation
  • Acoustic & thermal panel
  • Engine components
  • Ballistic containment cases
  • Electronic heat sinks
  • Friction/brake
  • EMI shielding
  • Leadings edges
  • Core attachment
  • Composite matrix
  • Rocket nozzles
  • Satellite structures 
  • Truck brake
  • High speed train brake
  • Piston
  • Battery electrode
  • Multi-layer PWBS
  • Multichip modules
  • Chip carriers and chip on board

Carbon benefits of Carbon & C/C Foams

SEM's of Carbon foam

Stress-strain curves of compression high-density carbon foams.

  • Modulus of carbon foams as high as 366 ksi, compressive strength 4200 psi, fracture strain 42% for 31 pcf (.49 g/cc) foam
  • 13 pcf foam has 400 psi compressive strength and fracture strain over 67%
  • Near zero CTE, no out-gassing, superior performance- to-weight ratio, high temperature stability
  • Chemical inertness
  • Excellent fracture toughness
  • Graphitic foam has over 78% compression strain
  • Conductivity can be tailored from low to high
  • WMR’s C/graphitic & C/C foams offer superior mechanical properties that are ideal for load carrying applications in severe environments.

Stress-strain curves of low-density carbon foams

Compression stress-strain curve of low-density graphitic foam