Applications

Countless Possibilities

Tooling

CFOAM® -based carbon foam composite tooling offers an alternative to conventional Invar®, steel, and aluminum tools – simplifying tool design and reducing the time to build a tool. CFOAM prototype tooling can enable up to 50% savings versus an Invar tool. Construction of aircraft, spacecraft, missile parts, automobiles, and sporting goods is rapidly moving to carbon fiber-reinforced thermoset and thermoplastic resins, resulting in higher strength-to-weight ratio, higher stiffness, and less susceptibility to corrosion and fatigue. CFOAM offers a very uniform thermal expansion when compared with polymer foams, as well as a higher thermal stability.

A comprehensive benefit analysis comparing the use of CFOAM versus Invar®, aluminum, and steel tools showed:

  • A low coefficient of thermal expansion for composite tooling, more closely matching the composite part.
  • Lower fabrication costs.
  • Lighter weight tools.
  • Tooling easier to modify or repair.
  • Increased autoclave part throughput due to low mass tooling.

For additional information on the tooling advantages of CFOAM,
contact Touchstone Advanced Composites at www.touchstoneac.com.

Thermal Protection

CFOAM’s combination of thermal and physical properties make it an ideal material for a number of advanced thermal protection systems.

CFOAM can insulate the underlying structure and components of a vehicle or device from excessive heat, while helping to define the outer surface and enhance structural integrity.

CFOAM delivers unique high temperature properties. In the absence of oxygen, CFOAM materials can be heated to 3000°C without melting, while retaining its dimensional stability. Given its low coefficient of thermal expansion and relatively low modulus, it also affords high thermal-shock resistance.

Electrical

CFOAM can be used for numerous electromagnetic shielding applications, including ships, tactical shelters, and other electronic enclosures, easily joining with electrically conductive adhesives to form a non-metallic “Faraday cage” enclosure. Multifunctional CFOAM electronic enclosures also provide fire protection, reduce weight by eliminating metallic components and corrosion issues, while provide longer service life in harsh environments.

CFOAM in the open-cell configuration offers an ideal material for the construction of advanced electronics, due to its large surface area, high electrical conductivity, and chemically inert state. The resistivity of CFOAM can be tuned over a range of 9 orders of magnitude between 2 x 107 and 2 x 10-2 ohm-cm. In addition, CFOAM can be readily coated with a variety of polymeric and ceramic materials to create unique electrical components.

Fire Proofing

CFOAM demonstrates some of the best fire, smoke, and toxicity properties of all insulating core materials available today. It is being tested as a fire-stop material in construction applications, as well as an insulator to prevent thermal runaway for lithium-ion batteries.

CFOAM meets the “non-combustible” standard when tested in accordance with ISO 1182, as directed by the U.S. Coast Guard and the International Maritime Organization (IMO), whereas polymer-based foams do not, making them unsuitable for many marine applications. When tested under ASTM E1354, which measures composite material systems exposed to successive heat fluxes from 25-100 kW/m2, CFOAM underwent no ignition, released no heat, and generated no smoke.

CFOAM also is ideal for fire block and acoustic absorption applications in confined spaces with equipment enclosures, such as ships, trains, airplanes, buildings, and chemical plants, which have strict safety requirements.

Additional Applications

Filters

CFOAM, relatively inert and capable of operating at high temperature, also has an open-cell structure, making it an ideal candidate for use as a filter in extreme applications including aggressive solvents and some molten metals. The carbon surface in CFOAM can also be activated to enhance its ability to capture dissolved ions in solution.

Acoustic Absorption

As a unique acoustic absorption material, CFOAM may be utilized in shipbuilding, aerospace, and automotive industries. A one-inch thick CFOAM panel will absorb between 20-60% of a soundwave directed at it. Increasing the thickness of the foam can yield absorption values closer to 100%, and its high density relative to most polymer foams makes it well-suited for absorbing sound at lower frequencies. Given its excellent fire resistance, low thermal conductivity, low density, and high strength, CFOAM offers a state-of-the-art material system for many applications requiring sound absorption.

Heat Exchangers

Conventional heat exchangers and heat sinks, often made from aluminum or copper, afford relatively high thermal conductivity, but only marginal heat capacity per unit weight. Combining a phase-change material with CFOAM HTC graphite foam creates a novel heat exchanger much lighter in weight than either aluminum or copper, and demonstrating significantly greater heat capacity per pound by as much as 13X. This material is currently being tested in military and commercial applications.

Energy Absorption

CFOAM’s high strength at low density and inherent crushability provides significant energy absorbing properties in composite structures where it can be used as a core. CFOAM’s blast and crash resistant properties and performance continues to be researched for application in ground vehicles, aircraft, ships, infrastructure, shelters, cargo areas, and trains.