Carbon Fiber Composite Research Articles

Investigation of mechanical properties and self‐healing efficiency of carbon fibers composites infused with unsaturated polyester vitrimer

AbstractUnsaturated polyester resins (UPR) are widely in composite manufacturing, particularly in the energy, wind, and construction sectors. When these composites sustain damage, defects or cracks, several methodologies are employed to heal and repair them to extend their lifespan while reducing environmental impacts. In this work, the use of vitrimeric UPR (UPRv) as a matrix for carbon fiber composite, was investigated in terms of healing efficiency by mechanical and thermal properties. Flexural and interlaminar shear strength tests revealed healing efficiencies exceeding 40% and 90%, respectively. These results were attributed to the transesterification exchange occurring within the crosslinked networks of UPRv. As described in our previous work, the incorporation of “Covalent Adaptable Networks (CANs)” enables the conversion of commercial thermoset (UPR) into vitrimeric resins, thereby providing reprocessing and healing capabilities. Furthermore, a comparison between pristine and healed composites with Mode I DCB and Mode II ENF tests, confirm how the introduction of vitrimer in composite facilitates the manufacturing of a self‐healing product, with a significant recovery of the original properties.Highlights Application of a previous synthetized vitrimeric unsaturated polyester resin (UPRv)—fabrication of CF's composites reinforced with UPRv—investigation of the self‐healing property of the developed laminates—potential application as green and sustainable composites.

Multi-scale collaborative prediction of optimal configuration for carbon fiber woven composites based on deep learning neural networks

Since carbon fiber woven composite panels contain complex fiber bundle structures, the aim of this paper is to investigate the factors influencing the macro-equivalent properties and topological flexibility of composite panels resulting from variations in fiber bundle configuration. Firstly, the structural topology optimization design of carbon fiber composite plates was achieved using a multi-scale modeling approach with the variable density method. Nonlinear relationships between carbon fiber bundle configuration parameters and macroscopic equivalent properties, as well as macroscale topological flexibility, were determined using deep learning methods, respectively. The maximum error in the predicted values of the deep learning network model does not exceed 0.5% when compared with the results of the finite element calculations. In addition, utilizing deep learning networks to predict macro-equivalent properties of composites can significantly decrease computational time. The impact of varying the number of filaments in fiber bundles and the spacing of the fiber bundles on the flexibility of the topology was determined using a deep learning network. The optimal topological flexibility, along with its corresponding fiber bundle spacing and number of fiber bundle filaments, are globally searched within the design domain using an adaptive genetic algorithm. The study in this paper can provide a reference for designing fiber bundle configurations of composites for practical applications.

Effect of Chitin Nanocrystal Deacetylation on a Nature-Mimicking Interface in Carbon Fiber Composites

The formation of a rigid, tough interface based on a nacre-like structure in carbon fiber (CF) composites is a promising way to eliminate low delamination resistance. An effective method of coating CFs is electrophoretic deposition (EPD), which, in the case of dissimilar components like graphene oxide (GO) and polymeric glue, usually requires chemical bonding/strong interactions. In this work, we focus on chitin nanocrystals (ChNCs), leading to an excellent mechanical performance of artificial nacre, where favorable interactions and bonding with GO are controlled by degrees of deacetylation (5, 15, and 30%). We prepared coatings based on GO/ChNC adducts with 95/5, 90/10, 50/50, and 25/75 ratios using optimized EPD conditions (pH, concentration, voltage, and time). The prepared materials were characterized using FTIR, TEM, XPS, SEM, DLS, and XRD. SEM evaluation indicates the formation of a homogeneous interlayer, which has a fair potential for chemical bonding with the epoxy matrix. Short-beam testing of epoxy matrix composites indicates that the coating does not decrease stiffness and has a relatively low dependence on composition. Therefore, all coatings are promising for a detailed study of delamination resistance using laminate samples. Moreover, facile EPD from the water solution/suspension has a fair potential for industrial applications.

Cryogenic properties of PEG/nano-SiO2 co-toughened winding resin and its carbon fiber-reinforced composites

The epoxy/acid anhydride system was toughened with a homogeneous solution of surface-treated nano-SiO2 and polyethylene glycol (PEG), which satisfies the specific requirements of wet winding processes and effectively enhances the performance of resin and carbon fiber composites at ultra-low temperatures (108K). The results show that when the uniform solution formed by 1 phr SiO2 and 10 phr PEG is added, the tensile strength and elongation at break of the modified resin were increased by 21.4% and 16.1%, respectively, at room temperature. At 108K, the strength and modulus of the modified resin were increased, and the elongation at break was 2.8%. The fracture morphology was analyzed and compared at both room temperature and ultra-low temperature, verifying the relationship between material structure and properties across different temperatures. These findings offer both theoretical and empirical backing for the development of ultra-low temperature carbon fiber composite gas storage tanks.

Interfacial enhancement by constructing a “flexible-rigid” structure between high-modulus fillers and low-modulus matrix in carbon fiber/silicone rubber composites

Silicone rubber (SR) has excellent resistance to high temperatures, and carbon fiber (CF) is a commonly reinforced material. However, the application of carbon fiber in SR composites is limited by the large difference in modulus between the two materials. In order to improve the interfacial bonding of the composites and to exert the reinforcement of carbon fibers, a modulus transition interface, a “flexible-rigid” structure was constructed between CF and SR by coating polydopamine-polyethyleneimine@silica (PDA-PEI@SiO2) on the carbon fiber surface. The results show that the “flexible-rigid” structure of the PDA-PEI@SiO2 layer not only enhanced the mechanical properties but also improved the thermal resistance and wave-transmission properties of the CF/SR composites. Surface microscopy and structural analysis showed that the “flexible-rigid” structure was successfully coated on the fiber surface, and significantly improved the roughness of the fiber surface. It provided the mechanical meshing between the fiber and matrix when the CF/SR composites were subjected to the tensile loads. The tensile strength and elongation of the SR composite with CF-A-E@8SiO2 were 37.16 % and 27.46 % higher than that with unmodified CF, respectively. The electrical test showed that the “flexible-rigid” structure could reduce the dielectric constant and dielectric loss of CF/SR composites, thereby improving the wave-transmission properties. Further mechanism analysis of the interfacial bonding showed that abundant hydrogen bonds in the “flexible-rigid” structure at the interface promoted stress dissipation and avoided stress concentration. Meanwhile, the formation of Si-O-Si with high bonding energy also protected the interface from destruction. The thermogravimetric analysis (TGA) found that the introduction of Si-O-Si bonds could significantly improve the thermal resistance of the CF/SR composites at 350 °C for 2 h. It provides guidance for the improvement of the interface bonding in the fiber/rubber composite as well as its functionality.

Multifunctional properties of carbon nanotube yarn/aerogel laminate composites

This work explores the multifunctional performance of scalable carbon nanotube (CNT) yarn laminate composites. Tensile, thermal, electrical, and electromagnetic interference (EMI) shielding properties are compared to state-of-the-art unidirectional IM7/5250-4 carbon fiber composite (CFRP). CNT laminates achieved a specific tensile modulus of 249.7 ± 22.3 GPa/(g/cm3), which is over double the specific modulus of the CFRP, while maintaining a specific tensile strength of 1.88 ± 0.17 GPa/(g/cm3) which is comparable to the CFRP. CNT yarn laminates demonstrated superior thermal transport properties, with in-plane thermal conductivity of 75.78 ± 14.3 W/mK, over 13 times higher than the CFRP. CNT yarn laminates were also superior in electrical conductivity, achieving a longitudinal conductivity of 5359 ± 417 S/cm and transverse conductivity of 36.87 ± 2.55 S/cm. This translated to superior EMI shielding properties, achieving over 100 dB in the X-band, which is nearly double that of the CFRP. Incorporating CNT aerogel interwoven between CNT yarns reduced the large property variance observed in the measurements, demonstrating a multifunctional material with tensile, thermal, electrical, and EMI properties superior to the CFRP, while potentially mitigating the scalability challenges inherent to CNT nanomaterials.

Thermomechanical behavior of textile-reinforced geopolymer concrete based on mineral-impregnated carbon-fibers (MCFs) composites

State-of-the-art textile reinforcements are well employed to strengthen, rehabilitate or build new structures, whilst polymeric impregnation degrades considerably in elevated temperatures or aggressive environments. Herein, mineral-based matrices are regarded as a viable and novel technique. This study introduces a methodology to manufacture 2D-textile reinforcements using mineral-impregnated carbon fiber (MCF) automatically via a pultrusion and robotic–based structuring process. The reinforcing ability of MCF textiles without and with surface modification in geopolymer (GP) concrete was compared to commercial epoxy-impregnated textiles. After thermally stimulated rapid solidification, the resulting grid-like structures were incorporated into the concrete matrix. The MCF-GP-concrete composites were evaluated regarding their load-bearing capacity from 20 °C to 200 °C. Digital Image Correlation (DIC) and μCT analysis were used to study damage processes and interphase adhesion. The results demonstrated that GP concrete components with MCF textiles exhibited superior thermal resistance and a bi-linear stress-strain behavior compared to polymer matrix composite. Dilatometry and TGA measurements provided shrinkage and dehydration evidence for the thermally induced strength decrease. The enhanced chemical compatibility achieved via GP impregnation facilitates the formation of finely distributed crack patterns with reduced crack widths, contributing to improved durability scenarios and failure behavior of textile-reinforced concrete (TRC).

Preparation processes and thermal conductivities of magnetic field- and torsional vibration-induced superoriented carbon fiber composites

With the advancement of semiconductor technology, advanced electronic devices have become increasingly efficient, highly integrated and multifunctional, producing a large amount of heat during operation, thus decreasing the device efficiency and increasing the requirements for thermal interface materials. The use of a magnetic field to prepare pitch-based carbon fibers (CFs) with ultrahigh axial thermal conductivities and aspect ratios is a promising method for preparing thermal interface materials. However, past methods are not adequately simple or effective. Herein, we propose a simple, efficient method for preparing a novel thermally conductive CF interface material with a superoriented and closely arranged structure. The thermal conductivity of the vertical plane can reach 82.026 W m-1 K-1, which is higher than that of many other alloys. During the experiment, we prove that the torsional vibration of the vibrating plate can greatly resolve the issue of powder bridging generated during preparation. In addition, we discover and explain the heat return conduction phenomenon through numerical simulation. Our innovative preparation process and our analysis of thermal conduction can provide a new method and unique view for the design of thermal interface materials.

Constructing a Novel Moderately Modulus "Rigid-Flexible" Structure with Synergistic Reinforcement on the Carbon Fiber Surface to Enhance the Mechanical Properties of Carbon Fiber/Epoxy Composites at Elevated Temperatures.

To improve the mechanical performance of carbon fiber (CF)/epoxy composites in high-temperature environments, a moderately modulus gradient modulus interlayer was constructed at the interface phase region of composites. This involved the design of a "rigid-flexible" synergistic reinforcement structure, incorporating rigid nanoparticle GO@CNTs and a flexible polymer polynaphthyl ether nitrile ketone onto the CF surface. Notably, at 180 °C, compared to commercial CF composites, the CF-GO@CNTs-PPENK composites displayed a remarkable improvement in their mechanical characteristics (interfacial shear, interlaminar shear, flexural strength, and modulus), achieving enhancements of 173.0, 91.5, 225.7, and 376.4%, respectively. The principal reason for this the moderately modulus interface phase composed of GO@CNTs-PPENK (where GO and CNTs predominantly consist of carbon atoms with sp2-hybridized orbitals, forming highly stable C-C structures, while PPENK possesses a "twisted non-coplanar" structure), which exhibited resistance to deformation at high temperatures. Moreover, it greatly improved the mechanical interlocking, wettability, and chemical compatibility between CF and the epoxy. It also played a crucial role in balancing and buffering the modulus disparity. The interface failure behavior and reinforcement mechanisms of the CF composites were analyzed. Furthermore, validation of the presence of a moderately modulus gradient interlayer at the interface phase region of CF-GO@CNTs-PPENK composites was performed by using atomic force microscopy. This study has established a theoretical foundation for the development of high-performance CF composites for use in high-temperature fields.

Experimental study and numerical simulation of morphing characteristics of bistable laminates embedded with 3D printed shape memory polymers

Bistable laminates have potential applications in areas such as buffer and soft robotics due to their two stable states and ability to deform through both snap-through and snap-back processes. However, conventional orthotropic bistable laminates with two stable state configurations and snap loads are similar in magnitude. There is a problem that the deformation cannot be easily driven when the laminate stiffness is high. To solve this problem, a clever design is needed to reduce the snap-back load and increase the snap-through load so that the driven deformation can be realized more easily. In this paper, we propose a design method to suppress and control the deformation of bistable laminates by utilizing the shape memory of 3D-printed shape memory polymers (SMP), which enables the laminates to increase the stiffness while reducing the driving force. First, a numerical model of viscoelasticity of the laminate is established to study its deformation characteristics, and the numerical results are compared with experimental results with good agreement. The effect of SMPs on the snap load and principal curvature of bistable laminates is also investigated. Finally, the interlayer interface bonding of the bistable laminates is examined in microscopic perspective. The results demonstrate that 3D printed SMPs can effectively enhance the snap-through load and reduce the snap-back load of bistable laminates, achieving deformation suppression and control while maintaining good interlaminar bonding with carbon fiber composites. This study provides new insights and practical significance for the deformation suppression and active control of bistable structures.

Inverse effects of cooling rates on the interfacial shear strength of carbon Fiber/PEEK composites with and without presence of transcrystal layers

The crystallization behavior of polyetheretherketone (PEEK) is essential for the interfacial properties of its carbon fiber (CF) reinforced composites. It has already been well known that the transcrystalline (TC) layer at the CF/matrix interface is beneficial of improving the interfacial shear strength (IFSS). However, not all CF can induce the formation of TC layers in the PEEK matrix. This study aims to compare the effects of cooling rates on the IFSS of CF/PEEK composites with and without existence of the TC layer. In comparison to the original PEEK matrix (PEEK-O), we applied both physical (PEEK-A) and chemical (PAEK) modifications to increase the nucleation ability of the matrices. As a result, obvious TC layer was only observed in CF/PEEK-O composite. We further found that the effects of cooling rates on the IFSS of CF composites were opposite for samples with and without the TC layer. For CF/PEEK-O composite which contains the TC layer, the fast-cooling sample showed a smaller IFSS than the slow-cooling sample. This work reveals the key role of crystallization behavior at the interface in modulating the effects of cooling rates on IFSS, which is beneficial for the customized manufacturing and processing of different CF/PEEK composites.

Mechanical properties and design of hybrid composites of carbon and jute fibers with polypropylene

Natural fibers have both environmentally friendly and ecological advantages in the fiber material industry. Improving the mechanical properties and durability of natural fiber composites is an important research approach. As one of the representatives of synthetic fibers, carbon fiber has excellent mechanical properties and chemical stability, but its high cost and low toughness limit further application. Combining environmentally friendly, low-cost natural fibers with carbon fibers can broaden the development of natural fiber-reinforced composites in industrial applications. In this paper, the composites made of jute fibers and polypropylene (PP) as well as carbon fibers coupled with KH550 modification were prepared and their properties were investigated. By introducing a macroscopic model similar to the core-shell structure, an environmentally friendly material with better mechanical properties was achieved, with carbon fiber woven fabric serving as the shell and jute fiber mat as the core. The results show that a low-cost hybrid composite was successfully prepared by using a small amount of carbon fiber woven fabric instead of jute fiber mat, and the tensile, flexural and impact properties of the composites were improved by 488.27%, 70.75% and 463.39%, respectively, compared with those of the pure jute fibers composites. This study provides a rapid and reliable approach to improve the mechanical properties of the natural fiber composites.

Electrical conductivities and temperature distributions of carbon fiber 3D woven composites with different electric field direction

Electrical conductivities and temperature generations are related closely for carbon fiber composites under electric fields. Here we reported the current conductivity and electro-thermal behavior of carbon fiber reinforced 3D orthogonal woven structure composites (3DOWCs) along different current directions. The influence of woven architectures and contacts on electrical and thermal behaviors was analyzed with finite element analysis (FEA) model. We found that the conductivity was the highest along warp direction and the lowest along Z-binder direction. The conductivity increased with the increase of in-plane angles. The overall conductivity of Z-binder direction was affected by weft/Z-binder yarn interface. In-plane angle directions, the warp/weft interfacial conductivity affected overall conductivities, which had the largest temperature contribution. The maximum current density and temperature of warp yarns decreased with the increase of in-plane angles. The proportion of weft yarns in current density and temperature rise increased with the increase of in-plane angles.

Effect of temperature on flexural and interlaminar shear strength properties of carbon‐epoxy composites: Experiment and modeling

AbstractCarbon fiber composites are known for excellent specific mechanical properties at room temperature. It is important to model the effect of temperature on flexural strength and interlaminar shear strength (ILSS). In this study, T700 carbon fiber composites with two different epoxy resins (Epofine, LY556) were prepared using filament winding and named as TE and TL composites. The dynamic mechanical analysis (DMA) tests revealed Tg of 177 and 192°C for TE and TL composites, respectively. Three‐point bending (flexural) and short‐beam shear (ILSS) tests were performed at −20, 0, RT, 90, 105, 150, 170, and 200°C. It was observed that flexural strength and ILSS decreases linearly with increase in temperature. Fracture analysis of flexural samples revealed fiber breakage at −20°C and micro‐buckling at elevated temperature are dominant failure mechanisms. Fracture analysis of ILSS samples showed delamination with microcracking at −20°C and plastic deformation of matrix at elevated temperature. A new empirical model was proposed to predict the temperature dependent flexural strength and ILSS. With this model, variation of flexure strength and ILSS with temperature can be estimated from respective values at RT, Tg and storage modulus values from DMA, thus extensive experimentation at high temperatures can be avoided.Highlights Mechanical properties of filament wound composites are tested from −20 to 200°C. Flexural strength and ILSS linearly decreases with increase in temperature. Fiber breakage at −20°C and micro bucking at 200°C are dominant in flexure. Delamination at −20°C and plastic deformation at 200°C are dominant in ILSS. Analytical model for finding temperature dependent flexural strength and ILSS.

Designing Prepregnation and Fused Filament Fabrication Parameters for Recycled PP- and PA-Based Continuous Carbon Fiber Composites.

Continuous carbon fiber (cCF)-based 3D-printed polymer composites are known for their excellent flexural properties; however, the optimization of the overall process is still desired, depending on the material types involved. Here, the improved manufacturing of cCF-based composites is reported, considering virgin polyamide (PA) and postindustrial waste polypropylene (PP), and the parameters affecting the material properties are evaluated. Firstly, the prepregnation technique was optimized to manufacture cCF polymer filaments with various fiber-to-polymer ratios. Secondly, the fused filament fabrication (FFF) technique was optimized. It was observed that the layer height needs to be sufficiently low for proper interlayer adhesion. The influence of the printing temperature is more complicated, with filaments characterized by a lower fiber-to-polymer ratio requiring a higher nozzle diameter and higher temperatures for efficient printing; and for lower diameters, the best flexural properties are observed for parts printed at lower temperatures, maintaining a high interspace distance. Plasma treatment of the cCF was also explored, as was annealing of the produced parts to enhance the flexural properties, the latter being specifically interesting for the PP-based composite due to a lower wetting caused by a higher viscosity, despite supportive interfacial interactions. Eventually, overall guidelines were formulated for the successful production of cCF-based composites.

Research progress on bamboo fiber reinforced polymeric composites: Processes, properties, and future directions

AbstractCharacterized by rapid maturation, short growth cycles, and high strength and toughness, bamboo can be compounded with polymers to produce bamboofiber reinforced polymeric composites (BFRPCs). These composites exhibit corrosion resistance comparable to traditional materials such as glass fiber and carbon fiber composites. Additionally, they possess features like low density, high strength, degradability, and environmental friendliness, with low production costs and strong industrial applicability. This paper reviews the accomplishments in BFRPCs and provides an overview of the production processes for BFRPCs. Furthermore, it summarizes the research status of mechanical properties, moisture absorption characteristics, interface performance, and flame retardancy of these composites. The current issues with BFRPCs were analyzed. Finally, the paper explores future research directions and potential applications of BFRPCs.Highlights The performance studies on BFRPCs are comprehensively presented. Composite processing of BFPRCs is reviewed. Pros and cons of various types of BFRPCs are analyzed. Overview of the applications of BFRPCs in various domains is presented. Future trends and challenges of BFRPCs are introduced.

Additive manufacturing and microstructure effects on thermal and mechanical properties of ply-hybrid carbon and glass fiber composites

The fiber hybridization in high-strength composites is one of the most researched strategies to enhance their limited toughness. In this work, hybrid composites at laminate level by stacking together plies of carbon and glass fiber were prepared using fused filament fabrication (FFF) technique. The large void content and the poor adhesion between layers attributed to this technology are overcome by the addition of an optimized thermo-pressurized treatment. The analysis of post-processing temperature effects on the microstructural, thermal and interlaminar properties of additive manufactured hybrid composites, revealed a progressive porosity reduction preserving the dimensional accuracy. The enhancement of mechanical properties is due to different contributions that occurred during post-processing: (i) drying effect, which reduces the plasticization of the composites; (ii) improvement of interface adhesion due to the miscibility of polymers; and (iii) significant porosity reduction (below 1 %). This work opens a wider space of possibilities, since FFF allows more complex designs than traditional composite manufacturing, and additionally provides an approach to promote molecular diffusion at the interface, which is the most critical region of FFF parts.

Enhancing Mechanical Characteristics of PETG Carbon Fiber Composite through Various Shell Thickness in FDM Processing

The utilization of PETG (Polyethylene Terephthalate Glycol) carbon fiber composites in Fused Deposition Modelling (FDM) processes has gained significant attention due to their enhanced mechanical properties compared to traditional PETG filaments. This study focuses on investigating the impact of varying shell thickness on the mechanical characteristics of PETG carbon fiber composites fabricated through FDM. The objective is to optimize the shell thickness to achieve superior mechanical performance while maintaining printing efficiency. A series of PETG carbon fiber composites with different shell thicknesses were manufactured using an FDM 3D printer. Mechanical tests, including tensile strength, flexural strength, and impact resistance, were conducted to evaluate the performance of the fabricated specimens. Additionally, micro-structural analysis was performed to understand the influence of shell thickness on the interfacial bonding between PETG matrix and carbon fibers. Preliminary results indicate that increasing shell thickness positively affects the mechanical properties of PETG carbon fiber composites. Tensile and flexural strength show a noticeable improvement with an increase in shell thickness, attributed to enhanced interlayer adhesion and improved load-bearing.

Enhanced mechanical performance and damping behavior of CFRP composites through exfoliated MWCNT functionalization

In evaluating high-performance multiwall carbon nanotube (MWCNT) based carbon fiber composites, effective chemical functionalization of fillers for sufficient exfoliation and precise interface interactions with resin matrix are challenging to attain due to significant interlayer cohesive energy and inactive surfaces of composites. Herein, we demonstrate an effective way to produce carbon fiber-reinforced polymer (CFRP) composite with amended interfacial characteristics via incorporation of MWCNT through oxidation followed by silane functionalization with their exfoliation levels (0/48/60/72 h). The surface functional elements, morphological changes, elemental groups, quantitative information, and thermal degradation of silane functionalized MWCNTs were characterized by FESEM/HR-TEM, XRD, UV, and TG-DTA analysis, respectively. The influence of silane functionalized MWCNT reinforcement on CFRP's mechanical properties were examined using tensile, flexural, ILSS, and damping behavior was analyzed through impulse excitation technique (IET). The resulting silane-modified MWCNTs with 60 h oxidation (OAC-60) infused CFRP demonstrated significant enhancement in flexural strength (73.8%), tensile strength (58.2%), interlaminar shear strength (28.5%) compared to pure-CFRP.

PAN-based fiber-reinforced carbon-carbon composites for improved fire retardancy and thermal and electrical conductivities for harsh environments

Carbon-carbon (C-C) fiber composites are a new class of materials that are used in various industries due to their exceptional chemical, thermal and electrical conductivities properties. In this study, carbon-carbon fiber composites were manufactured where polyacrylonitrile (PAN) powder was dissolved in dimethylformamide (DMF) solution, and carbon fibers with desired concentrations (20–80 wt%) were immersed into this solution as reinforcement through evaporation and solidification. The PAN-fiber systems were then stabilized at 250–270°C for 120 min in the air and subsequently carbonized at 650, 750, and 850°C for 60 min in the presence of argon gas to obtain the desired C-C fiber composites. Thermogravimetric analysis (TGA) results showed that the carbonized samples had a small weight loss of 2.5%, while actual and oxidized samples had more weight loss. Moreover, the carbonized sample surface was more hydrophobic compared to other samples due to the carbon presence and surface texture changes. Fourier-Transform Infrared (FTIR) spectroscopy peaks showed the presence of different functional groups of PAN before oxidation and carbonization, but those peaks disappeared after oxidation and carbonization. The developed carbon-carbon composite passed the UL94 vertical flame retardancy testing with a V-0 rating. Surface smoothness, proper matrix and reinforcements bonding were confirmed by scanning electron microscopy (SEM) results and the manufactured composite properties changes were validated by the confocal microscopy images. The carbon-carbon fiber composite achieved an electrical conductivity value up to 4.75 × 103 S/m after the carbonization process. The excellent thermal, chemical, and electrical properties of these composites can be useful for numerous industrial applications in different extreme environments.