Current reports on carbon fiber (CF) modification mainly emphasize its interfacial improvement, yet often sacrifice the strength of CF itself. The comprehensive mechanical improvement of composite requires deeper understanding about the reinforcement. In this work, a process was established based on one-step growth of carbon nanofilament on continuous CF at ultra-low temperature. Both single-factor and orthogonal experiments were executed, while the conversion of catalyst, the generation of carbon nanostructures, and the damage and repair of CF were comprehensively studied. When using Cu5Ni5 catalyst, 0.4 L/min hydrogen, 0.3 L/min acetylene, and 350 ℃ chemical vapor deposition for 5 min, the obtained carbon nanofilament–carbon fiber reached 5.26 GPa tensile and 113 MPa interfacial shear strength. The interlaminar shear strength of its epoxy-based composite was also recorded as 134 MPa. Consequently, this composite far exceeded that of pristine CF in not only tensile strength and modulus by 78.4 % and 55.3 %, but also flexural strength and modulus by 216.0 % and 99.2 %, respectively. This work has fully unleashed the impressive reinforcing potential of CF in composite by extending the theory. Finally, it also contributes to energy conservation and cost reduction for mass production.
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