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Advanced Structural Carbon Products: Fibers, Foams & Composites


Published:September2011
No.Of Pages:239
Price:US $ 4850




Report Summary

* Coverage of the technological, economic, and business conditions in the
structural carbons industry
* Analyses of market trends, with data from 2010, estimates for 2011, and
projections of compound annual growth rates (CAGRs) through 2016
* Explanations of the types of materials in the industry, including carbon
fibers, carbon foams, monolithic structural graphite, and carbon-reinforced
carbon composites
* A focus on the U.S. market, but analysis and forecasts also are provided
for global markets
* Discussion of international aspects of the industry with respect to all the
geographic regions and types of material
* Comprehensive company profiles of major manufacturers.

INTRODUCTION

STUDY GOALS AND OBJECTIVES

The overall goal of this study is to provide a comprehensive understanding of
advances in structural carbon materials manufacturing, their commercial
applications, and worldwide markets. For the purposes of this report, these
materials are defined to include all types of carbon fibers, carbon foams,
monolithic structural graphite, carbon-reinforced carbon composites, and
certain graphene materials.

Specific objectives of the study include describing the major types of
structural carbon materials, including key physical and chemical properties,
raw materials, and manufacturing processes. Commercial applications in
which these materials are used will be discussed.

Present consumption and future demand for these materials will be
evaluated for the United States and other major geographical markets.
Trends in technology will be analyzed and forecasted. The impact of
governmental regulations will be assessed. The dynamics of the structural
carbons industry will be outlined along with profiles of key manufacturers.

REASONS FOR DOING THE STUDY

This study is an update of an earlier BCC report that was published in 2009.
The structural carbon materials industry and markets have continued to
develop in the two and a half years since the previous edition was published.

The structural carbon materials industry serves mature markets such as
defense and aerospace, with a wide variety of products satisfying the
requirements of well-established applications. However, continuous technical
innovations and efforts to make structural carbon technologies available for
new applications (at affordable prices) are leading to the development of
new markets.

Corporations in the structural carbons industry need understand the
significance of these trends to manage their enterprise and resources
effectively. Users of structural carbons must also understand the effect of
these changes in order to select the most cost-effective option among newly
available products and technologies prior to committing significant capital
resources.

Browse All Chemicals Market Research Reports

INTENDED AUDIENCE

Over the next half-decade significant change will take place in global
structural carbon products and applications. Technological advances in
improving structure-property relationships of advanced carbon materials and
breakthroughs in the manufacturing processes—resulting in lower costs—will
lead to novel applications. This study analyzes the driving forces that will
shape the structural carbons industry over next few years.

Consequently, the information presented in this study should be useful to:

Members of the financial community who must understand, assess, and rate
the effect of forthcoming changes in the structural carbons industry based
upon the financial performance of the companies active in this market
segment Chief executive officers who must effectively manage the assets of
their company so as to benefit from forthcoming changes in the structural
carbons industry Directors of planning who must incorporate anticipated
changes in the structural carbons industry into corporate planning
documents Directors of manufacturing who must implement new structural
carbons technology and products into their operations Directors of
engineering, research, and development who must incorporate the latest in
structural carbons technology and products into their designs and projects
Decision makers at major structural carbons consumers, such as the
Department of Defense contractors involved in aerospace and aircraft
manufacturing Executives at companies engaged in developing competitive
materials and technologies such as other reinforcement fibers like Kevlar or
composites manufactured with other matrix materials such as ceramics or
metal.

SCOPE OF REPORT

The report Advanced Structural Carbon Products: Fibers, Foams &
Composites covers technological, economic, and business conditions in the
structural carbons industry. Although this report is primarily a study of the
U.S. market, analysis and forecasts are also provided for global markets.
Included in this report are descriptions of market forces relevant to the
structural carbons industry and their areas of application.

The U.S. market is presented by type of structural carbons along with
growth forecasts through 2016. The driving forces in the industry and the
structure of the industry are also examined.

International aspects of the structural carbons industry are discussed with
respect to all the geographic regions and type of structural carbon material.
Lastly, brief profiles of the major manufacturers are presented.

METHODOLOGY AND INFORMATION SOURCES

The report’s findings and conclusions are based on information gathered
from a wide range of primary and secondary sources, including vendors,
users, and engineering and consulting firms. Interview data were combined
with information gathered through an extensive review of secondary sources
such as trade publications, trade associations, company literature, and
online databases to produce the projections contained in this report.

The base year for analysis and projection is 2010. With 2010 as a baseline,
market projections were developed for 2011 to 2016. These projections are
based on a combination of a consensus among industry sources, combined
with BCC’s understanding of the key market drivers and their impact from a
historical and analytical perspective.
ANALYST'S CREDENTIALS

This report is an update of an earlier report prepared by Dr. Ravindra
Deshpande. Dr. Deshpande has over 13 years of research and product
development experience in the manufacturing industry. He holds a Ph.D. in
Chemical Engineering along with an MBA. Dr. Deshpande has published
several papers in peer-reviewed journals and is lead inventor on several
patents.

The analyst responsible for updating the report is Andrew McWilliams, a
partner in the Boston-based international technology and marketing
consulting firm, 43rd Parallel, LLC. Mr. McWilliams is the author of numerous
other BCC studies of advanced materials and their applications, including
Materials and Devices for High-Performance Sports Products (AVM053A);
Advanced Materials and Technologies for Public Works Infrastructure
Projects (AVM062A); Nanocomposites, Nanoparticles, Nanoclays, and
Nanotubes (NAN021D); Lightweight Materials in Transportation(AVM056B);
Advanced Materials and Devices for Renewable Energy (EGY053B); The
Market for Thermal Management Technologies (SMC024G); and Graphene:
Technologies, Applications, and Markets (AVM075A).

Table Of Contents

CHAPTER ONE: INTRODUCTION
STUDY GOALS AND OBJECTIVES
REASONS FOR DOING THE STUDY
INTENDED AUDIENCE
SCOPE OF REPORT
METHODOLOGY AND INFORMATION SOURCES
ANALYST’S CREDENTIALS
RELATED BCC REPORTS
BCC ONLINE SERVICES
DISCLAIMER

CHAPTER TWO: SUMMARY
SUMMARY TABLE U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY
USER SEGMENT, THROUGH 2016 ($ MILLIONS)
SUMMARY FIGURE U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY
USER SEGMENT, 2010-2016 ($ MILLIONS)

CHAPTER THREE: INDUSTRY AND MARKETS OVERVIEW
UNITED STATES MARKET
FIGURE 1 UNITED STATES MARKET FOR ADVANCED STRUCTURAL CARBONS
BY TYPE, 2010 (TOTAL = $1.96 BILLION)
FIGURE 2 PROJECTED GROWTH RATE IN U.S. STRUCTURAL CARBONS
MARKET, 2011-2016 (CAGR%)
GLOBAL MARKETS
FIGURE 3 GLOBAL ADVANCED STRUCTURAL CARBONS MARKET BY TYPE,
2010 (TOTAL = $4.9 BILLION) (%)
FIGURE 4 GLOBAL STRUCTURAL CARBONS CONSUMPTION BY WORLD
REGION, 2010 (%)
RESEARCH AND TECHNOLOGY TRENDS
INDUSTRY STRUCTURE

CHAPTER FOUR: TECHNICAL OVERVIEW
INTRODUCTION TO ADVANCED STRUCTURAL CARBON PRODUCTS
IMPORTANCE OF MECHANICAL PROPERTIES
CARBON FIBERS
RAW MATERIALS FOR CARBON FIBERS
Types of Raw Materials
Rayon
PAN
Pitch
Raw Material and Fiber Properties Relationship
TABLE 1 DEPENDENCE OF CARBON FIBER PROPERTIES ON RAW MATERIALS
PAN-Based Fibers
Pitch-Based Fibers
Rayon-Based Fibers
MANUFACTURING PROCESS
PAN Carbon Fiber Process
Precursor Preparation
Polymerization
Spinning and Stretching
Stabilization
Carbonization
Surface Treatment
Sizing
Pitch Carbon Fiber Process
Precursor Preparation
Pitch Refining
Isotropic Pitch
Anisotropic or Mesophase Pitch
Thermal Modifications
Solvent Modification
Chemical Modification
Catalytic Modification
Melt Spinning
Stabilization
Carbonization
Graphitization
Viscose Rayon Carbon Fiber Process
Vapor-Grown Carbon Fibers
CHEMICAL AND PHYSICAL PROPERTIES
Structural Property Relationship for Carbon Fibers
Density
Modulus
Impact of Fiber Diameter
Electrical and Thermal Conductivity
Thermal Stability
TABLE 2 STRUCTURAL PROPERTY RELATIONSHIPS FOR CARBON FIBERS
DERIVED FROM VARIOUS PRECURSORS
CARBON FIBER PRODUCT FORMS
Carbon Fiber Product Grades
PAN-Derived Fibers
Pitch-Derived Fibers
Tow
Carbon Fiber Cloth
Prepreg
RECENT DEVELOPMENTS IN MANUFACTURING TECHNOLOGIES
Microwave-Assisted Plasma (MAP) Process
Low Cost Carbon Fiber from Renewable Resources
Low Cost Carbon Fiber from Polyolefin
Ultraviolet (UV) Stabilization of PAN-based Carbon
Fibers
Rapid Oxidation Step
Surface Modification of Carbon Fibers
Carbon Nanotube Reinforcement of Carbon Fibers
Continuous Carbon Fiber Produced from Carbon
Nanotubes
Carbon Nanofibers
Activated Carbon Fibers
MANUFACTURERS OF PAN-BASED FIBERS
Small-Tow Manufacturers
Cytec’s Carbon Fiber Production
Hexcel’s Carbon Fiber Production
Other Manufacturers
Large-Tow Carbon Fiber Manufacturers
Zoltek Companies, Inc.
Toho Tenax America
SGL Carbon Fibers and Composites
MANUFACTURERS OF PITCH-BASED CARBON FIBERS
CARBON FIBER COMPOSITES
Carbon-Fiber-Reinforced Polymer Composites (CFRP)
Manufacturing Processes
Molding Processes
Roving Processes
Mechanical Properties
TABLE 3 TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBERREINFORCED
POLYMER COMPOSITES
Carbon-Fiber-Reinforced Metal Composites (CFRM)
Manufacturing Processes
Mechanical Properties
TABLE 4 TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBERREINFORCED
METAL COMPOSITES
CARBON FOAMS
 RAW MATERIALS
TABLE 5 PROPERTIES OF PITCH RAW MATERIALS USED FOR CARBON FOAM
MANUFACTURING (°C /%)
MANUFACTURING PROCESS
Flash Process
Blowing Gases
Sol-Gel Process
CHEMICAL AND PHYSICAL PROPERTIES
TABLE 6 PHYSICAL PROPERTIES OF PITCH-DERIVED CARBON FOAMS
RECENT TRENDS IN CARBON FOAM TECHNOLOGY
Uniform-Density-Gradient Carbon Foams
Reinforced Carbon Foams
High-Thermal-Conductivity Carbon Foams
Magnetic Carbon Nanofoams
Low-Cost Carbon Foams
MANUFACTURERS OF CARBON FOAMS
Honeywell
POCO Graphite
Touchstone Research Laboratory
University of Dayton and Wright U.S. Air Force
Laboratory Alliance
STRUCTURAL GRAPHITE
TYPES AND MANUFACTURING OF GRAPHITE MATERIALS
Natural Graphite
Synthetic Graphite
FIGURE 5 SCHEMATIC OF MANUFACTURING PROCESS FOR SYNTHETIC
GRAPHITE
PHYSICAL AND CHEMICAL PROPERTIES
Crystalline Structure
FIGURE 6 CRYSTALLINE STRUCTURE OF GRAPHITE
Lubrication
Thermal Properties
Oxidation Resistance
Chemical Resistance
Mechanical Properties
TABLE 7 PHYSICAL PROPERTIES OF GRAPHITE MATERIALS
EMERGING TECHNOLOGIES
Porous Graphite
High-Temperature Graphite Process
Expandable Graphite
CARBON-CARBON STRUCTURAL COMPOSITES
TYPES OF STRUCTURAL COMPOSITE MATERIALS
Types of Structural Composite … (Continued)
CARBON-REINFORCED CARBON MATRIX COMPOSITES
TABLE 8 ADVANTAGES AND DISADVANTAGES OF CARBONCARBON
COMPOSITES
DIFFERENCES BETWEEN GRAPHITE AND CARBONCARBON COMPOSITES
TABLE 9 COMPARISON OF PHYSICAL PROPERTIES OF GRAPHITE AND
CARBON-CARBON COMPOSITES
CHEMICAL AND PHYSICAL PROPERTIES
REINFORCEMENT ARCHITECTURE
One-Dimensional Architecture
Two-Dimensional Architecture
Three-Dimensional Architecture
Multidimensional Architecture
Foam Reinforcement
MANUFACTURING PROCESSES
Infiltration of Matrix Phase
Raw Materials for Matrix Phase
Chemical Vapor Infiltration Process
Temperature Gradient Process
Isothermal Process
Pressure Gradient Process
Liquid Pitch Infiltration Process
Raw Materials
Manufacturing Process
Low-Pressure Process
High-Pressure Process
Thermosetting Resins as Matrix Precursors
FIGURE 7 REPRESENTATION OF CARBON-CARBON COMPOSITE
MANUFACTURING PROCESS
STRUCTURE AND PROPERTY RELATIONSHIPS
Microstructural Features
TABLE 10 COMPARISON OF CARBON-CARBON COMPOSITES PROPERTIES
MANUFACTURED BY VARIOUS PROCESSING ROUTES
Mechanical Properties
Young’s Modulus
Strength
Fatigue and Creep
Effect of Temperature on Mechanical Properties
Effect of Oxidation on Mechanical Properties
Thermal Properties
Friction and Wear Properties
OXIDATION PROTECTION FOR CARBON-CARBON COMPOSITES
TECHNOLOGY TRENDS
Oxidation Inhibition of Carbon-Carbon Composites
Rapid-Oxidative-Stabilization Composites
High-Purity Carbon-Carbon Composites
High-Density Carbon-Carbon Composites
Elimination of Need for Oxidative Stabilization of Carbon
Composites
High Thermal Conductivity Carbon-Carbon Composites
Sequential Deposit of Carbon Matrix and In Situ
Polymerization
Rapid Processing of Carbon-Carbon Composites
Protective Coatings
Detecting Flaws in the Carbon Composites
Carbon-Carbon Composites from Densified Carbon Foam
Low-Temperature Densification Using Sugar Pyrolysis
Thick Three Dimensional Preforms for Carbon-Carbon
Composites
High-Strength Composites Developed by NASA and JPL
Carbon-Carbon Frictional Composites for Elevator Brakes
Joining Carbon-Carbon Composites
Nanotubes in Carbon-Carbon Composites
GRAPHENE
PROPERTIES
RAW MATERIALS AND PRODUCTION PROCESSES
Established Technologies
“Scotch Tape” Method
Epitaxial Method
Graphite Oxide Reduction Method
Experimental Approaches
Metal-Carbon Melt Method
Pyrolysis of Sodium Ethoxide Method
Production of Graphene from Carbon Nanotubes
Production of Graphene from Table Sugar
Dissolving Graphite in Chlorosulphonic Acid
“Molecular Wedge” Method
Radio Frequency Catalytic Chemical Vapor
Deposition
COMPANIES DEVELOPING GRAPHENE STRUCTURAL MATERIALS
General Motors
Graftech
Graphenea

CHAPTER FIVE: COMMERCIAL APPLICATIONS
CARBON FIBER APPLICATIONS
TABLE 11 PROPERTIES AND APPLICATIONS OF CARBON FIBERS
AEROSPACE AND DEFENSE INDUSTRY
Space Vehicles
Unmanned Spacecraft
Manned Spacecraft
Launch Vehicles
Total U.S. Space Market
TABLE 12 U.S. SPACE VEHICLE MARKET, THROUGH 2016 ($ BILLIONS)
Defense Market
Defense Aviation
TABLE 13 SALES OF U.S. MILITARY AIRCRAFT, THROUGH 2016 ($
BILLIONS)
Missiles
TABLE 14 U.S. MISSILE SHIPMENTS, THROUGH 2016 ($ BILLIONS)
Commercial Aviation
Large Aircraft
TABLE 15 DELIVERIES OF LARGE U.S.-MADE COMMERCIAL AIRCRAFT BY
TYPE, THROUGH 2016 (UNITS)
Carbon Fiber Consumption
TABLE 16 CONSUMPTION OF CARBON-FIBER-REINFORCED COMPOSITES IN
U.S.-MADE BOEING COMMERCIAL AIRLINERS GROUND TRANSPORT
Trains and Locomotives
Motor Vehicles
INDUSTRIAL APPLICATIONS
WIND ENERGY
TABLE 17 TRENDS IN U.S. WIND POWER CAPACITY, THROUGH 2016 (MW)
TABLE 18 U.S. MARKET FOR WIND TURBINE ROTOR BLADES, THROUGH
2016 ($ MILLIONS)
SPORTING GOODS
Golf Clubs
TABLE 19 U.S. MARKET FOR CARBON FIBER COMPOSITE GOLF CLUBS,
THROUGH 2016 ($ MILLIONS)
Bicycles
Recreational Boating
Sport Fishing
TABLE 20 U.S. SHIPMENTS OF CARBON FIBER FISHING RODS, THROUGH-
2016 ($ MILLIONS)
Other Applications
INFRASTRUCTURE
New Bridge Construction
Bridge Repairs
Column Repairs
Seismic Retrofit
High-Strength Building Construction
Engineered Wood Products
Tension Leg Platform Tethers from Carbon Composites
Smarter and Stronger Concrete
New Manufacturing Process for Reinforced Concrete
THERMAL MANAGEMENT
Conductive Plastics
Carbon Nanotubes
OTHER APPLICATIONS
Biocompatibility Applications
Electrochemical Applications
Static Dissipation Applications
Lightweight Telescope Mirrors
Hollow Carbon Fibers in Molecular Sieve Applications
Emerging Energy Systems
Turtle Airship Uses Carbon Composites
CARBON FIBERS MARKET GROWTH
TABLE 21 U.S. CONSUMPTION OF CARBON FIBERS, THROUGH 2016
(THOUSAND LBS.)
FIGURE 8 U.S. CARBON FIBER CONSUMPTION BY INDUSTRY SEGMENT,
2010 VS. 2016 (%)
TABLE 22 U.S. MARKET FOR CARBON FIBERS, THROUGH 2016 ($ MILLIONS)
FIGURE 9 U.S. CARBON FIBER MARKET BY INDUSTRY, 2010 VS. 2016 (% OF
TOTAL MARKET VALUE)
CARBON FOAM APPLICATIONS
AEROSPACE AND DEFENSE
Radiators
Fire Barrier Applications
Brakes
GROUND TRANSPORTATION
Automotive Radiators
Shock Absorbers and Bumpers
Other Automotive Applications
INDUSTRIAL APPLICATIONS
Sandwich Panels
Electronic Heat Sinks
Phase-Change Materials
ENERGY
Batteries
Fuel Cells
Radiators
Humidifiers
Bipolar Plates
Supercapacitors
Nuclear Reactor Cores
Gas Storage
OTHER APPLICATIONS
Air Filtration Devices
Personal Cooling Devices
Health Care Applications
Acoustic Absorber Materials
CARBON FOAM MARKET GROWTH
TABLE 23 U.S. CONSUMPTION OF CARBON FOAM, THROUGH 2016
(THOUSAND LBS.)
FIGURE 10 U.S. CONSUMPTION OF CARBON FOAM BY INDUSTRY SECTOR,
2010 VS. 2016 (% TOTAL CONSUMPTION)
TABLE 24 U.S. CARBON FOAM MARKET GROWTH BY INDUSTRY, THROUGH
2016 ($ MILLIONS)
STRUCTURAL GRAPHITE APPLICATONS
AEROSPACE AND DEFENSE
GROUND TRANSPORTATION
INDUSTRIAL APPLICATIONS
Chemical Industry Applications
Mechanical Applications
Bearings and Brushes
TABLE 25 TYPICAL APPLICATIONS FOR GRAPHITE BEARINGS
Seals
Friction Materials
Metallurgy
Glassware
Refractory Applications
ENERGY
Fuel Cells
Nuclear Industry Applications
Hydrogen Storage
STRUCTURAL GRAPHITE MARKET GROWTH
TABLE 26 U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY,
THROUGH 2016 (THOUSAND LBS.)
FIGURE 11 U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY
SEGMENT, 2010 VS. 2016 (% OF TOTAL LBS. CONSUMED)
TABLE 27 U.S. MARKET FOR STRUCTURAL GRAPHITE BY INDUSTRY
SEGMENT, THROUGH 2016 ($ MILLIONS)
CARBON-CARBON COMPOSITES APPLICATIONS
AEROSPACE
Space Vehicle Thermal Protection Systems
Space Vehicle Thermal … (Continued)
Aircraft Engine Components
Aircraft Brakes
Other Aerospace Applications
GROUND TRANSPORTATION
INDUSTRIAL APPLICATIONS
Refractory Structures
Glass Industry
Corrosion-Resistant Structures
Thermal-Management Solutions
ENERGY
OTHER APPLICATIONS
Biocompatible Structures
CARBON-CARBON COMPOSITES MARKET GROWTH
TABLE 28 U.S. CONSUMPTION OF CARBON-CARBON COMPOSITES BY
INDUSTRY, THROUGH 2016 (THOUSAND LBS.)
FIGURE 12 U.S. CARBON-CARBON COMPOSITES CONSUMPTION BY
INDUSTRY TYPE, 2010 VS. 2016 (%)
TABLE 29 U.S. MARKET FOR CARBON-CARBON COMPOSITES BY INDUSTRY,
THROUGH 2016 ($ MILLIONS)
STRUCTURAL GRAPHENE APPLICATIONS
INDUSTRIAL APPLICATIONS
Thermal Management Solutions
ENERGY
Hydrogen Storage
Oxidized Graphene Sheets
Other Developments
MARKET GROWTH
TABLE 30 U.S. CONSUMPTION OF STRUCTURAL GRAPHENE BY INDUSTRY,
THROUGH 2016 (THOUSAND LBS.)
MARKETS FOR ADVANCED STRUCTURAL CARBONS
TABLE 31 U.S. CONSUMPTION OF STRUCTURAL CARBONS BY TYPE OF
MATERIAL, THROUGH 2016 (THOUSAND LBS.)
FIGURE 13 STRUCTURAL CARBON PRODUCT SHARES OF TOTAL
U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016 (%)
TABLE 32 U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE OF
MATERIAL, THROUGH 2016 ($ MILLIONS)
FIGURE 14 STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S.
STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016 (%)

CHAPTER SIX: INDUSTRY STRUCTURE AND MARKET DRIVERS
MARKETS FOR STRUCTURAL CARBON MATERIALS
MANUFACTURERS OF STRUCTURAL CARBONS
Carbon Fibers
FIGURE 15 LEADING U.S. CARBON FIBER SUPPLIERS’ SHARE OF TOTAL U.S.
CONSUMPTION, 2010 (%)
Carbon Foams
FIGURE 16 LEADING U.S. CARBON FOAM SUPPLIERS’ SHARE OF TOTAL U.S.
CONSUMPTION, 2010 (%)
Structural Graphite
FIGURE 17 LEADING U.S. STRUCTURAL GRAPHITE SUPPLIERS’ SHARE OF
TOTAL U.S. CONSUMPTION, 2010 (%)
Carbon-Carbon Composites
FIGURE 18 LEADING U.S. CARBON-CARBON COMPOSITE SUPPLIERS’ SHARE
OF TOTAL U.S. CONSUMPTION, 2010 (%)
SWOT ANALYSIS OF STRUCTURAL CARBONS INDUSTRY
Strengths
Weaknesses
Opportunities
Threats
MARKET DRIVERS
ECONOMIC FACTORS
LEGAL AND REGULATORY FACTORS
Price-Fixing in the Carbon Fibers and Composites
Industry
Price-Fixing in the Graphite Industry
INDUSTRY FACTORS
Capacity Trends
Price Trends
New Technologies and New Entrants to the Business
Influence and Leverage
Buyers’ Influence and Leverage
Suppliers’ Influence and Leverage
Substitute Products
COMPETITIVE STRATEGIES IN THE STRUCTURAL CARBONS INDUSTRY
NEW BUSINESS DEVELOPMENT
COMPETITIVE PRICING
VERTICAL INTEGRATION
GLOBAL STRATEGIC ALLIANCES
SGL - BMW Joint Venture
SGL-Mitsubishi Joint Venture
Mitsubishi Rayon’s Expansion Plans and Alliance with
SGL
Zoltek-DeWind Supply Agreement
Zoltek and Chomarat
GrafTech and Ballard Power Systems
Zoltek and Leggett & Pratt
Hexcel and Airbus Industries
Hexcel and Boeing

CHAPTER SEVEN: INTELLECTUAL PROPERTY AND TECHNOLOGY
TRENDS ANALYSIS
INTELLECTUAL PROPERTY ANALYSIS
TABLE 33 PATENTS ISSUED TO LEADING MANUFACTURES IN STRUCTURAL
CARBON MATERIALS TECHNOLOGY, 1996-2010
TECHNOLOGY DEVELOPMENT TRENDS

CHAPTER EIGHT: INTERNATIONAL ASPECTS OF STRUCTURAL
CARBONS BUSINESS
TABLE 34 GLOBAL MARKET FOR STRUCTURAL CARBON BY TYPE OF
MATERIAL, 2010 ($ MILLIONS)
FIGURE 19 COMPARISON OF ADVANCED STRUCTURAL CARBONS
CONSUMPTION IN WORLD REGIONS BY TYPE OF MATERIAL, 2010 (%)
TABLE 35 GLOBAL STRUCTURAL CARBONS MARKET GROWTH BY REGION,
THROUGH 2016 ($ MILLIONS)

CHAPTER NINE: PROFILE OF MANUFACTURERS
U.S. MANUFACTURERS
AAR COMPOSITES
ADVANCED CARBON TECHNOLOGIES, INC.
ADVANCED COMPOSITES, INC.
AEROSPACE COMPOSITE PRODUCTS CO.
ALBANY ENGINEERED COMPOSITES
APPLIED SCIENCES, INC.
ASBURY CARBONS
BOEING CO.
BTG COMPOSITES, INC.
CARBON-CARBON ADVANCED TECHNOLOGIES, INC.
CHOMARAT NORTH AMERICA
CYTEC CORP.
FIBER MATERIALS, INC.
FIBERSPAR CORP.
FORESEE ORTHOPEDIC PRODUCTS
GENERAL MOTORS CO.
GOODRICH CORP.
GRAFIL, INC.
GRAPHITE METALLIZING CORP.
GRAPHITE SALES, INC.
GRAFTECH INTERNATIONAL, LTD.
GRAPHTEK, LLC
HELWIG CARBON PRODUCTS, INC.
HEXCEL CORP.
HITCO CARBON COMPOSITES, INC.
HONEYWELL INTERNATIONAL, INC.
KIRKWOOD INDUSTRIES, INC.
MER CORP.
MINERALS TECHNOLOGY, INC.
MORGAN ADVANCED MATERIALS AND TECHNOLOGY
PLANSEE THERMAL MANAGEMENT SOLUTIONS
POCO GRAPHITE, INC.
ROC CARBON CO.
SCHUNK GRAPHITE TECHNOLOGY, LLC
SGL CARBON GROUP
SHAMOKIN FILLER CO.
SIOUX MANUFACTURING CORP.
SPAULDING COMPOSITES CO.
SPENCER COMPOSITE CORP.
ST. MARYS CARBON CO.
SUPERIOR GRAPHITE CO.
TOHO TENAX AMERICA, INC.
TORAY CARBON FIBERS AMERICA, INC.
TOUCHSTONE RESEARCH LABORATORY, LTD.
TPI COMPOSITES, INC.
ULTRAMET, INC.
V2 COMPOSITE, INC.
YLA, INC.
ZOLTEK CORP.
INTERNATIONAL MANUFACTURERS
ANAORI CARBON CO., LTD.
ATLAS COMPOSITES, LTD.
C2 COMPOSITES
GRAPHENEA
GRUPO ANTOLIN INGENIERIA S.A
MERSEN GROUP
MITSUBISHI CHEMICAL CORP.
MITSUBISHI RAYON CO., LTD.
NIPPON GRAPHITE FIBER CORP
NIPPON SHEET GLASS CO., LTD.
TAIWAN CARBON TECHNOLOGY CO., LTD.
TOHO TENAX CO., LTD.
TORAY INDUSTRIES, INC.

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Advanced structural carbon products fibers, foams & composites

  • 1. Advanced Structural Carbon Products: Fibers, Foams & Composites Published:September2011 No.Of Pages:239 Price:US $ 4850 Report Summary * Coverage of the technological, economic, and business conditions in the structural carbons industry * Analyses of market trends, with data from 2010, estimates for 2011, and projections of compound annual growth rates (CAGRs) through 2016 * Explanations of the types of materials in the industry, including carbon fibers, carbon foams, monolithic structural graphite, and carbon-reinforced carbon composites * A focus on the U.S. market, but analysis and forecasts also are provided for global markets * Discussion of international aspects of the industry with respect to all the geographic regions and types of material * Comprehensive company profiles of major manufacturers. INTRODUCTION STUDY GOALS AND OBJECTIVES The overall goal of this study is to provide a comprehensive understanding of advances in structural carbon materials manufacturing, their commercial applications, and worldwide markets. For the purposes of this report, these materials are defined to include all types of carbon fibers, carbon foams, monolithic structural graphite, carbon-reinforced carbon composites, and certain graphene materials. Specific objectives of the study include describing the major types of structural carbon materials, including key physical and chemical properties, raw materials, and manufacturing processes. Commercial applications in which these materials are used will be discussed. Present consumption and future demand for these materials will be evaluated for the United States and other major geographical markets.
  • 2. Trends in technology will be analyzed and forecasted. The impact of governmental regulations will be assessed. The dynamics of the structural carbons industry will be outlined along with profiles of key manufacturers. REASONS FOR DOING THE STUDY This study is an update of an earlier BCC report that was published in 2009. The structural carbon materials industry and markets have continued to develop in the two and a half years since the previous edition was published. The structural carbon materials industry serves mature markets such as defense and aerospace, with a wide variety of products satisfying the requirements of well-established applications. However, continuous technical innovations and efforts to make structural carbon technologies available for new applications (at affordable prices) are leading to the development of new markets. Corporations in the structural carbons industry need understand the significance of these trends to manage their enterprise and resources effectively. Users of structural carbons must also understand the effect of these changes in order to select the most cost-effective option among newly available products and technologies prior to committing significant capital resources. Browse All Chemicals Market Research Reports INTENDED AUDIENCE Over the next half-decade significant change will take place in global structural carbon products and applications. Technological advances in improving structure-property relationships of advanced carbon materials and breakthroughs in the manufacturing processes—resulting in lower costs—will lead to novel applications. This study analyzes the driving forces that will shape the structural carbons industry over next few years. Consequently, the information presented in this study should be useful to: Members of the financial community who must understand, assess, and rate the effect of forthcoming changes in the structural carbons industry based upon the financial performance of the companies active in this market segment Chief executive officers who must effectively manage the assets of their company so as to benefit from forthcoming changes in the structural carbons industry Directors of planning who must incorporate anticipated
  • 3. changes in the structural carbons industry into corporate planning documents Directors of manufacturing who must implement new structural carbons technology and products into their operations Directors of engineering, research, and development who must incorporate the latest in structural carbons technology and products into their designs and projects Decision makers at major structural carbons consumers, such as the Department of Defense contractors involved in aerospace and aircraft manufacturing Executives at companies engaged in developing competitive materials and technologies such as other reinforcement fibers like Kevlar or composites manufactured with other matrix materials such as ceramics or metal. SCOPE OF REPORT The report Advanced Structural Carbon Products: Fibers, Foams & Composites covers technological, economic, and business conditions in the structural carbons industry. Although this report is primarily a study of the U.S. market, analysis and forecasts are also provided for global markets. Included in this report are descriptions of market forces relevant to the structural carbons industry and their areas of application. The U.S. market is presented by type of structural carbons along with growth forecasts through 2016. The driving forces in the industry and the structure of the industry are also examined. International aspects of the structural carbons industry are discussed with respect to all the geographic regions and type of structural carbon material. Lastly, brief profiles of the major manufacturers are presented. METHODOLOGY AND INFORMATION SOURCES The report’s findings and conclusions are based on information gathered from a wide range of primary and secondary sources, including vendors, users, and engineering and consulting firms. Interview data were combined with information gathered through an extensive review of secondary sources such as trade publications, trade associations, company literature, and online databases to produce the projections contained in this report. The base year for analysis and projection is 2010. With 2010 as a baseline, market projections were developed for 2011 to 2016. These projections are based on a combination of a consensus among industry sources, combined with BCC’s understanding of the key market drivers and their impact from a historical and analytical perspective.
  • 4. ANALYST'S CREDENTIALS This report is an update of an earlier report prepared by Dr. Ravindra Deshpande. Dr. Deshpande has over 13 years of research and product development experience in the manufacturing industry. He holds a Ph.D. in Chemical Engineering along with an MBA. Dr. Deshpande has published several papers in peer-reviewed journals and is lead inventor on several patents. The analyst responsible for updating the report is Andrew McWilliams, a partner in the Boston-based international technology and marketing consulting firm, 43rd Parallel, LLC. Mr. McWilliams is the author of numerous other BCC studies of advanced materials and their applications, including Materials and Devices for High-Performance Sports Products (AVM053A); Advanced Materials and Technologies for Public Works Infrastructure Projects (AVM062A); Nanocomposites, Nanoparticles, Nanoclays, and Nanotubes (NAN021D); Lightweight Materials in Transportation(AVM056B); Advanced Materials and Devices for Renewable Energy (EGY053B); The Market for Thermal Management Technologies (SMC024G); and Graphene: Technologies, Applications, and Markets (AVM075A). Table Of Contents CHAPTER ONE: INTRODUCTION STUDY GOALS AND OBJECTIVES REASONS FOR DOING THE STUDY INTENDED AUDIENCE SCOPE OF REPORT METHODOLOGY AND INFORMATION SOURCES ANALYST’S CREDENTIALS RELATED BCC REPORTS BCC ONLINE SERVICES DISCLAIMER CHAPTER TWO: SUMMARY SUMMARY TABLE U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, THROUGH 2016 ($ MILLIONS) SUMMARY FIGURE U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY USER SEGMENT, 2010-2016 ($ MILLIONS) CHAPTER THREE: INDUSTRY AND MARKETS OVERVIEW UNITED STATES MARKET FIGURE 1 UNITED STATES MARKET FOR ADVANCED STRUCTURAL CARBONS
  • 5. BY TYPE, 2010 (TOTAL = $1.96 BILLION) FIGURE 2 PROJECTED GROWTH RATE IN U.S. STRUCTURAL CARBONS MARKET, 2011-2016 (CAGR%) GLOBAL MARKETS FIGURE 3 GLOBAL ADVANCED STRUCTURAL CARBONS MARKET BY TYPE, 2010 (TOTAL = $4.9 BILLION) (%) FIGURE 4 GLOBAL STRUCTURAL CARBONS CONSUMPTION BY WORLD REGION, 2010 (%) RESEARCH AND TECHNOLOGY TRENDS INDUSTRY STRUCTURE CHAPTER FOUR: TECHNICAL OVERVIEW INTRODUCTION TO ADVANCED STRUCTURAL CARBON PRODUCTS IMPORTANCE OF MECHANICAL PROPERTIES CARBON FIBERS RAW MATERIALS FOR CARBON FIBERS Types of Raw Materials Rayon PAN Pitch Raw Material and Fiber Properties Relationship TABLE 1 DEPENDENCE OF CARBON FIBER PROPERTIES ON RAW MATERIALS PAN-Based Fibers Pitch-Based Fibers Rayon-Based Fibers MANUFACTURING PROCESS PAN Carbon Fiber Process Precursor Preparation Polymerization Spinning and Stretching Stabilization Carbonization Surface Treatment Sizing Pitch Carbon Fiber Process Precursor Preparation Pitch Refining Isotropic Pitch Anisotropic or Mesophase Pitch Thermal Modifications Solvent Modification Chemical Modification Catalytic Modification
  • 6. Melt Spinning Stabilization Carbonization Graphitization Viscose Rayon Carbon Fiber Process Vapor-Grown Carbon Fibers CHEMICAL AND PHYSICAL PROPERTIES Structural Property Relationship for Carbon Fibers Density Modulus Impact of Fiber Diameter Electrical and Thermal Conductivity Thermal Stability TABLE 2 STRUCTURAL PROPERTY RELATIONSHIPS FOR CARBON FIBERS DERIVED FROM VARIOUS PRECURSORS CARBON FIBER PRODUCT FORMS Carbon Fiber Product Grades PAN-Derived Fibers Pitch-Derived Fibers Tow Carbon Fiber Cloth Prepreg RECENT DEVELOPMENTS IN MANUFACTURING TECHNOLOGIES Microwave-Assisted Plasma (MAP) Process Low Cost Carbon Fiber from Renewable Resources Low Cost Carbon Fiber from Polyolefin Ultraviolet (UV) Stabilization of PAN-based Carbon Fibers Rapid Oxidation Step Surface Modification of Carbon Fibers Carbon Nanotube Reinforcement of Carbon Fibers Continuous Carbon Fiber Produced from Carbon Nanotubes Carbon Nanofibers Activated Carbon Fibers MANUFACTURERS OF PAN-BASED FIBERS Small-Tow Manufacturers Cytec’s Carbon Fiber Production Hexcel’s Carbon Fiber Production Other Manufacturers Large-Tow Carbon Fiber Manufacturers Zoltek Companies, Inc. Toho Tenax America
  • 7. SGL Carbon Fibers and Composites MANUFACTURERS OF PITCH-BASED CARBON FIBERS CARBON FIBER COMPOSITES Carbon-Fiber-Reinforced Polymer Composites (CFRP) Manufacturing Processes Molding Processes Roving Processes Mechanical Properties TABLE 3 TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBERREINFORCED POLYMER COMPOSITES Carbon-Fiber-Reinforced Metal Composites (CFRM) Manufacturing Processes Mechanical Properties TABLE 4 TYPICAL MECHANICAL PROPERTIES OF CARBON-FIBERREINFORCED METAL COMPOSITES CARBON FOAMS RAW MATERIALS TABLE 5 PROPERTIES OF PITCH RAW MATERIALS USED FOR CARBON FOAM MANUFACTURING (°C /%) MANUFACTURING PROCESS Flash Process Blowing Gases Sol-Gel Process CHEMICAL AND PHYSICAL PROPERTIES TABLE 6 PHYSICAL PROPERTIES OF PITCH-DERIVED CARBON FOAMS RECENT TRENDS IN CARBON FOAM TECHNOLOGY Uniform-Density-Gradient Carbon Foams Reinforced Carbon Foams High-Thermal-Conductivity Carbon Foams Magnetic Carbon Nanofoams Low-Cost Carbon Foams MANUFACTURERS OF CARBON FOAMS Honeywell POCO Graphite Touchstone Research Laboratory University of Dayton and Wright U.S. Air Force Laboratory Alliance STRUCTURAL GRAPHITE TYPES AND MANUFACTURING OF GRAPHITE MATERIALS Natural Graphite Synthetic Graphite FIGURE 5 SCHEMATIC OF MANUFACTURING PROCESS FOR SYNTHETIC GRAPHITE
  • 8. PHYSICAL AND CHEMICAL PROPERTIES Crystalline Structure FIGURE 6 CRYSTALLINE STRUCTURE OF GRAPHITE Lubrication Thermal Properties Oxidation Resistance Chemical Resistance Mechanical Properties TABLE 7 PHYSICAL PROPERTIES OF GRAPHITE MATERIALS EMERGING TECHNOLOGIES Porous Graphite High-Temperature Graphite Process Expandable Graphite CARBON-CARBON STRUCTURAL COMPOSITES TYPES OF STRUCTURAL COMPOSITE MATERIALS Types of Structural Composite … (Continued) CARBON-REINFORCED CARBON MATRIX COMPOSITES TABLE 8 ADVANTAGES AND DISADVANTAGES OF CARBONCARBON COMPOSITES DIFFERENCES BETWEEN GRAPHITE AND CARBONCARBON COMPOSITES TABLE 9 COMPARISON OF PHYSICAL PROPERTIES OF GRAPHITE AND CARBON-CARBON COMPOSITES CHEMICAL AND PHYSICAL PROPERTIES REINFORCEMENT ARCHITECTURE One-Dimensional Architecture Two-Dimensional Architecture Three-Dimensional Architecture Multidimensional Architecture Foam Reinforcement MANUFACTURING PROCESSES Infiltration of Matrix Phase Raw Materials for Matrix Phase Chemical Vapor Infiltration Process Temperature Gradient Process Isothermal Process Pressure Gradient Process Liquid Pitch Infiltration Process Raw Materials Manufacturing Process Low-Pressure Process High-Pressure Process Thermosetting Resins as Matrix Precursors FIGURE 7 REPRESENTATION OF CARBON-CARBON COMPOSITE
  • 9. MANUFACTURING PROCESS STRUCTURE AND PROPERTY RELATIONSHIPS Microstructural Features TABLE 10 COMPARISON OF CARBON-CARBON COMPOSITES PROPERTIES MANUFACTURED BY VARIOUS PROCESSING ROUTES Mechanical Properties Young’s Modulus Strength Fatigue and Creep Effect of Temperature on Mechanical Properties Effect of Oxidation on Mechanical Properties Thermal Properties Friction and Wear Properties OXIDATION PROTECTION FOR CARBON-CARBON COMPOSITES TECHNOLOGY TRENDS Oxidation Inhibition of Carbon-Carbon Composites Rapid-Oxidative-Stabilization Composites High-Purity Carbon-Carbon Composites High-Density Carbon-Carbon Composites Elimination of Need for Oxidative Stabilization of Carbon Composites High Thermal Conductivity Carbon-Carbon Composites Sequential Deposit of Carbon Matrix and In Situ Polymerization Rapid Processing of Carbon-Carbon Composites Protective Coatings Detecting Flaws in the Carbon Composites Carbon-Carbon Composites from Densified Carbon Foam Low-Temperature Densification Using Sugar Pyrolysis Thick Three Dimensional Preforms for Carbon-Carbon Composites High-Strength Composites Developed by NASA and JPL Carbon-Carbon Frictional Composites for Elevator Brakes Joining Carbon-Carbon Composites Nanotubes in Carbon-Carbon Composites GRAPHENE PROPERTIES RAW MATERIALS AND PRODUCTION PROCESSES Established Technologies “Scotch Tape” Method Epitaxial Method Graphite Oxide Reduction Method Experimental Approaches
  • 10. Metal-Carbon Melt Method Pyrolysis of Sodium Ethoxide Method Production of Graphene from Carbon Nanotubes Production of Graphene from Table Sugar Dissolving Graphite in Chlorosulphonic Acid “Molecular Wedge” Method Radio Frequency Catalytic Chemical Vapor Deposition COMPANIES DEVELOPING GRAPHENE STRUCTURAL MATERIALS General Motors Graftech Graphenea CHAPTER FIVE: COMMERCIAL APPLICATIONS CARBON FIBER APPLICATIONS TABLE 11 PROPERTIES AND APPLICATIONS OF CARBON FIBERS AEROSPACE AND DEFENSE INDUSTRY Space Vehicles Unmanned Spacecraft Manned Spacecraft Launch Vehicles Total U.S. Space Market TABLE 12 U.S. SPACE VEHICLE MARKET, THROUGH 2016 ($ BILLIONS) Defense Market Defense Aviation TABLE 13 SALES OF U.S. MILITARY AIRCRAFT, THROUGH 2016 ($ BILLIONS) Missiles TABLE 14 U.S. MISSILE SHIPMENTS, THROUGH 2016 ($ BILLIONS) Commercial Aviation Large Aircraft TABLE 15 DELIVERIES OF LARGE U.S.-MADE COMMERCIAL AIRCRAFT BY TYPE, THROUGH 2016 (UNITS) Carbon Fiber Consumption TABLE 16 CONSUMPTION OF CARBON-FIBER-REINFORCED COMPOSITES IN U.S.-MADE BOEING COMMERCIAL AIRLINERS GROUND TRANSPORT Trains and Locomotives Motor Vehicles INDUSTRIAL APPLICATIONS WIND ENERGY TABLE 17 TRENDS IN U.S. WIND POWER CAPACITY, THROUGH 2016 (MW) TABLE 18 U.S. MARKET FOR WIND TURBINE ROTOR BLADES, THROUGH 2016 ($ MILLIONS)
  • 11. SPORTING GOODS Golf Clubs TABLE 19 U.S. MARKET FOR CARBON FIBER COMPOSITE GOLF CLUBS, THROUGH 2016 ($ MILLIONS) Bicycles Recreational Boating Sport Fishing TABLE 20 U.S. SHIPMENTS OF CARBON FIBER FISHING RODS, THROUGH- 2016 ($ MILLIONS) Other Applications INFRASTRUCTURE New Bridge Construction Bridge Repairs Column Repairs Seismic Retrofit High-Strength Building Construction Engineered Wood Products Tension Leg Platform Tethers from Carbon Composites Smarter and Stronger Concrete New Manufacturing Process for Reinforced Concrete THERMAL MANAGEMENT Conductive Plastics Carbon Nanotubes OTHER APPLICATIONS Biocompatibility Applications Electrochemical Applications Static Dissipation Applications Lightweight Telescope Mirrors Hollow Carbon Fibers in Molecular Sieve Applications Emerging Energy Systems Turtle Airship Uses Carbon Composites CARBON FIBERS MARKET GROWTH TABLE 21 U.S. CONSUMPTION OF CARBON FIBERS, THROUGH 2016 (THOUSAND LBS.) FIGURE 8 U.S. CARBON FIBER CONSUMPTION BY INDUSTRY SEGMENT, 2010 VS. 2016 (%) TABLE 22 U.S. MARKET FOR CARBON FIBERS, THROUGH 2016 ($ MILLIONS) FIGURE 9 U.S. CARBON FIBER MARKET BY INDUSTRY, 2010 VS. 2016 (% OF TOTAL MARKET VALUE) CARBON FOAM APPLICATIONS AEROSPACE AND DEFENSE Radiators Fire Barrier Applications
  • 12. Brakes GROUND TRANSPORTATION Automotive Radiators Shock Absorbers and Bumpers Other Automotive Applications INDUSTRIAL APPLICATIONS Sandwich Panels Electronic Heat Sinks Phase-Change Materials ENERGY Batteries Fuel Cells Radiators Humidifiers Bipolar Plates Supercapacitors Nuclear Reactor Cores Gas Storage OTHER APPLICATIONS Air Filtration Devices Personal Cooling Devices Health Care Applications Acoustic Absorber Materials CARBON FOAM MARKET GROWTH TABLE 23 U.S. CONSUMPTION OF CARBON FOAM, THROUGH 2016 (THOUSAND LBS.) FIGURE 10 U.S. CONSUMPTION OF CARBON FOAM BY INDUSTRY SECTOR, 2010 VS. 2016 (% TOTAL CONSUMPTION) TABLE 24 U.S. CARBON FOAM MARKET GROWTH BY INDUSTRY, THROUGH 2016 ($ MILLIONS) STRUCTURAL GRAPHITE APPLICATONS AEROSPACE AND DEFENSE GROUND TRANSPORTATION INDUSTRIAL APPLICATIONS Chemical Industry Applications Mechanical Applications Bearings and Brushes TABLE 25 TYPICAL APPLICATIONS FOR GRAPHITE BEARINGS Seals Friction Materials Metallurgy Glassware Refractory Applications
  • 13. ENERGY Fuel Cells Nuclear Industry Applications Hydrogen Storage STRUCTURAL GRAPHITE MARKET GROWTH TABLE 26 U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY, THROUGH 2016 (THOUSAND LBS.) FIGURE 11 U.S. CONSUMPTION OF STRUCTURAL GRAPHITE BY INDUSTRY SEGMENT, 2010 VS. 2016 (% OF TOTAL LBS. CONSUMED) TABLE 27 U.S. MARKET FOR STRUCTURAL GRAPHITE BY INDUSTRY SEGMENT, THROUGH 2016 ($ MILLIONS) CARBON-CARBON COMPOSITES APPLICATIONS AEROSPACE Space Vehicle Thermal Protection Systems Space Vehicle Thermal … (Continued) Aircraft Engine Components Aircraft Brakes Other Aerospace Applications GROUND TRANSPORTATION INDUSTRIAL APPLICATIONS Refractory Structures Glass Industry Corrosion-Resistant Structures Thermal-Management Solutions ENERGY OTHER APPLICATIONS Biocompatible Structures CARBON-CARBON COMPOSITES MARKET GROWTH TABLE 28 U.S. CONSUMPTION OF CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2016 (THOUSAND LBS.) FIGURE 12 U.S. CARBON-CARBON COMPOSITES CONSUMPTION BY INDUSTRY TYPE, 2010 VS. 2016 (%) TABLE 29 U.S. MARKET FOR CARBON-CARBON COMPOSITES BY INDUSTRY, THROUGH 2016 ($ MILLIONS) STRUCTURAL GRAPHENE APPLICATIONS INDUSTRIAL APPLICATIONS Thermal Management Solutions ENERGY Hydrogen Storage Oxidized Graphene Sheets Other Developments MARKET GROWTH TABLE 30 U.S. CONSUMPTION OF STRUCTURAL GRAPHENE BY INDUSTRY,
  • 14. THROUGH 2016 (THOUSAND LBS.) MARKETS FOR ADVANCED STRUCTURAL CARBONS TABLE 31 U.S. CONSUMPTION OF STRUCTURAL CARBONS BY TYPE OF MATERIAL, THROUGH 2016 (THOUSAND LBS.) FIGURE 13 STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016 (%) TABLE 32 U.S. MARKET FOR STRUCTURAL CARBON MATERIALS BY TYPE OF MATERIAL, THROUGH 2016 ($ MILLIONS) FIGURE 14 STRUCTURAL CARBON PRODUCT SHARES OF TOTAL U.S. STRUCTURAL CARBON CONSUMPTION, 2010 VS. 2016 (%) CHAPTER SIX: INDUSTRY STRUCTURE AND MARKET DRIVERS MARKETS FOR STRUCTURAL CARBON MATERIALS MANUFACTURERS OF STRUCTURAL CARBONS Carbon Fibers FIGURE 15 LEADING U.S. CARBON FIBER SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010 (%) Carbon Foams FIGURE 16 LEADING U.S. CARBON FOAM SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010 (%) Structural Graphite FIGURE 17 LEADING U.S. STRUCTURAL GRAPHITE SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010 (%) Carbon-Carbon Composites FIGURE 18 LEADING U.S. CARBON-CARBON COMPOSITE SUPPLIERS’ SHARE OF TOTAL U.S. CONSUMPTION, 2010 (%) SWOT ANALYSIS OF STRUCTURAL CARBONS INDUSTRY Strengths Weaknesses Opportunities Threats MARKET DRIVERS ECONOMIC FACTORS LEGAL AND REGULATORY FACTORS Price-Fixing in the Carbon Fibers and Composites Industry Price-Fixing in the Graphite Industry INDUSTRY FACTORS Capacity Trends Price Trends New Technologies and New Entrants to the Business Influence and Leverage Buyers’ Influence and Leverage
  • 15. Suppliers’ Influence and Leverage Substitute Products COMPETITIVE STRATEGIES IN THE STRUCTURAL CARBONS INDUSTRY NEW BUSINESS DEVELOPMENT COMPETITIVE PRICING VERTICAL INTEGRATION GLOBAL STRATEGIC ALLIANCES SGL - BMW Joint Venture SGL-Mitsubishi Joint Venture Mitsubishi Rayon’s Expansion Plans and Alliance with SGL Zoltek-DeWind Supply Agreement Zoltek and Chomarat GrafTech and Ballard Power Systems Zoltek and Leggett & Pratt Hexcel and Airbus Industries Hexcel and Boeing CHAPTER SEVEN: INTELLECTUAL PROPERTY AND TECHNOLOGY TRENDS ANALYSIS INTELLECTUAL PROPERTY ANALYSIS TABLE 33 PATENTS ISSUED TO LEADING MANUFACTURES IN STRUCTURAL CARBON MATERIALS TECHNOLOGY, 1996-2010 TECHNOLOGY DEVELOPMENT TRENDS CHAPTER EIGHT: INTERNATIONAL ASPECTS OF STRUCTURAL CARBONS BUSINESS TABLE 34 GLOBAL MARKET FOR STRUCTURAL CARBON BY TYPE OF MATERIAL, 2010 ($ MILLIONS) FIGURE 19 COMPARISON OF ADVANCED STRUCTURAL CARBONS CONSUMPTION IN WORLD REGIONS BY TYPE OF MATERIAL, 2010 (%) TABLE 35 GLOBAL STRUCTURAL CARBONS MARKET GROWTH BY REGION, THROUGH 2016 ($ MILLIONS) CHAPTER NINE: PROFILE OF MANUFACTURERS U.S. MANUFACTURERS AAR COMPOSITES ADVANCED CARBON TECHNOLOGIES, INC. ADVANCED COMPOSITES, INC. AEROSPACE COMPOSITE PRODUCTS CO. ALBANY ENGINEERED COMPOSITES APPLIED SCIENCES, INC. ASBURY CARBONS
  • 16. BOEING CO. BTG COMPOSITES, INC. CARBON-CARBON ADVANCED TECHNOLOGIES, INC. CHOMARAT NORTH AMERICA CYTEC CORP. FIBER MATERIALS, INC. FIBERSPAR CORP. FORESEE ORTHOPEDIC PRODUCTS GENERAL MOTORS CO. GOODRICH CORP. GRAFIL, INC. GRAPHITE METALLIZING CORP. GRAPHITE SALES, INC. GRAFTECH INTERNATIONAL, LTD. GRAPHTEK, LLC HELWIG CARBON PRODUCTS, INC. HEXCEL CORP. HITCO CARBON COMPOSITES, INC. HONEYWELL INTERNATIONAL, INC. KIRKWOOD INDUSTRIES, INC. MER CORP. MINERALS TECHNOLOGY, INC. MORGAN ADVANCED MATERIALS AND TECHNOLOGY PLANSEE THERMAL MANAGEMENT SOLUTIONS POCO GRAPHITE, INC. ROC CARBON CO. SCHUNK GRAPHITE TECHNOLOGY, LLC SGL CARBON GROUP SHAMOKIN FILLER CO. SIOUX MANUFACTURING CORP. SPAULDING COMPOSITES CO. SPENCER COMPOSITE CORP. ST. MARYS CARBON CO. SUPERIOR GRAPHITE CO. TOHO TENAX AMERICA, INC. TORAY CARBON FIBERS AMERICA, INC. TOUCHSTONE RESEARCH LABORATORY, LTD. TPI COMPOSITES, INC. ULTRAMET, INC. V2 COMPOSITE, INC. YLA, INC. ZOLTEK CORP. INTERNATIONAL MANUFACTURERS
  • 17. ANAORI CARBON CO., LTD. ATLAS COMPOSITES, LTD. C2 COMPOSITES GRAPHENEA GRUPO ANTOLIN INGENIERIA S.A MERSEN GROUP MITSUBISHI CHEMICAL CORP. MITSUBISHI RAYON CO., LTD. NIPPON GRAPHITE FIBER CORP NIPPON SHEET GLASS CO., LTD. TAIWAN CARBON TECHNOLOGY CO., LTD. TOHO TENAX CO., LTD. TORAY INDUSTRIES, INC. About Us: ReportsnReports is an online library of over 100,000+ market research reports and in-depth market research studies & analysis of over 5000 micro markets. We provide 24/7 online and offline support to our customers. Get in touch with us for your needs of market research reports. Follow us on Twitter: http://twitter.com/marketsreports Our Facebook Page: http://www.facebook.com/pages/ReportsnReports/191441427571689 Contact: Mr.Priyank 7557 Rambler road, Suite727,Dallas,TX75231 Tel: + 1 888 391 5441 E-mail: sales@reportsandreports.com http://www.reportsnreports.com Visit our Market Research Blog