In this study, a graphite block is fabricated using artificial graphite processing byproduct and phenolic resin as raw materials. Mechanical and electrical property changes are confirmed due to the preforming method. After fabricating preforms at 50, 100, and 150 MPa, CIP molding at 150 MPa is followed by heat treatment to prepare a graphite block. 150UP-CIP shows a 12.9% reduction in porosity compared with the 150 MPa preform. As the porosity is decreased, the bulk density, flexural strength, and shore hardness are increased by 14.9%, 102.4%, and 13.7%, respectively; and the deviation of density and electrical resistivity are decreased by 51.9% and 34.1%, respectively. Therefore, as the preforming pressure increases, the porosity decreases, and the electrical and mechanical properties improve.

The change in the open porosity of bulk graphite as a function of the uniaxial molding pressure during manufacturing is studied using artificial graphite powder. Subsequently, the graphite is impregnated to determine the effect of the open porosity on the impregnation efficiency and to improve the density of the final bulk graphite. Bulk graphite is manufactured with different uniaxial molding pressures after mixing graphite powder, which is the by-product of processing the final graphite products and phenolic resin. The bulk density and open porosity are measured using the Archimedes method. The bulk density and open porosity of bulk graphite increase as the molding pressure increases. The open porosity of molded bulk graphite is 25.35% at 30 MPa and 29.84% at 300 MPa. It is confirmed that the impregnation efficiency increases when the impregnation process is performed on a specimen with large open porosity. In this study, the bulk density of bulk graphite molded at 300 MPa is 11.06% higher than that before impregnation, which is the highest reported increase. Therefore, it is expected that the higher the uniaxial pressure, the higher the density of bulk graphite.

In the manufacturing of bulk graphite, pores produced by vaporization and discharge of volatile materials in binders during carbonization reduce the density of bulk graphite, which adversely affects the electrical conductivity, strength and mechanical properties. Therefore, an impregnation process is introduced to fill the pores and increase the density of bulk graphite. In this study, bulk graphite is prepared by varying the viscosity of the impregnant. The microstructure of bulk graphite is observed. The flexural strength and electrical resistivity are measured. As the viscosity of the impregnants decreases and the number of impregnations increases, it is shown that the number of pores decreases. The density before impregnation is 1.62 g/cm3. The density increases to 1.67 g/cm3 and porosity decreases by 18.6 % after three impregnations using 5.1 cP impregnant, resulting in the best pore-filling effect. After three times of impregnation with a viscosity of 5.1 cP, the flexural strength increases by 55.2 % and the electrical resistivity decreases by 86.76 %. This shows that a slight increase in density due to the pore-filling effect improves the properties of bulk graphite.

Pores produced by carbonization in bulk graphite process degrade the mechanical and electrical properties of bulk graphite. Therefore, the pores of bulk graphite must be reduced and an impregnation process needs to be performed for this reason. In this study, bulk graphite is impregnated by varying the viscosity of the impregnant. The pore volume and pore size distribution, according to the viscosity of the impregnant, are analyzed using a porosimeter. The total pore volume of bulk graphite is analyzed from the cumulative amount of mercury penetrated. The volume for a specific pore size is interpreted as the amount of mercury penetrating into that pore size. This decreases the cumulative amount of mercury penetrating into the recarbonized bulk graphite after impregnation because the viscosity of the impregnant is lower. The cumulative amount of mercury penetrating into bulk graphite before impregnation and after three times of impregnation with 5.1cP are 0.144 mL/g and 0.125 mL/gm, respectively. Therefore, it is confirmed that the impregnant filled the pores of the bulk graphite well. In this study, the impregnant with 5.1 cP, which is the lowest viscosity, shows the best effect for reducing the total pore volume. In addition, it is confirmed by Raman analysis that the impregnant is filled inside the pores. It is confirmed that phenolic resin, the impregnant, exists inside the pores through micro-Raman analysis from the inside of the pore to the outside.

Conductive polymer composites with high electrical and mechanical properties are in demand for bipolar plates of phosphoric acid fuel cells (PAFC). In this study, composites based on natural graphite/fluorinated ethylene propylene (FEP) and different ratios of carbon black are mixed and hot formed into bars. The overall content of natural graphite is replaced by carbon black (0.2 wt% to 3.0 wt%). It is found that the addition of carbon black reduces electrical resistivity and density. The density of composite materials added with carbon black 3.0 wt% is 2.168 g/cm3, which is 0.017 g/cm3 less than that of non-additive composites. In-plane electrical resistivity is 7.68 μΩm and through-plane electrical resistivity is 27.66 μΩm. Compared with non-additive composites, in-plane electrical resistivity decreases by 95.7 % and through-plane decreases by 95.9 %. Also, the bending strength is about 30 % improved when carbon black is added at 2.0 wt% compared to non-additive cases. The decrease of electrical resistivity of composites is estimated to stem from the carbon black, which is a conductive material located between melted FEP and acts a path for electrons; the increasing mechanical properties are estimated to result from carbon black filling up pores in the composites.

Milled carbon fiber (mCF) was prepared by a ball milling process, and X-ray diffraction (XRD) diffractograms were obtained by a 2θ continuous scanning analysis to study mCF crystallinity as a function of milling time. The raw material for the mCF was polyacrylonitrile- based carbon fiber (T700). As the milling time increased, the mean particle size of the mCF consistently decreased, reaching 1.826 μm at a milling time of 18 h. The XRD analysis showed that, as the milling time increased, the fraction of the crystalline carbon decreased, while the fraction of the amorphous carbon increased. The (002) peak became asymmetric before and after milling as the left side of the peak showed an increasingly gentle slope. For analysis, the asymmetric (002) peak was deconvoluted into two peaks, less-developed crystalline carbon (LDCC) and more-developed crystalline carbon. In both peaks, Lc decreased and d002 increased, but no significant change was observed after 6 h of milling time. In addition, the fraction of LDCC increased. As the milling continued, the mCF became more amorphous, possibly due to damage to the crystal lattices by the milling.

A composite material was prepared for the bipolar plates of phosphoric acid fuel cells(PAFC) by hot pressing a flake type natural graphite powder as a filler material and a fluorine resin as a binder. Average particle sizes of the powders were 610.3, 401.6, 99.5, and 37.7 μm. The density of the composite increased from 2.25 to 2.72 g/cm3 as the graphite size increased from 37.7 to 610.3 μm. The anisotropy ratio of the composite increased from 1.8 to 490.9 as the graphite size increased. The flexural strength of the composite decreased from 15.60 to 8.94MPa as the graphite size increased. The porosity and the resistivity of the composite showed the same tendencies, and decreased as the graphite size increased. The lowest resistivity and porosity of the composite were 1.99 × 10−3 Ωcm and 2.02 %, respectively, when the graphite size was 401.6 μm. The flexural strength of the composite was 10.3MPa when the graphite size was 401.6 μm. The lowest resistance to electron mobility was well correlated with the composite with lowest porosity. It was possible the flaky large graphite particles survive after the hot pressing process.

Isotropic pitch-based fibers produced from coal tar pitch with the melt-blowing method were carbonized at temperatures ranging from 800 to 1600oC to investigate their crystalline structure and physical properties as a function of the carbonization temperature. The in-plane crystallite size (La) of the carbonized pitch fiber from X-ray diffraction increased monotonously by increasing the carbonization temperature resulting in a gradual increase in the electrical conductivity from 169 to 3800 S/cm. However, the variation in the d002 spacing and stacking height of the crystallite (Lc) showed that the structural order perpendicular to the graphene planes got worse in carbonization temperatures from 800 to 1200oC probably due to randomization through the process of gas evolution; however, structural ordering eventually occurred at around 1400oC. For the carbonized pitch powder without stabilization, structural ordering perpendicular to the graphene planes occurred at around 800–900oC indicating that oxygen was inserted during the stabilization process. Additionally, the shear stress that occurred during the melt-blowing process might interfere with the crystallization of the CPF.

Polyacrylonitrile (PAN)-based carbon fibers have high specific strength, elastic modulus, thermal resistance, and thermal conductivity. Due to these properties, they have been increasingly widely used in various spheres including leisure, aviation, aerospace, military, and energy applications. However, if exposed to air at high temperatures, they are oxidized, thus weakening the properties of carbon fibers and carbon composite materials. As such, it is important to understand the oxidation reactions of carbon fibers, which are often used as a reinforcement for composite materials. PAN-based carbon fibers T300 and T700 were isothermally oxidized in air, and microstructural changes caused by oxidation reactions were examined. The results showed a decrease in the rate of oxidation with increasing burn-off for both T300 and T700 fibers. The rate of oxidation of T300 fibers was two times faster than that of T700 fibers. The diameter of T700 fibers decreased linearly with increasing burn-off. The diameter of T300 also decreased with increasing burn-off but at slower rates over time. Cross-sectional observations after oxidation reactions revealed hollow cores in the longitudinal direction for both T300 and T700 fibers. The formation of hollow cores after oxidation can be traced to differences in the fabrication process such as the starting material and final heat treatment temperature.

The development of hollow carbon balls by CO2 oxidation of two types of carbon blacks was studied. Super P (SP) and Denka Black (DB) were used for this study. Specificsurface area (SSA), structural parameters, and microstructures were examined using Brunauer, Emmett and Teller apparatus, X-ray diffraction spectroscopy, and transmission electron microscope (TEM), respectively. The SSAs of both oxidized carbon blacks increased after oxidation. The SSAs of raw DB and SP were 73 m2/g and 60 m2/g, respectively. Maximum SSAs of oxidized DB and SP were 152 m2/g and 253 m2/g, respectively. The d002 of DB and SP showed almost no change after oxidation. The Lc of raw DB (38Å) and SP (19Å) increased with increasing weight loss. The Lc of SP increased up to 254 at 96% weight loss. The SSA increased about twice in DB (148 m2/g) and about four times in SP (254 m2/g) after 3 h oxidation compared with the original carbon blacks. Through TEM observation the outer parts of the oxidized carbon blacks showed a rigid shell structure and the inner parts looked empty. Generally it looked like an angular soccer ball, so we named it ‘hollow carbon ball.’ It is expected that the hollow carbon ball can be used as catalyst supports.

This study considered the effect of the heat treatment temperature on the compressive strength of coal powder compacts affected by density, porosity, and crystallinity. Coal powder compacts were made by pressing of milled coal powder and were heat treated at 200, 400, 600, 800, and 1000℃. The density and porosity of the heat treated specimens at each temperature were measured using the Archimedes method and changes in crystallinity were analyzed using Raman spectroscopy. Increases in compressive strength at 600℃ or higher temperatures were proportionally related to increases in the density and the degree of crystallinity.

We study the relationships between the thermal emissivity of nuclear graphites (IG-110, PCEA, IG-430 and NBG-18) and their surface structural change by oxidation using scanning electron microscope and X-ray diffraction (XRD). The nonoxidized (0% weight loss) specimen had the surface covered with glassy materials and the 5% and 10% oxidized specimens, however, showed high roughness of the surface without glassy materials. During oxidation the binder materials were oxidized first and then graphitic filler particles were subsequently oxidized. The 002 interlayer spacings of the non-oxidized and the oxidized specimens were about 3.38~3.39a. There was a slight change in crystallite size after oxidation compared to the nonoxidized specimens. It was difficult to find a relationship between the thermal emissivity and the structural parameters obtained from the XRD analysis.

Thermal emissivity of nuclear graphite was measured with its oxidation degree. Commercial nuclear graphites (IG-110, PECA, IG-430, and NBG-18) have been used as samples. Concave on graphites surface increased as its oxidation degree increased, and R value (Id/Ig) of the graphites decreased as the oxidation degree increased. The thermal emissivity increased depending on the decrease of the R (Id/Ig) value through Raman spectroscopy analysis. It was determined that the thermal emissivity was influenced by the crystallinity of the nuclear graphite.

Thermal emissivity of commercial nuclear graphites (IG-110, PCEA, IG-430 and NBG-18) following changes in oxidation degrees were examined. Specimens were oxidized to 0%, 5%, and 10% in air flow of 5l/min at 600℃ using a furnace, and the thermal emissivities were measured using an infrared spectrum analyzer. The measuring temperatures for the thermal emissivity were 100℃, 200℃, 300℃, 400℃ 500℃. Also density and porosity of the specimens were observed to compare with thermal emissivity. Results showed that emissivity increased with oxidation, and the 10% oxidized NBG-18 showed the highest emissivity (0.890) which value is larger for 24% than the value of as-received specimen. Investigation of factors affecting the emissivity revealed that increases in the surface roughness and porosity due to oxidation were responsible for the increase in emissivity after oxidation.

This study aims to find a correlation between XRD and Raman result of the oxidized high modulus carbon fibers as a function of its oxidation degrees, and compare with the isotropic carbon fiber reported early. La of the high modulus carbon fiber prepared by oxidation in carbon dioxide gas have been observed using laser Raman spectroscopy. The basic structural parameters of the fibers were evaluated by XRD as well. The La of the original high modulus carbon fibers were measured to be 144 a from Raman analysis and 135 a from XRD analysis. La of the 92% oxidized fiber were 168 a by using Raman and 182 a by using XRD. There was some correlation between the La value obtained from Raman and XRD. However the La value changes of the high modulus carbon fiber through whole oxidation process showed opposite tendency compare with the isotropic carbon fiber because of the fiber structure basically.

This study aims to find a correlation between XRD and Raman result of the activated carbon fibers as a function of its activation degrees. La of the isotropic carbon fiber prepared by oxidation in carbon dioxide gas have been observed using laser Raman spectroscopy. The basic structural parameters of the fibers were evaluated by XRD as well, and compared with Raman result. The La of the carbon fibers were measured to be 25.5 a from Raman analysis and 23.6 a from XRD analysis. La of the ACFs were 23.6 a and 20.4 a, respectively, representing less ordered through activation process. It seems that the ID/IG of Raman spectra were related to crystallite size(La). Raman spectroscopy has demonstrated its unique ability to detect structural changes during the activation of the fibers. There was good correlation between the La value obtained from Raman and XRD.

High modulus pitch based carbon fibers (HM) were exposed to isothermal oxidation using tube furnace in carbon dioxide gas to study the oxidation kinetics under the temperature of 800-1100℃. The kinetic equation f=1--(-atb) was introduced and the constant b was obtained in the range of 1.02~1.42. The oxidation kinetics were evaluated by the reaction-controlling regime (RCR) depending upon the apparent activation energies with the conversion increasing from 0.2 to 0.8. The activation energies decrease from 24.7 to 21.0 kcal/mole with the conversion increasing from 0.2 to 0.8, respectively. According to the RCR, the reaction was limited by more diffusion controlling regime for the HM fibers with the conversion increasing. Therefore, it seems that the oxidation which is under the diffusion controlling regime takes place continuously from the skin to the core of the fiber.

Isotropic pitch based carbon fibers were exposed to isothermal oxidation in carbon dioxide gas to study the activation kinetics under the temperature of 800~1100℃. The kinetic equation f=1--(-atb) was introduced and the constant b was obtained in the range of 0.92~1.25. It was shown that the activated carbon fiber shows the highly specific surface area (SSA) when the constant b comes close to 1. The activation kinetics were evaluated by the reaction-controlling regime (RCR) according to changes of the apparent activation energy with changes of the conversion. It was observed that the activation energies increase from 47.6 to 51.2 kcal/mole with the conversion increasing from 0.2 to 0.8. It was found that the pores of the activated carbon fiber under the chemical reaction were developed well through the fiber.

Isotropic pitch-based carbon fiber was isothermally activated in CO2 atmosphere. Structural parameters of the isotropic carbon fibers and activated carbon fibers (ACFs) were evaluated by X-ray diffraction (XRD). The d002 and La of the carbon fibers were measured to be 4.04 a and 23.6 a and those of ACFs were 4.29 a and 22.7 a, respectively, representing less ordered through activation process. The pores in the ACFs were characterized by BET, and they showed super-high specific surface area of maximum value 3,495 m2/g from average pore size of 8.3 a at 59% burn-off. It was recognized that 8-9 a was optimum range of pore size for efficient creation of high specific surface area. The average size of the pores formed at higher temperature (1100℃) was larger than that of the pores formed at lower temperature (900℃).