1. Overview of Carbon Fiber Material Development
Carbon fiber is a new type of high‑strength, high‑modulus fiber material with a carbon content above 95%.In the 1960s, high‑performance carbon fiber was initially commercialized as a reinforcing material, and high‑performance resin‑matrix composites reinforced with continuous carbon fiber came into being.
As noted by the non‑constant velocity drive shaft manufacturer, carbon fiber composites feature outstanding performance: light weight, high strength, and excellent mechanical properties. However, they involve complex production technologies and high costs.
Thanks to their superior performance, carbon fiber composites have met the demands of high‑tech development. Traditionally widely used in aerospace and military fields, they have gradually expanded from aerospace, sports goods, and other sectors into the automotive industry. With advances in technology, carbon fiber composites are becoming increasingly popular in automotive manufacturing.
2. Application of Carbon Fiber Composites in the Automotive Industry
For carbon fiber to gain widespread use in automobiles, two key issues must be addressed: cost and recyclability.It is believed that as production technologies mature, the manufacturing cost of carbon fiber will continue to decrease.
In addition to production costs, manufacturers must also consider the recycling of carbon fiber components. Compared with metallic materials, carbon fiber composites are more difficult to recycle.
3. Performance Advantages of Carbon Fiber in Automotive Applications
(1) Lightweight AdvantageCarbon fiber composites offer an unmatched combination of high specific strength and specific modulus, with a density of approximately 1.6 g/cm³, much lower than steel and aluminum.
When applied to vehicle bodies and components, they can reduce vehicle weight by about 35% and lower fuel consumption.
For example, Volkswagen’s XL1 model, which uses carbon fiber composite body and parts, has a total weight of only 795 kg, achieving high efficiency together with hybrid technology.
The BMW E92, in its original rear‑wheel‑drive configuration, was equipped with a conventional drive shaft weighing 10.6 kg.
By using a carbon fiber composite drive shaft, the weight was reduced to only 5.9 kg. Compared with the original equipment shaft, the MF carbon fiber drive shaft is significantly lighter. The simplified structure, without certain universal joints, further reduces power loss and lowers noise.
In detail, 6061‑T6 aluminum is used at the ends of the drive shaft (excluding the ball joint end).
(2) Durability Advantage
Carbon fiber composites mainly consist of carbon filaments and resin matrix.
Carbon is chemically stable, requiring no surface anti‑corrosion treatment. They exhibit excellent weather resistance and aging resistance, with a service life typically 2–3 times that of steel.
Functional components made of CFRP also have much higher fatigue strength than steel.
(3) High Strength and Safety Advantage
Carbon fiber composites outperform metallic materials in mechanical properties.
Their tensile strength is 4–5 times that of ordinary steel, and their rigidity is 3–4 times higher. Typical tensile strength exceeds 3,500 MPa, about five times that of ordinary steel.
Cockpits made of carbon fiber deform minimally in a collision, effectively protecting the occupant survival space.
Specially woven impact‑absorbing structures can break into small pieces during high‑speed crashes, absorbing large amounts of impact energy — more than three times that of conventional steel — significantly improving the vehicle’s passive safety.
These figures can be abstract. The exceptional toughness of carbon fiber composites can be clearly illustrated by crash incidents during the 2016 F1 season.
4. Application of Carbon Fiber Drive Shafts in Automobiles
Carbon fiber composite drive shafts effectively improve vehicle quality and performance, and play an important role in automotive lightweighting.Traditional automotive drive shafts were usually made of steel. Such shafts have relatively low bending natural frequency and perform poorly at high vehicle speeds.
Two‑section steel drive shafts also present numerous drawbacks. Carbon fiber composite drive shafts effectively solve these problems and enhance overall vehicle performance.
In comparative torsion tests: when torque reached 1,376 Nm, a conventional metal drive shaft showed obvious deformation.
By contrast, a carbon fiber drive shaft did not fracture until torque reached approximately 4,700 Nm.
Automotive drive shafts operate under complex loading conditions, especially high torque, demanding high material performance.
Carbon fiber reinforced composites feature anisotropy, high strength, and relatively low density. Replacing metal with carbon fiber as a drive shaft material better satisfies operational requirements.
Carbon fiber drive shafts can reduce weight by up to 60%, while offering excellent fatigue resistance and durability.
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