Co-authors​ :

 Nguyen Le Thao NGUYEN (AUSTRALIA), Claudia CREIGHTON (AUSTRALIA), Maghe MAXIME , Srinivas NUNNA , Russell J. VARLEY (AUSTRALIA) 

This experimental study presents the conversion of polyacrylonitrile (PAN), methyl acrylate (MA), and itaconic acid (IA) copolymer precursors into carbon fibres. The research systematically investigated the relationship between the concentration of itaconic acid and the fibre processability, thermal behaviour, energy consumption, and material properties during the thermal oxidative stabilization (TOS) process. Fibers containing various amounts of itaconic acid, from 0.3 to 3 wt%, were continuously processed on the state-of-the-art Carbon Nexus Pilot scale carbonization line. Through characterization of the fibres, it was found that with increasing concentrations of itaconic acid, the carbon fibres produced had better tensile properties and structure. The carbon fibres manufactured from the precursor containing 3 wt% of itaconic acid exhibited a tensile strength 25% higher in comparison with the 0.3 wt% precursor, highlighting the beneficial effect of the comonomer. In addition to lowering the overall processing temperature during TOS, itaconic acid enhanced the chemical structure of the oxidizing fibre via higher oxygen uptake. This study provided fundamental scientific information on precursor design for the manufacture of cost-effective and environmentally friendly carbon fibres. The results of this study can be used to improve the efficiency and effectiveness of carbon fiber production and to ultimately create high-performance, lightweight, and sustainable carbon fibre-reinforced materials.