Carbon Fiber Why Does It Matter?

(Figure 1) A carbon fiber hood on a Chevrolet ZR1 Corvette.

Carbon fiber is being used on many late-model vehicles and has become a buzzword in the industry. This article answers some questions you may have been wondering about on the use and repair of carbon fiber.

Carbon fiber is only on high-end low production vehicles. I don't work on high-end vehicles. Why should I worry about carbon fiber?
While it is true that carbon fiber is only on high-end vehicles today, it doesn't mean that won't change in the very near future. Just take a minute to think back 15 years ago. Would you have ever thought that Ford would have an aluminum box and cab on a full-size pickup truck? Did you ever think that an everyday car like a Honda Accord would have steel rated at 1,500 MPa? Probably not. Back then, aluminum-intensive or UHSS structures would have only been on high-end low production vehicles. Yet in that short time span of 15 years, this is the current reality of the collision repair industry.

So now think of carbon fiber in that same context. Carbon fiber is relatively new to the automotive industry and is currently being used on high-end low production vehicles. If history were to repeat itself, as it often does, in a short time period the collision repair industry could be faced with repairs of everyday vehicles made of carbon fiber. At this point you can either wait until there's a vehicle sitting in a stall that no one has a clue how to repair or you can start the process of learning about this new material so you will be prepared for the not-to-distant future.

6101(Figure 2) This illustration shows the basics of a composite structure.

Where should we begin?
Let's start with what is carbon fiber? Carbon fiber is a man-made filament or fiber that has a high-carbon content. The carbon content is typically between 92 - 99% carbon, which is one of the reasons that carbon fiber has a grayish-black look. It is made into a variety of different cloths, weaves, or chopped fibers. There are also different weights and qualities of carbon fiber that can vary greatly and need to be chosen based upon the requirements of the part. The fibers are combined with a resin material to make parts. This resin might be vinyl, vinyl-ester, epoxy, or one of many other types of resin. Once the resins and fibers are cured, you have a composite part. In the end, carbon fiber is the buzzword for a specific kind of composite that has amazing possibilities now and into the future (see Figure 2).

Is carbon fiber just used for exterior panels?
Carbon fiber is not a material that will only be used for body and trim panels, it will often be used anywhere steel and aluminum are commonly used. Carbon fiber is being used to build the structure of the entire vehicle like the Lamborghini Aventador. The BMW i3 and i8 are going to have almost the entire passenger cell made of carbon fiber. With carbon fiber being used as structural parts, the industry will have to learn a whole new process of what it will take to repair the vehicle after the collision (see Figure 3).

Is carbon fiber repairable?
Carbon fiber is repairable depending on the damage. There are new tools and equipment, repair techniques, and areas of knowledge that will need to be applied to repair a carbon fiber part or structure. Some examples of tool and equipment that will be needed are tap testers, vacuum pumps, and hot bonders. Repair techniques will include accurate ply orientation and creating a scarfed (tapered) repair. If some of these terms are unfamiliar to you, it's understandable.


Watch an overview video on the vacuum bagging process.

Conclusion
The first step to meet the challenges that carbon fiber presents, is to begin to acquire knowledge about the material and what is involved in the repair process with this space age material. The industry will need to identify when to make the investment in tools, material, and training. It is not a question of if carbon fiber is going to appear in high production vehicles, but when it will appear.


Related I-CAR Courses

  • I-CAR Repairers Realm: Steering Column Inspection After A Collision - Now Available Friday, 1 November 2024

    I-CAR had a discussion on consideration for steering column inspection after a collision.

  • OEM Emergency Response Guide: Polestar Thursday, 31 October 2024

    Are you looking for OEM emergency response guides (ERGs)? The Repairability Technical Support (RTS) team has located these guides and either houses them on the RTS website, provides links to...

  • Back-To-Basics: Stationary Glass Installation Considerations Wednesday, 30 October 2024

    Sometimes going back-to-basics can make the difference between a quality repair and a failed repair. When replacing stationary glass, there are extra considerations to perform a complete and quality...

  • One-Time-Use Parts And Fasteners: Genesis Friday, 25 October 2024

    What is a one-time-use part, and how do you determine if a fastener, clip, or part can be reused? These are questions that we are confronted with in the collision industry quite a lot. The other big...

  • OEM Linking Pin: Toyota/Lexus Sectioning Clarification Thursday, 24 October 2024

    As part of the I-CAR Repairability Technical Support (RTS) OEM linking pin activity, we are helping to connect the collision repair industry to the vehicle makers. A common question when it comes to...

  • Refinishing Park Assist Sensors: Jaguar Land Rover Tuesday, 22 October 2024

    Park assist sensors are part of the park assist system, just one of many advanced driver assistance systems (ADAS) found on vehicles today. Damaged sensors are typically replaced and may require...

  • I-CAR At SEMA 2024 Friday, 18 October 2024

    Attending the SEMA Show in Las Vegas this year? Well, I-CAR will be providing many different opportunities to connect with you at this year’s show.

  • Non-SRS Wiring Repair: BMW/Mini Thursday, 17 October 2024

    What is a non-SRS wiring repair? It is the repairing of an electrical component that is not part of the supplemental restraints system circuit (usually identified by yellow wire looms). As...

  • Paint Maker ADAS Radar Optimized Color Resources: BASF Wednesday, 16 October 2024

    Changes in advanced driver assistance systems (ADAS) radar technology are introducing new refinishing considerations. We know that paint film thickness can affect the performance of ADAS radars, but...

  • Repairer Driven News: BMW Adds Structural Steel Parts To Restricted List Thursday, 10 October 2024

    Repairer Driven News (RDN) has released an article highlighting BMW adding structural steel parts to their restricted list.