Cellulose derived composites—A new method for materials processing

This research demonstrated for the first time a method for producing net shape polymer, ceramic and carbon composites using wood as a precursor. The conversion of wood to carbon has been practiced for centuries but the controlled thermal decomposition to form a monolithic carbon to be used as a template for composites as demonstrated by this research is a unique discovery. This was accomplished by thermal decomposition of wood under controlled conditions to produce a crack-free porous carbon monolith which was readily shaped by conventional methods. The shaped carbons have converted to carbon/polymer composites, carbon/carbon composites, ceramics, and ceramic composites without significant changes in dimensions. This research has demonstrated that composites derived from wood can eliminate several expensive processing steps. Specifically, no fiber lay-up or powder consolidation is required, and final grinding and polishing steps are minimized.