Carbon Fiber Surface Functional Landscapes: Nanoscale Topography and Property Distribution

The ultimate properties of carbon fibers and their composites are largely dictated by the surface topography of the fibers and the interface characteristics, which are primarily influenced by the surface distribution of chemical functionalities and their interactions with the matrix resin. Nevertheless, nanoscale insights on the carbon fiber surface in relationship with its chemical modification are still rarely addressed. Here, we demonstrate a critical insight on the nanoscale surface topography characterization of modified novel carbon fibers using high-resolution atomic force microscopy at multiple length scales. We compare the nanoscale surface characteristics relevant to their role in controlling interfacial interactions for carbon fibers manufactured at two different tensions and two distinct chemically functionalized coatings. We used surface dimple (also known as nanopores) profiling, microroughness analysis, power spectral density analysis, and adhesion and electrostatic potential mapping to reveal the fine details of surface characteristics at different length scales. This analysis demonstrates that the carbon fibers processed at lower tension possess a higher fractal dimension with a more corrugated surface and higher surface roughness, which leads to increased surface adhesion and energy dissipation across nano- and microscales. Furthermore, electrochemical surface modification with amine- and fluoro-functional groups significantly masks the microroughness inherent to these fibers. This results in increased fractal dimension and decreased energy dissipation and adhesion due to the high chemical reactivity in the areas of asperities and surface defects combined with a significant increase in the surface potential, as revealed by Kelvin probe mapping. These local surface properties of carbon fibers are crucial for designing next-generation fiber composites with predictable interfacial strength and the overall mechanical performance by considering the fiber surface topography for proper control of interphase formation.