Optimization of the Filler-and-Binder Mixing Ratio for Enhanced Mechanical Strength of Carbon–Carbon Composites

In this paper, a method for optimizing the mixing ratio of filler coke and binder for high-strength carbon–carbon composites is proposed. Particle size distribution, specific surface area, and true density were analyzed to characterize the filler properties. The optimum binder mixing ratio was experimentally determined based on the filler properties. As the filler particle size was decreased, a higher binder mixing ratio was required to enhance the mechanical strength of the composite. When the d(50) particle size of the filler was 62.13 and 27.10 µm, the required binder mixing ratios were 25 and 30 vol.%, respectively. From this result, the interaction index, which quantifies the interaction between the coke and binder during carbonization, was deduced. The interaction index had a higher correlation coefficient with the compressive strength than that of the porosity. Therefore, the interaction index can be used in predicting the mechanical strength of carbon blocks and optimizing their binder mixing ratios. Furthermore, as it is calculated from the carbonization of blocks without additional analysis, the interaction index can be easily used in industrial applications.