Synthetic Graphite in Modern Military Applications
Two years ago, we explored in a blog synthetic graphite's role in military equipment, focusing on rocket nozzles and graphite bombs during the early phase of the Ukraine conflict. Today, we're revisiting this topic with fresh insights into how this versatile material continues to serve important functions across various branches of our armed forces, from the National Guards to the Air Force and beyond.
The U.S. Military's Graphite Dependency
The U.S. Air Force, perhaps more than any other military branch, relies on synthetic graphite components. From the thermal protection systems in hypersonic vehicles to components in aircraft engines, synthetic graphite's notable heat resistance and low reactivity means that many aerospace applications can’t do without it.
As we noted in our previous blog, "Synthetic graphite can withstand extreme temperatures, the kind that results from intense combustion that powers rockets. Not only that, but synthetic graphite is also not very reactive." These properties remain just as valuable today, with military aerospace technology advancing at a rapid pace.
Beyond Rocket Nozzles
While rocket nozzles remain one of the most visible applications, synthetic graphite's military uses extend far beyond this single component. For example, today's military aircraft utilize graphite in braking systems, where its thermal properties prevent overheating during high-speed landings on aircraft carriers and short runways.
The National Guard's disaster response vehicles incorporate synthetic graphite components that function well in extreme conditions. Specifically, these vehicles use graphite-based brushes and contacts in electrical systems that maintain conductivity even when exposed to water, dust, or extreme temperatures. Unlike copper or other metal contacts that can corrode or overheat, synthetic graphite maintains consistent electrical performance without degradation.
During wildfire response operations, when ambient temperatures can exceed 200°F, standard vehicle electrical systems risk failure. Graphite's natural heat dissipation properties keep electrical components functioning even at these elevated temperatures. Additionally, during flood rescue missions, like the ones the National Guard took part in in western North Carolina in the wake of Hurricane Helene, graphite's water-resistant electrical conductivity proves important—graphite continues to function effectively even when partially submerged, unlike metal contacts that rapidly short-circuit or corrode in wet conditions.
Armed Forces Applications Evolve
The previously discussed "graphite bomb" – a non-lethal weapon designed to disable electrical grids through short-circuiting – has evolved in its tactical implementation. These specialized weapons disperse clouds of carbon filaments derived from synthetic graphite across electrical infrastructure, temporarily disabling power without causing permanent structural damage.
This technology demonstrates the modern military's increasing focus on precision infrastructure-targeting tactics rather than traditional destructive force. For our armed forces operating in cities or other populated areas, the ability to temporarily disable systems rather than destroy them often makes sense, especially if restoring electricity in that area will be a strategic priority after the battle has taken place.
Strategic Material Status Heightened
Synthetic graphite's classification as a strategic material has only strengthened in recent years. The US Department of Energy now lists graphite among critical materials requiring domestic supply chain security. This inclusion of graphite on a list of critical materials acknowledges graphite’s strategic importance to our armed forces and to the green energy transition.
The same properties that make synthetic graphite valuable for military applications – thermal stability, conductivity, and chemical resistance – also make it important for civilian technologies like electric vehicle batteries and renewable energy storage systems, both of which we have written about extensively on this blog. This dual-use nature — important to armed forces applications and important to the energy sector, and all the overlap between those two — has elevated graphite’s importance to national security.
Domestic Production Concerns
The U.S. Air Force and other military branches have expressed growing concern about synthetic graphite supply chains. With China controlling approximately 80% of global graphite processing, the Pentagon has initiated programs to encourage domestic synthetic graphite production specifically for military applications.
This mirrors broader efforts to secure supply chains for critical materials like cobalt and lithium. The armed forces require reliable access to synthetic graphite not just for combat readiness, but also for maintaining the thousands of vehicles, aircraft, and systems that support military operations worldwide.
Graphite Research
Materials scientists and graphite manufacturers are always working to develop new synthetic graphite materials with enhanced properties. These collaborations focus on creating lighter, stronger, and more heat-resistant variants, some of which, as is the case for many advanced technologies, will find uses in aerospace and defense applications.
The Air Force Research Laboratory (AFRL) has been particularly active in this space, working to develop synthetic graphite composites that can withstand the extreme conditions of hypersonic flight. In one instance, the Air Force helped to fund work on graphene that led to a Nobel Prize in physics for two scientists.
Looking Ahead
In the years ahead, synthetic graphite's role in military technology shows no signs of diminishing. In fact, as armed forces worldwide continue to modernize with a focus on precision, efficiency, and reduced collateral damage, materials like synthetic graphite that enable these capabilities become even more valuable.
At Semco, we continue to follow these developments closely, recognizing that innovations in military applications often transfer to civilian uses, creating new opportunities for graphite components in civilian industries. The strategic importance of synthetic graphite, spanning both military applications and the green economy, guarantees its place as a material that will shape our future in more ways than one. If you are curious about graphite’s potential uses in your field, reach out to Semco Carbon. If something is happening in the field of graphite, we have likely studied it carefully.