Towards Sustainable Composite Manufacturing with Recycled Carbon Fiber Reinforced Thermoplastic Composites.

Currently, the vast majority of composite waste is either landfilled or incinerated, causing a massive burden on the environment and resulting in the loss of potentially valuable raw material. Here, conventional pyrolysis and reactive pyrolysis were used to reclaim carbon fibers from aeronautical scrap material, and to evaluate the feasibility of using reclaimed carbon fibers in structural components for the automotive sector. The need for fiber sizing was investigated as well as the behavior of the fiber material in macroscopic impact testing. The fibers were characterized with the single fiber tensile test, scanning electron microscopy, and the microbond test. Critical fiber length was estimated in both polypropylene and polyamide matrices. Tensile strength of the fiber material was better preserved with the reactive pyrolysis compared to the conventional pyrolysis, but in both cases the interfacial shear strength was retained or even improved. The impact testing revealed that the components made of these fibers fulfilled all required deformation limits set for the components with virgin fibers. These results indicate that recycled carbon fibers can be a viable option even in structural components, resulting in lower production costs and greener composites.

One Surface Treatment, Multiple Possibilities: Broadening the Use-Potential of Para-Aramid Fibers with Mechanical Adhesion.

Aramid fibers are high-strength and high-modulus technical fibers used in protective clothing, such as bulletproof vests and helmets, as well as in industrial applications, such as tires and brake pads. However, their full potential is not currently utilized due to adhesion problems to matrix materials. In this paper, we study how the introduction of mechanical adhesion between aramid fibers and matrix material the affects adhesion properties of the fiber in both thermoplastic and thermoset matrix. A microwave-induced surface modification method is used to create nanostructures to the fiber surface and a high throughput microbond method is used to determine changes in interfacial shear strength with an epoxy (EP) and a polypropylene (PP) matrix. Additionally, Fourier transform infrared spectroscopy, atomic force microscopy, and scanning electron microscopy were used to evaluate the surface morphology of the fibers and differences in failure mechanism at the fiber-matrix interface. We were able to increase interfacial shear strength (IFSS) by 82 and 358%, in EP and PP matrix, respectively, due to increased surface roughness and mechanical adhesion. Also, aging studies were conducted to confirm that no changes in the adhesion properties would occur over time.

Weathering of Antibacterial Melt-Spun Polyfilaments Modified by Pine Rosin.

For many antibacterial polymer fibres, especially for those with natural functional additives, the antibacterial response might not last over time. Moreover, the mechanical performance of polymeric fibres degrades significantly during the intended operation, such as usage in textile and industrial filter applications. The degradation process and overall ageing can lead to emitted volatile organic compounds (VOCs). This work focused on the usage of pine rosin as natural antibacterial chemical and analysed the weathering of melt-spun polyethylene (PE) and poly lactic acid (PLA) polyfilaments. A selected copolymer surfactant, as an additional chemical, was studied to better integrate rosin with the molecular structure of the plastics. The results reveal that a high 20 w-% of rosin content can be obtained by surfactant addition in non-oriented PE and PLA melt-spun polyfilaments. According to the VOC analysis, interestingly, the total emissions from the melt-spun PE and PLA fibres were lower for rosin-modified (10 w-%) fibres and when analysed below 60 ℃. The PE fibres of the polyfilaments were found to be clearly more durable in terms of the entire weathering study, i.e., five weeks of ultraviolet radiation, thermal ageing and standard washing. The antibacterial response against Gram-positive Staphylococcus aureus by the rosin-containing fibres was determined to be at the same level (decrease of 3-5 logs cfu/mL) as when using 1.0 w-% of commercial silver-containing antimicrobial. For the PE polyfilaments with rosin (10 w-%), full killing response (decrease of 3-5 logs cfu/mL) remained after four weeks of accelerated ageing at 60 ℃.

Resizing Approach to Increase the Viability of Recycled Fibre-Reinforced Composites.

Most recycling methods remove the essential sizing from reinforcing fibres, and many studies indicate the importance of applying sizing on recycled fibres, a process we will denote here as resizing. Recycled fibres are not continuous, which dissociates their sizing and composite lay-up processes from virgin fibres. In this study, commercial polypropylene and polyurethane-based sizing formulations with an aminosilane coupling agent were used to resize recycled glass and carbon fibres. The impact of sizing concentration and batch process variables on the tensile properties of fibre-reinforced polypropylene and polyamide composites were investigated. Resized fibres were characterized with thermal analysis, infrared spectroscopy and electron microscopy, and the tensile properties of the composites were analysed to confirm the achievable level of performance. For glass fibres, an optimal mass fraction of sizing on the fibres was found, as an excess amount of film former has a plasticising effect. For recycled carbon fibres, the sizing had little effect on the mechanical properties but led to significant improvement of handling and post-processing properties. A comparison between experimental results and theoretical prediction using the Halpin-Tsai model showed up to 81% reinforcing efficiency for glass fibres and up to 74% for carbon fibres.