Comprehensive Review of the Properties and Modifications of Carbon Fiber-Reinforced Thermoplastic Composites

Mechanical Recycling of Carbon Fiber-Reinforced Polymer in a Circular Economy

This review thoroughly investigates the mechanical recycling of carbon fiber-reinforced polymer composites (CFRPCs), a critical area for sustainable material management. With CFRPC widely used in high-performance areas like aerospace, transportation, and energy, developing effective recycling methods is essential for tackling environmental and economic issues. Mechanical recycling stands out for its low energy consumption and minimal environmental impact. This paper reviews current mechanical recycling techniques, highlighting their benefits in terms of energy efficiency and material recovery, but also points out their challenges, such as the degradation of mechanical properties due to fiber damage and difficulties in achieving strong interfacial adhesion in recycled composites. A novel part of this review is the use of finite element analysis (FEA) to predict the behavior of recycled CFRPCs, showing the potential of recycled fibers to preserve structural integrity and performance. This review also emphasizes the need for more research to develop standardized mechanical recycling protocols for CFRPCs that enhance material properties, optimize recycling processes, and assess environmental impacts thoroughly. By combining experimental and numerical studies, this review identifies knowledge gaps and suggests future research directions. It aims to advance the development of sustainable, efficient, and economically viable CFRPC recycling methods. The insights from this review could significantly benefit the circular economy by reducing waste and enabling the reuse of valuable carbon fibers in new composite materials.

Decomposition Kinetics and Lifetime Estimation of Thermoplastic Composite Materials Reinforced with rCFRP

Because of the high demand for carbon fiber reinforced polymer (CFRP) materials across all industries, the reuse and/or recycling of these materials (rCFRP) is necessary in order to meet the principles of the circular economy, including recycling and reuse. The objective of this study is to estimate the lifespan of thermoplastic matrix composite materials reinforced with waste materials (CFRP), which undergo only a mechanical cutting process. This estimation is carried out through the thermal decomposition of polymers, including polymer matrix composite materials, which is a complex process due to the numerous reactions involved. Some authors calculate these kinetic parameters using thermogravimetric analysis (TGA) as it is a quick method, and it allows the identification of gases released during decomposition, provided that the equipment is prepared for it. This study includes a comparison between polyamides 11 and 12, as well as between polyamide composite materials with carbon fiber (CF) and polyamides reinforced with CF/epoxy composite material. The latter is treated with plasma to improve adhesion with polyamides. The behavior of weight as a function of temperature was studied at speeds of 3, 6, 10, 13, 17, and 20 °C/min, finding stability of the polyamides up to a temperature of 400 °C, which was consistent with the analysis by mass spectroscopy, where gas evolution is evident after 400 °C. The estimation of the lifespan was carried out using two different methods including the Toop equation and the free kinetics model (MFK). The energy of the decomposition process was determined using the MFK model, which establishes the energy as a function of the degree of conversion. It is estimated that at 5% decomposition, mechanical properties are lost.

Innovative CF/PVC Foam Applicated for Automotive Synthetic Leather with High-Performance and Reduced VOC Emissions

Polyvinyl chloride (PVC) foam, valued for its mechanical and thermal properties along with cost-effectiveness, is extensively utilized across diverse industries. However, its high volatile organic compound (VOC) emissions hinder its adoption in eco-friendly synthetic leather. This study proposes a solution by optimizing the formulation design and foaming processes and achieving mechanical property enhancement via carbon-fiber-reinforced PVC composite foam (CF/PVC). The aim is to reduce PVC usage via enhancing its intrinsic properties. Systematic investigations were carried out on the impact of foaming raw materials, foaming processes, fiber content, and fiber length on the foaming performance, mechanical properties, and VOC emissions. The material formulation and process parameters were successfully optimized. Further assessment of various indicators such as the density, mechanical properties, and tear resistance of synthetic leather samples confirmed that the innovative CF/PVC foam developed in this study meets the requirements for automotive interior applications. Notably, the tensile strength and tear resistance of CF/PVC composite synthetic leather increased by 50% and 29%, respectively, compared to pure PVC, while VOC emissions decreased by 28%. It is anticipated that a more pronounced reduction in VOC emissions will be achieved in practical automotive interior leather applications when further considering the reinforcing effect of fibers, which leads to a reduction in PVC usage. The findings present a technical reference for innovative applications, aiming to enhance PVC foam performance and minimize emissions.

Reaction-induced morphological transitions in a blend of diblock copolymers and reactive monomers: dissipative particle dynamics simulation

The dissipative particle dynamics (DPD) method is applied to the morphological transitions of microphase-separated domains in a mixture of symmetric AB-diblock copolymers and reactive C-monomers, where polymerization and cross-linking reactions take place among C-monomers. The initial structure for the DPD simulation is an equilibrated cylindrical domain structure prepared by the density-biased Monte Carlo method with density profiles obtained from the self-consistent field theory. By introducing a cross-linking reaction among reactive C-monomers, we confirmed that the DPD simulation reproduces the morphological transitions observed in experiments, where the domain morphology changes due to segregation between A-blocks of diblock copolymers and cross-linking networks of C-monomers. When the cross-linking reaction of C-monomers is sufficiently fast compared to the deformation of the domains, the initial cylindrical domains are preserved, while the distance between the domains increases. On the other hand, when the formation of the cross-linking network is slow, the domains can deform and reconnect with each other in the developing cross-linking network. In this case, we observe morphological transitions from the initial domain morphology with a large-curvature interface to another domain morphology with a smaller-curvature interface, such as the transition from the cylindrical phase to the lamellar phase. We calculated the spatial correlations in the microphase-separated domains and found that such correlations are affected by the speed of the formation of the cross-linking network depending on whether the bridging between microphase-separated domains occurs in a nucleation and growth process or in a spinodal decomposition process.

Atomistic Modeling of the Effect of Temperature on Interfacial Properties of 3D-Printed Continuous Carbon Fiber-Reinforced Polyamide 6 Composite: From Processing to Loading

The combination of continuous fiber-reinforced thermoplastic composites (CFRTPCs) and the continuous fiber 3D printing (CF3DP) technique enables the rapid production of complex structural composites. In these 3D-printed composites, stress transfer primarily relies on the fiber-resin interface, making it a critical performance factor. The interfacial properties are significantly influenced by the temperatures applied during the loading and forming processes. While the effect of the loading temperature has been extensively researched, that of the forming temperature remains largely unexplored, especially from an atomistic perspective. Our research aims to employ molecular dynamics simulations to elucidate the effect of temperature on the interfacial properties of continuous carbon fiber-reinforced polyamide 6 (C/PA6) composites fabricated using the CF3DP technique, considering both loading and forming aspects. Through molecular dynamics simulations, we uncovered a positive correlation between the interfacial strength and forming temperature. Moreover, an increased forming temperature induced a notable shift in the failure mode of C/PA6 under uniaxial tensile loading. Furthermore, it was observed that increasing loading temperatures led to the deterioration of the mechanical properties of PA6, resulting in a gradual transition of the primary failure mode from adhesive failure to cohesive failure. This shift in the failure mode is closely associated with the glass transition of PA6.

Joint Performance of a Continuous Glass Fiber/Polypropylene Composite

Thermoplastic composite structures possess superior properties compared with thermosetting composites, including recyclability and high damage tolerance. However, the poor adhesion properties of thermoplastic composites make their joining process challenging. In this research, three bonding techniques, namely adhesive, mechanical joining, and hybrid bonding, are investigated using lap shear specimens to evaluate their mechanical properties and failure modes. The stress distributions at the joints of the three bonding techniques are analyzed by numerical simulation. The findings demonstrate that hybrid bonding enhances the strength of composite joints, albeit at the expense of some stiffness due to the presence of an open hole. This method is particularly suitable for applications that necessitate robust connections requiring high strength.

Novel Sustainable Composites Incorporating a Biobased Thermoplastic Matrix and Recycled Aerospace Prepreg Waste: Development and Characterization

Carbon fiber-reinforced polymer (CFRP) composite materials are widely used in engineering applications, but their production generates a significant amount of waste. This paper aims to explore the potential of incorporating mechanically recycled aerospace prepreg waste in thermoplastic composite materials to reduce the environmental impact of composite material production and promote the use of recycled materials. The composite material developed in this study incorporates a bio-based thermoplastic polymer, polyamide 11 (PA11), as the matrix material and recycled aerospace prepreg waste quasi-one-dimensionally arranged as reinforcement. Mechanical, thermal, and thermomechanical characterizations were performed through tensile, flexural, and impact tests, as well as differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA). Compared to previous studies that used a different recycled CFRP in the shape of rods, the results show that the recycled prepregs are a suitable reinforcement, enhancing the reinforcement-matrix adhesion and leading to higher mechanical properties. The tensile results were evaluated by SEM, and the impact tests were evaluated by CT scans. The results demonstrate the potential of incorporating recycled aerospace prepreg waste in thermoplastic composite materials to produce high-performance and sustainable components in the aerospace and automotive industries.

Influence of Molecular Weight on Thermal and Mechanical Properties of Carbon-Fiber-Reinforced Plastics Based on Thermoplastic Partially Crystalline Polyimide

For the first time, a study of the influence of the molecular weight of the thermoplastic partially crystalline polyimide R-BAPB on the thermophysical and mechanical properties of carbon plastics was presented. The molecular weight of polyimide was determined using the method of light scattering and the study of the intrinsic viscosity of polyamic acid solutions. To obtain CFRPs, the uniform distribution of polyimide powder on continuous carbon fibers via electrostatic spraying and further hot calendering and pressing were applied. The study of the structure of the obtained carbon plastics via scanning electron microscopy has shown that the growth of the molecular weight of polyimide prevents the impregnation of carbon fiber with the introduced polyimide. Moreover, an increase in the molecular weight of polyimide leads to a rise in glass transition and thermal decomposition temperatures up to 590 °C, while the degree of crystallinity of CFRP falls. Nonetheless, raising the molecular weight from 22,000 to 70,000 g/mol of a binder polymer improves the interlayer fracture toughness G_1C by more than five times.

A Molecular Dynamics Simulation for Thermal Activation Process in Covalent Bond Dissociation of a Crosslinked Thermosetting Polymer

A novel algorithm for covalent bond dissociation is developed to accurately predict fracture behavior of thermosetting polymers via molecular dynamics simulation. This algorithm is based on the Monte Carlo method that considers the difference in local strain and bond-dissociation energies to reproduce a thermally activated process in a covalent bond dissociation. This study demonstrates the effectiveness of this algorithm in predicting the stress-strain relationship of fully crosslinked thermosetting polymers under uniaxial tensile conditions. Our results indicate that the bond-dissociation energy plays an important role in reproducing the brittle fracture behavior of a thermosetting polymer by affecting the number of covalent bonds that are dissociated simultaneously.

Deformation Behavior of Single Carbon Fibers Impregnated with Polysulfone by Polymer Solution Method

Tensile deformation behavior of continuous high-strength and high-modulus single carbon fibers impregnated with a polysulfone solution was investigated. The effect of the carbon fiber type, mass fraction of the polymer, and the loading rate on the tensile strength was studied. It was observed that, whereas for high-modulus carbon fibers the magnitude of tensile strength depends significantly on the loading rate, for high-strength carbon fibers, such dependence was nearly not observed. SEM study shows that at low loading rates, elementary filaments inside the impregnated fiber are able to align themselves along the load application axis because a thermoplastic matrix can flow under the tensile stresses' force. As a result, the fiber's strength properties can be realized more effectively in the thermoplastic-based composites than in the same composite with an epoxy matrix.

Synthesis, Characterization, and Antibacterial Properties of ZnO Nanostructures Functionalized Flexible Carbon Fibers

BACKGROUND

Studies on the surface functionalization of flexible carbon fibers without any substrate by using cost-effective, fast, and practical processes that may provide antibacterial properties to carbon fiber have received great importance recently.

OBJECTIVE

The objective of this patent study is to obtain zinc oxide nanostructures functionalized carbon fibers by a facile, cheap, fast, and repeatable method, and to show their effective antibacterial activity.

METHODS

Electroplating and electrochemical anodization were used to synthesize zinc oxide nanostructures on carbon fiber surfaces, respectively, and their antibacterial properties were studied by zone inhibition test against Staphylococcus aureus and Pseudomonas aeruginosa.

RESULTS

The zinc oxide nanostructures on carbon fiber surfaces were successfully synthesized in minutes, and they exhibited effective antibacterial properties against Staphylococcus aureus and Pseudomonas aeruginosa. The morphological properties of the nanocomposite were studied using scanning electron microscopy, which showed that ZnO on the CF surface exhibits a flake-like nanostructure. Fourier transform infrared spectrophotometer, x-ray diffraction spectroscopy, Raman spectroscopy, and x-ray photoelectron spectroscopy were used to analyze the composite's compositional, structural, crystallographic, and spectral characteristics. The results from all analyses were in a good agreement, indicating that the wurtzite crystalline ZnO nanostructure was successfully produced on the CF surface.

CONCLUSION

As a consequence, a method for the surface functionalization of carbon fiber using zinc oxide nanostructures has been developed that is feasible, low-cost, rapid, and repeatable. The flexible nanocomposite structure has a significant potential to be employed as a scaffold in sensor technology, wearable devices, and particularly in medical textiles due to its antibacterial and woven-able properties.

Microstructural Characterization and Property of Carbon Fiber Reinforced High-Density Polyethylene Composites Fabricated by Fused Deposition Modeling

As a promising industrial thermoplastic polymer material, high-density polyethylene (HDPE) possesses distinct properties of ease to process, good biocompatibility, high recyclability, etc. and has been widely used to make packaging, prostheses and implants, and liquid-permeable membranes. Traditional manufacturing processes for HDPE, including injection molding, thermoforming, and rotational molding, require molds or post processing. In addition, part shapes are highly restricted., Thus, fused deposition modeling (FDM) is introduced to process HDPE materials to take advantage of FDM's free of design, no mold requirement, ease and low cost of processing. To improve the mechanical properties (such as stiffness and strength) and thermal resistance of HDPE, carbon fiber (CF) was incorporated into HDPE, and CF-reinforced HDPE composites were successfully fabricated using FDM process. In addition, the effects of CF content on surface quality, microstructure characterizations, tensile properties, dynamic mechanical properties, and thermal properties have been investigated. Experimental results show that an appropriate CF content addition is beneficial for improving surface quality, and mechanical and thermal properties.

An Injecting Molding Method for Forming the HFRP/PA6 Composite Parts

Carbon/glass fiber-reinforced polymer hybrid composite (HFRP) has the advantages of a light weight and high strength. For the lightweight design of automobile parts, composite parts made of HFRP and polymer materials are increasingly in demand. The method of the injection molding is usually adopted to fabricate composite part with HFRP and polymer materials. The connecting strength between the two materials has an important influence on the service life of the composite part. In this paper, HFRP and polyamide-6 (PA6) were used to fabricate a composite part by the injection molding method. In order to improve the connecting strength between HFRP and PA6, a kind of micro-grooves was fabricated on the HFRP surface. The micro-grooves on the surface of the HFRP provided sufficient adhesion and infiltrating space of molten PA6 material into the mold. In addition, the glass fiber in HFRP can also be used as nucleating agent to facilitate the rapid crystallization of PA6. The micro-grooves on the surface of HFRP were embedded into PA6 like nails, which could improve the connecting strength at the interface effectively. The paper investigated the effects of mold temperature, injection pressure, holding pressure and holding time on the injection quality and connecting strength of composite parts in detail. With a mold temperature of 240 °C, an injection pressure of 8 MPa, a holding pressure of 8 MPa and a holding time of 3 s, the maximum tensile strength of 10.68 MPa was obtained for the composite part. At the effect of micro-grooves, the tensile strength of the composite part could be increased by 126.27%.

Evaluation of Microscopic Damage of PEEK Polymers under Cyclic Loadings Using Molecular Dynamics Simulations

Full-atomic molecular dynamics simulations were conducted to investigate the time evolution of microscopic damage in polyetheretherketone (PEEK) polymers under cyclic loading conditions. Three characteristics were used to quantify microscopic damage: entropy, distribution of the end-to-end distance of polymers, and the volume fraction of voids. Our results show that the degree of disentanglement of polymers and the volume fraction of voids increase with cyclic loading, which may lead to entropy generation. Uniaxial tensile strength simulations of the polymer system before and after cyclic loading were performed. The tensile strength after cyclic loading was lower than that before loading. Furthermore, two systems with the same entropy and different loading histories showed almost the same strength. These results imply that entropy generation is expressed as the total microscopic damage and can potentially be employed for effective evaluation of the degradation of material characteristics.

Elevated Strain Rate Characterization of Compression Molded Direct/In-Line Compounded Carbon Fibre/Polyamide 66 Long Fibre Thermoplastic

Compression molded direct compounded carbon fibre D-LFT was evaluated at quasi-static strain rates through uniaxial tension tests (including a specimen size study) and a variation of the ISO 6603-2 puncture test. No significant size effects were observed for the modulus or strength obtained from tensile specimens with four gauge lengths (6.25 mm to 57 mm). Failure strain decreased by 27.5%/29.9%, respectively, across the gauge length range for the 0°/90° directions. Intermediate strain rate (10 s^-1 to 200 s^-1) characterization was completed through uniaxial tension tests on a novel apparatus and ISO 6603-2 puncture tests. Intermediate rate tensile tests showed minimal rate sensitivity for the 0°/90° directions. Initial stiffness was 50% higher for ISO 6603-2 impact tests compared to quasi-static tests. Displacement at the onset of fracture was 95% lower for impact tests compared to quasi-static loading. The peak force/displacement at peak force were reduced for impact tests (21% and 20%, respectively) compared to quasi-static testing.

Effect of Polyphenylene Sulphide Particles and Films on the Properties of Polyphenylene Sulphide Composites

Glass fibre-reinforced polyphenylene sulphide composites were prepared by hot-pressing glass fibre fabrics and polyphenylene sulphide resins. The effects of different polyphenylene sulphide resin forms on the properties of the composites were investigated using scanning electron microscopy, dynamic mechanical analyser, pendulum impact tester and universal testing machine. The results showed that different polyphenylene sulphide resin forms had nearly no effect on the glass transition temperature of the composites, which are all located at about 100 °C. Compared with other polyphenylene sulphide composites, the bending strength of polyphenylene sulphide film composites was the highest, reaching 314.58 MPa, and the impact strength of polyphenylene sulphide particle composites was the highest, reaching 245.4 KJ/m². The bending strength and impact strength were calculated using a standard fraction, and the highest standard fraction was obtained when the ratio of polyphenylene sulphide film to particle was 1:2. The impact strength and bending strength could be obtained. The impact strength reached 229.8 KJ/m², and the bending strength reached 284.16 MPa.

Effect of Fiber Type and Content on Surface Quality and Removal Mechanism of Fiber-Reinforced Polyetheretherketone in Ultra-Precision Grinding

Polyetheretherketone (PEEK) is a promising thermo-plastic polymer material due to its excellent mechanical properties. To further improve the mechanical properties of PEEK, different kinds of short fibers are added into the PEEK matrix. The grinding machinability of short-fiber-reinforced PEEK varies with the effect of fiber type and content. Therefore, it is crucial to investigate the surface quality and removal mechanism of fiber-reinforced PEEK in ultra-precision grinding. In this paper, different fiber types and mass fractions of short-fiber-reinforced PEEK, including carbon-fiber-reinforced PEEK (CF/PEEK) and glass-fiber-reinforced PEEK (GF/PEEK), are employed. The grinding machinability of short-fiber-reinforced PEEK was investigated using grinding experiments with grinding wheels of different grit sizes. The effects of the fiber type and mass fraction on the surface quality and removal mechanism during grinding were discussed. The results showed that the brittle-ductile transition depth of carbon fiber was much larger than that of glass fiber, so it was easier to achieve ductile removal in grinding with the carbon fiber. Therefore, the ground surface roughness of CF/PEEK was smaller than that of GF/PEEK under the same grinding conditions. With the increase in carbon fiber mass fraction, the ground surface roughness of CF/PEEK decreased due to the higher hardness. The brittle-ductile transition depth of glass fiber was small, and it was easy to achieve brittle removal when grinding. When the glass fiber removal mode was brittle removal, the GF/PEEK surface roughness increased with the increase in glass fiber content.

Effect of Electrostatic Interactions on the Interfacial Energy between Thermoplastic Polymers and Graphene Oxide: A Molecular Dynamics Study

In this study, the atomistic-scale mechanisms affecting the interfacial stability of a thermoplastic polymer/graphene oxide interface are investigated using molecular dynamics simulations. Different combinations of thermoplastic polymers (polyethersulfone (PES) and polyetherimide (PEI)) and graphene oxides modified with –O–, –OH, and –COOH are prepared. PES is found to be more strongly stabilized with modified/functionalized graphene oxide in the order of –COOH, –OH, –O–, which is opposite to the stability order of PEI. Our results suggest that these orders of stability are governed by a balance between the following two factors resulting from electrostatic interactions: (1) atoms with a strong charge bias attract each other, thereby stabilizing the interface; (2) the excluded-volume effect of the functional groups on graphene oxide destabilizes the interface by preventing π-π stacking of aromatic rings.

Carbon Fiber/PLA Recycled Composite

Due exceptional properties such as its high-temperature resistance, mechanical characteristics, and relatively lower price, the demand for carbon fiber has been increasing over the past years. The widespread use of carbon-fiber-reinforced polymers or plastics (CFRP) has attracted many industries. However, on the other hand, the increasing demand for carbon fibers has created a waste recycling problem that must be overcome. In this context, increasing plastic waste from the new 3D printing technology has been increased, contributing to a greater need for recycling efforts. This research aims to produce a recycled composite made from different carbon fiber leftover resources to reinforce the increasing waste of Polylactic acid (PLA) as a promising solution to the growing demand for both materials. Two types of leftover carbon fiber waste from domestic industries are handled: carbon fiber waste (CF) and carbon fiber-reinforced composite (CFRP). Two strategies are adopted to produce the recycled composite material, mixing PLA waste with CF one time and with CFRP the second time. The recycled composites are tested under tensile test conditions to investigate the impact of the waste carbon reinforcement on PLA properties. Additionally, thermogravimetric analysis (TGA), X-ray diffraction (XRD), and Fourier-transformed infrared spectroscopy (FTIR) is carried out on composites to study their thermal properties.

Study on Axial Compression Behavior of Concrete Short Columns Confined by Flax/Glass Fiber Hybrid-Reinforced Epoxy Resin Composites

In this study, we aimed to explore the effect of concrete short columns confined by flax/glass fiber hybrid-reinforced epoxy resin (FFRP/GFRP) composites. Taking the same fiber hybrid ratio and different paving orders as parameters, analysis of the axial compressive mechanical properties of eight groups of FFRP/GFRP composite-confined concrete short columns, including one group of flax fiber-reinforced epoxy resin (FFRP) composite-confined concrete short columns and one group of unconstrained concrete short column, was conducted. The effects of different layering sequences on failure modes, load–displacement curves, energy dissipation ductility and the stress–strain relationship of hybrid composite-confined concrete short columns were analyzed. The results show that the axial compression failure modes of FFRP/GFRP composite-confined concrete short columns with the same hybrid ratio and different paving sequences were basically the same, and the CC-H6 group was the most prominent. The ultimate bearing capacity and axial deflection were 91.05% and 11.49% higher than those of the control group (CC-FFRP), and the energy dissipation coefficient was also the largest, at 9.79. The failure trend of the stress–strain curve of the confined concrete short column specimens was basically the same, and the stress and axial strain of the members were increased by 247.9~292.5% and 486.7~701.0%, respectively.