Reuse of Carbon Fibers and a Mechanically Recycled CFRP as Rod-like Fillers for New Composites: Optimization and Process Development

Abstract

The rising amount of carbon fiber reinforced polymer (CFRP) composite waste requires new processes for reintroducing waste into the production cycle. In the present research, the objective is the design and study of a reuse process for carbon fibers and CFRP by mechanical recycling consisting of length and width reduction, obtaining rods and reintegrating them as fillers into a polymeric matrix. Preliminary studies are carried out with continuous and discontinuous unidirectional fibers of various lengths. The processing conditions are then optimized, including the length of the reinforcement, the need for a plasma surface treatment and/or for resin post-curing. The resin is thermally characterized by differential scanning calorimetry (DSC), while the composites are mechanically characterized by tensile strength tests, completed by a factorial design. In addition, the composites tested are observed by scanning electron microscopy (SEM) to study the fracture mechanics. Optimal processing conditions have been found to reduce the reinforcement length to 40 mm while maintaining the mechanical properties of continuous reinforcement. Furthermore, the post-curing of the epoxy resin used as matrix is required, but a low-pressure plasma treatment (LPPT) is not recommended on the reinforcement.

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

“…Chemical recycling involves the degradation of the polymer matrix to recover the fibers, but scalability and the handling of chemicals pose challenges [ 23 , 24 ]. Mechanical recycling involves physically shredding and grinding composites and stands out among the routes for composite recycling due to its ability to address multiple challenges [ 25 ]. Unlike thermal and chemical recycling, mechanical recycling avoids high energy requirements and scalability issues while at the same time reducing the emission of pollutant gases and the problems associated with the disposal of chemicals and solvents.…”