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.

Development of Hybrid Composite Utilizing Micro-Cellulose Fibers Extracted from Date Palm Rachis in the Najran Region.

Environmental effects can be reduced by using renewable resources in various applications. The date palm fibers (DPF) used in this study were extracted from waste date ranches of the Najran region by retting and manual peeling processes. The biocomposites were developed by reinforcing the silane-treated DPF (SDPF) at different wt.% in eugenol phthalonitrile (EPN) and difunctional benzoxazine (BA-a) copolymer. The impact strength, tensile, flexural, and dynamic mechanical properties and thermogravimetric analysis were evaluated to understand the mechanical, thermomechanical, and thermal properties. Results confirmed that 30 wt.% SDPF-reinforced poly (EPN/BA-a) composites produced the highest mechanical and thermomechanical properties, and were considered optimized SDPF reinforcement. Furthermore, hybrid composites with 30 wt.% SDPF and 15 wt.% silane-treated glass fibers (SGF) reinforcement having different lamination sequences were also studied. The lamination sequences showed a significant impact on the mechanical and thermomechanical properties, as properties were further enhanced by adding a core layer of SGF in hybrid composites. However, the thermal properties of SDPF/SGF laminates were higher than SDPF biocomposites, but the SGF lamination sequence did not produce any impact. According to the limiting oxygen and heat resistance indexes, the developed SDPF/SGF laminates are self-extinguishing materials and can be used in temperature-tolerant applications up to 230 °C.

Development of New Bio-Composite of PEO/Silk Fibroin Blends Loaded with Piezoelectric Material.

New bio-composite nanofibers composed of polyethylene oxide (PEO)/silk fibroin (SF)/barium titanate (BaTiO3) are introduced in this study. The SF solution was added to the PEO solution to form a PEO/SF blend with different weight percentages (5, 10, 15, 20 wt.%). The PEO/15 wt.% SF blend was selected to continue the experimental plan based on the optimum nanofiber morphology. Different wt.% of BaTiO3 particles (0.2, 0.4, 0.8, 1 wt.%) were added to the PEO/15 wt.% SF blend solution, and the suspensions obtained were introduced to an electrospinning device. The fabricated tissue was characterized by scanning electron microscope (SEM), X-ray diffraction (XRD) and Fourier-transform infrared (FTIR) spectroscopy. The zeta potential of the solution and the piezoelectric performance of the fabricated tissue were characterized. A newly designed pizoTester was used to investigate piezoelectric properties. The results showed that a well-organized, smooth PEO/15 wt.% SF/0.2 wt.% BaTiO3 nanofiber composite with low bead contents was obtained. Improved properties and electrical coupling were achieved in the newly introduced material. Electrospun PEO/15 wt.% SF/0.2 wt.% BaTiO3 mats increased the output voltage (1150 mV) compared to pristine PEO and PEO/SF composite fibers (410 and 290 mV, respectively) upon applying 20 N force at 5 Hz frequency. The observed enhancement in piezoelectric properties suggests that the prepared composite could be a promising material in cardiac tissue engineering (CTE).

Effect of Accelerated Weathering on the Thermal, Tensile, and Morphological Characteristics of Polypropylene/Date Nanofiller Composites.

The aging of polypropylene (PP) composites reinforced with date palm nanofiber (DNF) was investigated in this study in order to predict their long-term performance. To produce composites, date palm nanofibers in the range of 1-5 wt% loading were dry-melt-blended with polypropylene. These biocomposites were then subjected to UV exposure (Xenon arch source) for accelerated weathering for 250 and 500 h according to a standard method. The change in thermal properties before and after accelerated weathering was investigated using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). TGA analysis shows that the maximum degradation temperature for sample at 1 wt% loading was 382.7 °C, which slightly decreased to 379.9 °C after 250 h and to 367.7 °C after 500 h of weathering. DSC analysis also revealed lower crystallinity of the same samples after exposure to accelerated weathering. Mechanical properties were also studied to identify the damage induced by accelerated weathering. The tensile strength of the highest loading (5 wt%) of the sample was found to occur at 34.83 MPa, which was slightly lowered to 31.64 after 500 h treatment. A minimal decrease in tensile strength, deterioration, and weathering-induced oxidation indicates the excellent stability of these composites. Therefore, our study provides insight into the aging behavior of such composites, which may be useful in dry conditions, as well as nonstructural automotive and other parts for which minimum tensile strength (~25 MPa) is specified.

Impact of Hybrid Fillers on the Properties of High Density Polyethylene Based Composites.

The main objective of this work is to develop a variety of hybrid high-density polyethylene (HDPE) micro- and nanocomposites and to investigate their thermal, mechanical, and morphological characteristics as a function of number of fillers and their contents percentage. In this study, 21 formulations of the composites were prepared using fillers with different sizes including micro fillers such as talc, calcium carbonate (CaCO3), as well as nano-filler (fumed silica (FS)) though the melt blending technique. The morphological, mechanical, and thermal properties of the composite samples were evaluated. The morphological study revealed negligible filler agglomerates, good matrix-filler interfacial bonding in case of combined both CaCO3 and FS into the composites. Sequentially, improvements in tensile, flexural and Izod impact strengths as a function of fillers loading in the HDPE matrix have been reported. The maximum enhancement (%) of tensile, flexural and impact strengths were 127%, 86% and 16.6%, respectively, for composites containing 25% CaCO3 and 1% FS without any inclusion of talc filler; this indicates that the types/nature, size, quantity and dispersion status of fillers are playing a major role in the mechanical properties of the prepared composites more than the number of the used fillers.

Influence of Carbon Micro- and Nano-Fillers on the Viscoelastic Properties of Polyethylene Terephthalate.

In this research study, three carbon fillers of varying dimensionality in the form of graphite (3D), graphite nano-platelets (2D), and multiwall carbon nanotubes (1D) were incorporated into a matrix of poly (ethylene terephthalate), forming carbon-reinforced polymer composites. Melt compounding was followed by compression moulding and then a quenching process for some of the samples to inhibit crystallization. The samples were analysed using dynamic mechanical thermal analysis (DMTA) and scanning electron microscopy (SEM), considering the dimensionality and loading of the carbon fillers. The dynamic mechanical analysis revealed a similar decline of storage moduli for all composites during the glassy to rubbery transition. However, storage moduli values at room temperature increased with higher loading of nano-fillers but only to a certain level; followed by a reduction attributed to the formation of agglomerates of nanotubes and/or rolled up of nano-platelets, as observed by SEM. Much greater reinforcement was observed for the carbon nanotubes compared to the graphite and or the graphite nano-platelets. The quenched PET samples showed significant changes in their dynamic mechanical properties due to both filler addition and to cold crystallization during the DMTA heating cycle. The magnitude of changes due to filler dimensionality was found to follow the order: 1D > 2D > 3D, this carbon filler with lower dimensionality have a more significant effect on the viscoelastic properties of polymer composite materials.

Experimental and Theoretical Analysis of Mechanical Properties of Graphite/Polyethylene Terephthalate Nanocomposites.

In this work, graphite nanoplatelets (GNP) were incorporated into poly (ethylene terephthalate) (PET) matrix to prepare PET-GNP nanocomposites using a melt compounding followed by compression moulding and then quenching process. Both static and dynamic mechanical properties of these quenched materials were characterized as a function of GNP contents using dynamic mechanical thermal analysis (DMTA) and tensile machine, respectively. The results demonstrated that the addition of GNP improved the stiffness of PET significantly. Additionally, the maximum increase in the storage modulus of 72% at 6 wt.% GNP. The incorporation of GNP beyond 6 wt.% into PET decreases the storage moduli, but they remain higher than pure PET. The observed reduction could be due to agglomeration, resulting in poorer dispersion and distribution of higher levels of GNP into the PET matrix. In contrast to the results for moduli, tensile strength and elongations at break reduce with increasing the GNP content. For example, tensile strength reduced from ∼46 MPa (neat PET) to ∼39 MPa (-15%) for the nanocomposites containing 2 wt.% GNP. This reduction is accompanied by a decline in elongation at break from ∼6.3 (neat PET) to ∼3.4 (-46%) for the same nanocomposites. Such reductions are followed by a gradual decrease in upon further addition of GNP. These reductions indicate that increasing GNP loadings, results in brittleness in nanocomposites. In addition, it was found that quenched PET and composite samples were not fully crystallized after processing and therefore (cold) crystallized during the first heating cycle DMTA, as indicated by a rise in storage moduli above the glass transition temperature during the DMTA first heat. Furthermore, mathematical models based on non-linear theories are developed to capture the experimental data. For this, a set of mechanical stress-strain data is used for model parameters' identification. Another set of data is used for the model validation that demonstrates good agreements with the experimental study.

Enhancing the Performance of a Metal-Free Self-Supported Carbon Felt-Based Supercapacitor with Facile Two-Step Electrochemical Activation.

Carbon felt (CF) is an inexpensive carbon-based material that is highly conductive and features extraordinary inherent surface area. Using such a metal-free, low-cost material for energy storage applications can benefit their practical implementation; however, only limited success has been achieved using metal-free CF for supercapacitor electrodes. This work thoroughly studies a cost-effective and simple method for activating metal-free self-supported carbon felt. As-received CF samples were first chemically modified with an acidic mixture, then put through a time optimization two-step electrochemical treatment in inorganic salts. The initial oxidative exfoliation process enhances the fiber's surface area and ultimately introduced oxygen functional groups to the surface, whereas the subsequent reduction process substantially improved the conductivity. We achieved a 205-fold enhancement of capacitance over the as-received CF, with a maximum specific capacitance of 205 Fg-1, while using a charging current density of 23 mAg-1. Additionally, we obtained a remarkable capacitance retention of 78% upon increasing the charging current from 0.4 to 1 Ag-1. Finally, the cyclic stability reached 87% capacitance retention after 2500 cycles. These results demonstrate the potential utility of electrochemically activated CF electrodes in supercapacitor devices.

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

Carbon fiber-reinforced polymers are considered a promising composite for many industrial applications including in the automation, renewable energy, and aerospace industries. They exhibit exceptional properties such as a high strength-to-weight ratio and high wear resistance and stiffness, which give them an advantage over other conventional materials such as metals. Various polymers can be used as matrices such as thermosetting, thermoplastic, and elastomers polymers. This comprehensive review focuses on carbon fiber-reinforced thermoplastic polymers due to the advantages of thermoplastic compared to thermosetting and elastomer polymers. These advantages include recyclability, ease of processability, flexibility, and shorter production time. The related properties such as strength, modulus, thermal conductivity, and stability, as well as electrical conductivity, are discussed in depth. Additionally, the modification techniques of the surface of carbon fiber, including the chemical and physical methods, are thoroughly explored. Overall, this review represents and summarizes the future prospective and research developments carried out on carbon fiber-reinforced thermoplastic polymers.

Improving pitting corrosion resistance of the commercial titanium through graphene oxide-titanium oxide composite.

Titanium oxide has been commonly used for wide range of applications due to excellent corrosion resistance. This study presents the impact of graphene oxide (GO) addition to titanium oxide as coating materials during titanium anodization process on the corrosion behaviour. The GO was prepared by electrochemical exfoliation using low voltage mode in a sodium sulphate electrolyte, which is easier and more environmentally friendly compared to the chemical approach. Raman and scanning electron microscope were used to examine the success of the exfoliation process. The surface morphologies and potentiodynamic polarization results indicate that the addition of GO significantly inhibit the pitting corrosion and stabilize passivation current densities over wide ranges of anodic potentials. The untreated titanium, however, noticeably displayed fluctuation of anodic current densities, confirming the presence of pitting corrosion. The results obtained by electrochemical impedance spectroscopy (EIS) also confirm that the addition of GO enhanced corrosion protection even at higher frequency ranges. The cyclic polarization scan results show a positive shift in the re-passivation potential Erep after the addition of GO. This work emphasizes that the addition of GO during anodization of titanium not only protect its surface from pitting corrosion but also provide a strong passive layer.

Facile Synthesis of Hydrophilic Homo-Polyacrylamides via Cu(0)-Mediated Reversible Deactivation Radical Polymerization.

In this work, copper-mediated reversible deactivation radical polymerization (RDRP) of homo-polyacrylamides was conducted in aqueous solutions at 0.0 °C. Various degrees of polymerization (DP = 20, 40, 60, and 80) of well-defined water-soluble homopolymers were targeted. In the absence of any significant undesirable side reactions, the dispersity of polydiethylacrylamide (PDEA) and polydimethylacrylamide (PDMA) was narrow under controlled polymerization conditions. To accelerate the polymerization rate, disproportionation of copper bromide in the presence of a suitable ligand was performed prior to polymerization. Full conversion of the monomer was confirmed by nuclear magnetic resonance (NMR) analysis. Additionally, the linear evolution of the polymeric chains was established by narrow molecular weight distributions (MWDs). The values of theoretical and experimental number average molecular weights (Mn) were calculated, revealing a good matching and robustness of the system. The effect of decreasing the reaction temperature on the rate of polymerization was also investigated. At temperatures lower than 0.0 °C, the controlled polymerization and the rate of the process were not affected.

Evaluation of the Infill Design on the Tensile Response of 3D Printed Polylactic Acid Polymer.

The current study explores the effects of geometrical shapes of the infills on the 3D printed polylactic acid (PLA) plastic on the tensile properties. For this purpose, by utilizing an accessible supply desktop printer, specimens of diamond, rectangular, and hexagonal infill patterns were produced using the fused filament fabrication (FFF) 3D printing technique. Additionally, solid samples were printed for comparison. The printed tensile test specimens were conducted at environmental temperature, Ta of 23 °C and crosshead speed, VC.H of 5 mm/min. Mainly, this study focuses on investigating the percentage infill with respect to the cross-sectional area of the investigated samples. The mechanical properties, i.e., modulus of toughness, ultimate tensile stress, yield stress, and percent elongation, were explored for each sample having a different geometrical infill design. The test outcomes for each pattern were systematically compared. To further validate the experimental results, a computer simulation using finite element analysis was also performed and contrasted with the experimental tensile tests. The experimental results mainly suggested a brittle behavior for solidly infilled specimen, while rectangular, diamond, and hexagonal infill patterns showed ductile-like behavior (fine size and texture of infills). This brittleness may be due to the relatively higher infill density results that led to the high bonding adhesion of the printed layers, and the size and thickness effects of the solid substrate. It made the solidly infilled specimen structure denser and brittle. Among all structures, hexagon geometrical infill showed relative improvement in the mechanical properties (highest ultimate tensile stress and modulus values 1759.4 MPa and 57.74 MPa, respectively) compared with other geometrical infills. Therefore, the geometrical infill effects play an important role in selecting the suitable mechanical property's values in industrial applications.

Fracture toughness, vibration modal analysis and viscoelastic behavior of Kevlar, glass, and carbon fiber/epoxy composites for dental-post applications.

The use of flexible dental posts concentrates the stress at the dentin and the use of stiff posts increases the stress at the interface. Efforts were directed toward introducing inhomogeneous materials for resolving the disadvantages of both flexible and stiff posts. The main objective of this study was to develop three different fiber/epoxy composite posts. These composites were fabricated using carbon, glass, and Kevlar fibers. Characterization tests were conducted. In the tensile tests, the carbon, glass and Kevlar fiber composites exhibited tensile strengths of 200%, 91%, and 40% of the stainless-steel tensile strength, respectively, and exhibited stiffness values of 62%, 33%, and 12% of the stainless-steel stiffness. The carbon fiber/epoxy composite have a fracture toughness close to that of aluminum alloy. Vibration modal analysis indicated that the frequency response of the carbon fiber composite was lower than those of the glass and Kevlar composites. The highest tensile strength, storage moduli, and stiffness were recorded for the carbon fiber composites and the lowest were for Kevlar fiber composite. The low stiffness and strength of the Kevlar composite are attributed to the fact that Kevlar fibers had lower wettability with epoxy resin than both glass and carbon fibers. Moreover, the Kevlar fiber composite exhibited higher delamination. However, the stiffness and strength of Kevlar made its composite more sensitive than the other composites to free vibrations generated by a simple force induced by a hammer. Based on the results, the carbon fiber/epoxy composite has appropriate characteristics for application in new dental posts.

Addition of Graphite Filler to Enhance Electrical, Morphological, Thermal, and Mechanical Properties in Poly (Ethylene Terephthalate): Experimental Characterization and Material Modeling.

Poly(ethylene terephthalate)/graphite (PET/G) micro-composites were fabricated by the melt compounding method using a minilab extruder. The carbon fillers were found to act as nucleating agents for the PET matrix and hence accelerated crystallization and increased the degree of crystallinity. TGA showed that carbon fillers improved the resistance to thermal and thermo-oxidative degradation under both air and nitrogen atmospheres. However, a poor agreement was observed at higher loadings of the filler where the composites displayed reduced reinforcement efficiency. The results demonstrate that the addition of graphite at loading >14.5 wt.% made electrically conductive composites. It was calculated that the electric conductivities of PET/graphite micro-composites were enhanced, above the percolation threshold values by two orders of magnitudes compared to the PET matrix. The minimum value of conductivity required to avoid electrostatic charge application of an insulating polymer was achieved, just above the threshold values. The addition of graphite also improved thermal stability of PET, accelerated its crystallization process and increased the degree of crystallinity. Microscopic results exhibit no indication of aggregations at 2 wt.% graphite, whereas more agglomeration and rolling up could be seen as the graphite content was increased in the PET matrix (in particular, above the percolation threshold value). Furthermore, based on the mechanical experimental characterization of the PET/graphite micro-composites, a large deformation-based mathematical model is proposed for material behavior predictions. The model fits well the experimental data and predicts other mechanical data that are not included in the parameter identification.

Evaluation of Mechanical, Physical, and Morphological Properties of Epoxy Composites Reinforced with Different Date Palm Fillers.

The present study deals with the fabrication of epoxy composites reinforced with 50 wt% of date palm leaf sheath (G), palm tree trunk (L), fruit bunch stalk (AA), and leaf stalk (A) as filler by the hand lay-up technique. The developed composites were characterized and compared in terms of mechanical, physical and morphological properties. Mechanical tests revealed that the addition of AA improves tensile (20.60-40.12 MPa), impact strength (45.71-99.45 J/m), flexural strength (32.11-110.16 MPa) and density (1.13-1.90 g/cm3). The water absorption and thickness swelling values observed in this study were higher for AA/epoxy composite, revealing its higher cellulosic content, compared to the other composite materials. The examination of fiber pull-out, matrix cracks, and fiber dislocations in the microstructure and fractured surface morphology of the developed materials confirmed the trends for mechanical properties. Overall, from results analysis it can be concluded that reinforcing epoxy matrix with AA filler effectively improves the properties of the developed composite materials. Thus, date palm fruit bunch stalk filler might be considered as a sustainable and green promising reinforcing material similarly to other natural fibers and can be used for diverse commercial, structural, and nonstructural applications requiring high mechanical resistance.

Characterization of natural fiber obtained from different parts of date palm tree (Phoenix dactylifera L.).

The current study is motivated by the strict environmental regulations regarding the utilization and consumption of ecofriendly materials. In this context, the aim of this study has been to prepare and characterize different date palm tree (Phoenix dactylifera L.) fibers processed through the conventional water retting method. The chemical, elemental, crystallinity, thermal and morphological characterization of trunk (DPTRF), leaf stalk (DPLST), sheath or leaf sheath (DPLSH) and fruit bunch stalk (DPFBS) fibers was carried out. Chemical analysis revealed that the four types of date palm fibers display noteworthy differences in the content of cellulose, hemicellulose and lignin. Also, the amount of calcium is relatively high in all the date palm fibers; besides this, DPTRF exhibited 69.2% crystallinity, which is lower than that of DPLSH with 72.4% crystallinity. Moreover, DPLST and DPFBS fibers are more thermally stable (higher thermal degradation temperature) than DPTRF and DPLSH samples. Morphological analysis revealed that the fracture surface of DPFBS was relatively rougher, which would probably lead to increased bonding strength with polymers in composites. Overall, we conclude that DPFBS would be promising alternative sustainable and biomass material for the isolation of respective cellulose nanofibers and cellulose nanocrystals as potential reinforcement in polymer composites.

Porous Polyethylene Coated with Functionalized Hydroxyapatite Particles as a Bone Reconstruction Material.

In this study, porous polyethylene scaffolds were examined as bone substitutes in vitro and in vivo in critical-sized calvarial bone defects in transgenic Sprague-Dawley rats. A microscopic examination revealed that the pores appeared to be interconnected across the material, making them suitable for cell growth. The creep recovery behavior of porous polyethylene at different loads indicated that the creep strain had two main portions. In both portions, strain increased with increased applied load and temperature. In terms of the thermographic behavior of the material, remarkable changes in melting temperature and heat fusion were revealed with increased the heating rates. The tensile strength results showed that the material was sensitive to the strain rate and that there was adequate mechanical strength to support cell growth. The in vitro cell culture results showed that human bone marrow mesenchymal stem cells attached to the porous polyethylene scaffold. Calcium sulfate-hydroxyapatite (CS-HA) coating of the scaffold not only improved attachment but also increased the proliferation of human bone marrow mesenchymal stem cells. In vivo, histological analysis showed that the study groups had active bone remodeling at the border of the defect. Bone regeneration at the border was also evident, which confirmed that the polyethylene acted as an osteoconductive bone graft. Furthermore, bone formation inside the pores of the coated polyethylene was also noted, which would enhance the process of osteointegration.