Repurposed/recycled discontinuous carbon fiber organosheet development and composite properties

Abstract

The high cost of carbon fiber composites often limits their use in automotive applications. This paper describes the study of an emerging class of materials, chopped fiber reinforced thermoplastic (polyphenylene sulfide) organosheets that provide mechanical properties exceeding sheet molding compounds at low material and manufacturing cost with long shelf life at room temperature. The tensile and shear properties were found to be directionally-dependent, while the impact of void content on these properties was small. It was shown that tensile testing of the dry preforms can serve as a method of screening the degree of anisotropy, reducing the need for extensive processing trials. Due to the anisotropy and microstructure variance of these materials, designs must encompass laminate stacking sequence and the variability in mechanical properties. Monte Carlo simulations of composite lamination theory utilizing stochastic mechanical properties conservatively predict the mechanical properties of organosheet laminates. This paper offers one of the first in-depth evaluations of this novel new class of composite materials made of repurposed/recycled carbon fiber.