Filler Distribution Research Articles

Nanoarchitectured composite of polysulfone and carbon-based fillers bearing magnetically stimulable function for efficient CO2 capture

Mitigating the global warming caused by CO2 emissions from anthropogenic sources is a hot research topic in the current era. The high cost and difficulty in handling liquid solvent absorbents for CO2 capture are the main barriers to their industrial application. Earth-abundant solid sorbents are favorable candidates for CO2 separation, offering a low energy penalty for CO2 desorption. Here, Polysulfone (PSF) nanocomposites were prepared by simple solution blending. The carbon-based fillers, namely carbon nanotubes (CNT), and activated carbon (CA) in the range of 5–20 wt%, containing iron nanoparticles, were used as fillers. Their morphological, thermal, CO2 capture capacity and magnetic properties were comprehensively studied. Transmission electron microscopy (TEM) evidenced uniform filler distribution in the polymer matrix with sizes of 47–54 nm. Thermal analysis revealed an approximately 4 °C improvement in both the initial (Tonset) and maximum (Tmax) degradation temperatures by adding 5 wt% of nanoparticles compared to the pristine polymer. The glass transition temperature (Tg) of the pristine PSF and produced nanocomposites showed identical values as estimated by differential scanning calorimetry (DSC). The increase in filler amount gradually decreased the water contact angle values, indicating a hydrophilic classification of the PSF nanocomposites. The obtained PSF nanocomposites exhibited an efficient CO2 capture capacity of about 40–61 mgCO2/g at 45 °C, higher than pristine PSF. This remarkable achievement sets a new benchmark compared to previously developed systems. The introduction of the filler transforms the diamagnetic polymer matrix into a ferromagnet, presenting a coercivity of about 480 Oe, enhancing the material's potential for applications in microelectronics.

Impact of ambient and vacuum pressure on the physico mechanical properties of flexible polyurethane foam reinforced with CaCO3

AbstractThis study investigates the effects of variable pressure conditions (550 and 1013 mbar) on the physico‐mechanical and structural properties of flexible polyurethane foam, incorporating different compositions of calcium carbonate (CaCO3) filler. The objective is to achieve sustained mechanical and structural properties of flexible polyurethane foam while reducing costs through variable pressure foaming technology. With CaCO3 filler concentrations ranging from 20 to 100 parts per hundred (pphp) of polyol, it was found that foam produced at low pressure (550 mbar) demonstrated improved resilience and durability, particularly with CaCO3 compositions up to 100 pphp. Conversely, foam produced at standard atmospheric pressure (1013 mbar) using compositions up to 100 pphp did not exhibit significant enhancements in physico‐mechanical properties. The study employs various characterization techniques, including mechanical testing, scanning electron microscopy, differential scanning calorimetry, thermal gravimetric analysis, and Fourier transform infrared spectroscopic analysis, to assess the flexible polyurethane foam. It provides a detailed examination of the effects of variable pressure on cellular structure, cell size, filler distributions, mechanical properties, and thermal stability of flexible polyurethane foam using CaCO3 filler.

Modulating Thermal Conductivity and Flame Retardancy of Polyolefin Composites via Distributed Structures of Magnesium Hydroxide and Hexagonal Boron Nitride.

Thermally conductive and flame-retardant polyolefin composites are facing great challenges in meeting the increasing demands for fire safety and thermal management. Aiming at simultaneously enhancing thermal conductivity and flame retardancy, hexagonal boron nitride (hBN) and magnesium hydroxide (MH) were adopted in ethylene-vinyl acetate copolymer/polyolefin elastomer (EVA/POE) blends to design composites with selective filler distributions and co-continuous networks via different processing schemes. The thermal conductivity and flame retardancy show strong dependence on the distributed structure of hBN and MH. The composites with hBN-rich centers and MH-rich edges in the filled POE phase show a thermal conductivity of 0.70 W/(m·K) and an LOI of 27.7%, which are very close to the thermal conductivity of EVA/POE/hBN and the LOI of EVA/POE/MH at the same total filler content. The composites with MH-rich centers and hBN-rich edges show pHRR, THR and TSP values of 169 kW/m2, 49.8 MJ/m2 and 1.8 m2, which are decreased by 40%, 33% and 62% in comparison with EVA/POE/MH, respectively. Modulating the filler structure distribution provides a strategy to co-enhance thermal conductivity and flame retardancy.

Bio‐marine shell powder‐filled jute fabric/epoxy composites: Chemical, combustion, and mechanical properties

AbstractNatural fiber/resin composites exhibit poor fiber–matrix compatibility and easy combustion. In this study, jute‐fiber‐reinforced epoxy resin was used to prepare composite materials by adding marine shell powder, which is a natural non‐combustible inorganic filler that originates from a variety of sources. The morphology, composition, thermal stability, combustion performance, and mechanical properties of the prepared composites were tested using several characterization methods. The results show that the marine shell powder was evenly distributed in the epoxy resin and did not affect the adhesion between the epoxy resin and the jute fiber. When 20% marine shell powder (SMJF20) was added to the jute‐fiber‐reinforced epoxy resin composite, the pyrolytic residual content was 21.88% (60.2% higher than that without), and the maximum heat release rate was 350.75 kW/m2 (22.8% lower than that without). The total heat release and total smoke release of SMJF20 were also 13.9% and 30% lower than that of MJF, respectively. The addition of marine shell powder did not significantly affect the tensile strength, whereas the tensile modulus of SMJF20 increased by approximately 13.9%, the fracture strain decreased by approximately 13.4%, and the bending strength and modulus decreased by approximately 12.9% and 13.0%, respectively. Marine shell powder is an ideal biomass filler for jute‐fiber‐reinforced epoxy resins.Highlights Jute‐fiber‐epoxy composites fortified with non‐combustible marine shell powder. Effective filler distribution without compromising epoxy‐jute fiber adhesion. 20% marine shell powder significantly reduces heat release and smoke release. Tensile strength unaffected; tensile modulus and residual content increased. Marine shell powder proves ideal for enhancing epoxy resin with jute fibers.

Percolation behavior and sensing performance of polypropylene‐based conductive polymer composites under compressive strains and temperature

AbstractPercolation behavior is highly significant for mechanical, thermal, and electrical properties, as well as manufacturing processes of conductive polymer composites (CPCs). It has been reported that temperature and external loads are important parameters directly affecting the percolation threshold. Herein, carbon black/polypropylene (CB/PP) and carbon black/multiwalled carbon nanotubes/polypropylene (CB/MWCNTs/PP) composites are prepared via the melt blending method. After the synthesis of composites, the rheological properties, the filler distribution, crystallization, and conductive network formation within the composite are evaluated. The effect of conductive network structure on conductive percolation behavior is studied under various compressive strains and temperatures. Finally, the sensing performance under compressive strain and temperature cycling is discussed. Obtained results reveal that MWCNTs work as “bridges” between segregated CB particles leading to a synergic effect on the conducting properties. The volume resistivity of PP‐based CPCs exhibits a critical strain and a positive temperature coefficient (PTC), resulting in altered percolation. PP‐based CPCs with the addition of MWCNTs have greater PTC intensity, demonstrating sensing stability and sensitivity to compressive strain under temperature cycling. This study underscores the essential contribution of MWCNTs in building conductive networks and elucidates the potential application of PP‐based CPCs with superior sensing performance under compressive strain and varying temperatures.

Distribution of Filler in Polymer Composites. Role of Particle Size and Concentration

Distribution of Filler in Polymer Composites. Role of Particle Size and Concentration

Properties of Nanohybrid Dental Composites-A Comparative In Vitro Study.

(1) Background: the current study investigated three nanohybrid composites: two commercial products ClearfilMajestyTM (CM) and HarmonizeTM (HU), compared with an experimental product PS2. (2) Methods: Two sample types were molded using Teflon dies. The first sample type was represented by standard discs (20 mm diameter and 2 mm thickness) (n = 60, 20/each material), used for surface conditioning investigation, specifically roughness monitoring and color stability analysis using AFM and the CIELab test, respectively. The second sample type was a standard cylindrical specimen (4 mm diameter and 6 mm height) for compression testing (n = 60, 20/each material). After complete polymerization, the samples were ground with sandpaper and further polished. The filler size and distribution in the polymer matrix were investigated with SEM. Data were statistically analyzed using the Anova Test followed by Tukey's post hoc test on the Origin Lab 2019 software produced by OriginLab Corporation, Northampton, MA, USA. (3) Results: A mono-disperse system was identified in HU samples, while CM and PS2 revealed both nano- and microfiller particles. The samples' observation after immersion in coffee and tea indicated that a lower roughness combined with optimal filler lamination within the polymer matrix assured the best color preservation. The compression strength was lower for the HU sample, while higher values were obtained for the complex filler systems within CM and PS2. (4) Conclusions: the behavior of the investigated nanohybrid composites strongly depends on the microstructural features.

Polymer‐based filaments with embedded magnetocaloric Ni‐Mn‐Ga Heusler alloy particles for additive manufacturing

AbstractOne important issue associated to magnetocaloric materials that hinders its technological application is the poor processability and structural integrity of those with the highest performance, usually intermetallics undergoing first‐order magnetic phase transitions. Additionally, the performance of these magnetocaloric materials highly depends on the structural stability of the magnetocaloric phase, which is, in many cases, very sensitive to temperature and mechanical processes. Additive manufacturing via the extrusion of polymer‐based composites is regarded as a promising way to overcome these issues. A recently presented manufacturing method of encapsulating functional fillers into polymer capsules has been used to produce a composite filament with a large load of magnetocaloric off‐stoichiometric Ni2MnGa Heusler alloy fillers with a uniform distribution throughout the polymer matrix as demonstrated by x‐ray tomography characterization. The incorporation of these metallic particles causes changes in the thermal behavior of the polymer as well as an increase in the flowability of the composite with respect to the polymer at the same temperature. The increased flowability of the composites found during manufacturing can be compensated by lowering the extrusion temperatures, making this technique even more convenient for preserving the filler properties, which is an important concern when additive manufacturing magnetocaloric materials. This is confirmed by the magnetic and magnetocaloric behavior of the composites, with responses proportional to the fraction of fillers.Highlights Ultrasonic‐atomization produces highly spherical Ni‐Mn‐Ga Heusler alloy particles. Ni‐Mn‐Ga filled polymer capsules allow a direct extrusion of composites for AM. X‐ray tomography shows uniform volumetric filler distribution within the filaments. Decreased viscosity of the matrix favors the lowering of the processing temperature. The low processing temperatures avoid altering the MCE of the alloy fillers.

Coaxially MXene-confined solid-state electrolyte for flexible high-rate lithium metal battery

Solid-state polymer electrolytes (SPEs) possess conspicuous merits of facile manufacturing, superior mechanical toughness, and favorable chemical stability with Li anodes, but the intrinsically low room temperature ionic conductivity (∼10−8 −10−6 S cm−1) and negligible Lithium-ion transfer number (0.1–0.2) badly inhibited its commercial application in lithium metal batteries (LMBs). Herein, we design the three-dimensionally and coaxially MXene-confined solid-state polymer electrolyte (C-MX SPE) for the directional acceleration movement of Li+ ion by introducing MXene nanosheets into the polyacrylonitrile (PAN) fiber. Benefiting from the confinement effect, the homogeneously and coaxially MXene-confined SPE possess an impressive Li+ ion transference number of 0.72 and ionic conductivity of 3.07 × 10−3 S cm−1 at room temperature, which are 3 and 20 times of magnitude higher than the randomly MXene-dispersed (R-MX) SPE (0.22 and 1.61 ×10−4 S cm−1), respectively. Also, the Lithium/SPE/Lithium symmetric cell exhibits a flat galvanostatic charge/discharge under 1 mA cm−2 for 2000 h without dendrites, revealing its 3D skeleton structure could mechanically suppress Li dendrite growth. Based on it, the assembled flexible solid-state lithium metal batteries (SSLMBs) possess a rate-capability of 101 mAh g−1 @ 10 C, a capacity retention of 85.18% after 500 cycles @ 1 C at room temperature and a stability of bending-needling-cutting performance. Evidently, this three-dimensionally and coaxially MXene-confined SPE may represent a promising strategy to address the random distribution and agglomeration of inorganic fillers in SPE and guide a direction for the development of high-performance, secure, and flexible SSLMBs.

Pore-Networked Soft Materials Based on Metal-Organic Polyhedra.

ConspectusThe last two decades have witnessed a tremendous development of crystalline microporous adsorbents in a wide range of applications including molecular adsorption, storage and separation, purification, as well as catalysis. The main players as porous materials that have contributed to the developments are extended molecular frameworks (e.g., metal-organic frameworks, MOFs; covalent-organic frameworks, COFs) or discrete porous molecules (e.g., metal-organic cages, MOCs; porous organic cages, POCs) thanks to the high degrees of freedom in their structural designability and tunability. To overcome the processability issue originating from their powder forms after synthesis, one main strategy is to hybridize the microporous adsorbents as pore-containing fillers with solvents or polymers as processable matrices to produce porous soft materials, such as porous liquids, gels/aerogels, and mixed-matrix membranes, depending on the form of matrix used. Nevertheless, the fabrication of "ideal" hybrid materials relies on the homogeneous distribution of the pore-containing fillers within the matrices. It is still challenging to find a versatile way to solve the aggregation issues of fillers and their insufficient interaction with the matrices, which are concerned with inhibiting the translation of the distinctive properties of microporous adsorbents into the obtained hybrid soft materials.Herein, we describe a new bottom-up approach for the fabrication of "pore-networked soft materials" based on the concept of directly interconnecting the pore-containing fillers into a continuous pore network within the matrices. The advantages of the pore-networking strategy lie in two main aspects: (i) the elimination of the need to struggle with the aggregation issue of fillers due to their overall interconnection throughout the matrices; (ii) the generation of continuous pore networks that guarantee the efficient molecular mass transfer in the materials. In this Account, we summarize our state-of-the-art progress of pore-networked soft materials based on the use of MOCs, alternatively called metal-organic polyhedra (MOPs) herein, as pore units for the pore network construction. The good solubility of MOPs in organic solvents allows them to be feasibly processed in solution, wherein the coordination of MOPs with organic linkers leads to the formation of linked MOP gels featuring not only intrinsic MOP cavities but also tunable extrinsic porosities generated between linked MOPs through the control of MOP/linker structures and network connectivity. Furthermore, the matrix of the linked MOP network, here referred to as the continuous phase with respect to the entire porous MOP network, is not limited to the solvents. We anticipate that the implementation of air, liquids, and polymers as the matrices could result in different forms of pore-networked soft materials like aerogels, foams, gels, monoliths, and membranes. For instance, we demonstrate the fabrication of linked MOP aerogel and permanently porous gel with their potential applications on selective CO2 photoreduction and gas sorption, respectively. We believe that the pore-network strategies will advance the development of porous soft materials featuring unique advantages and properties beyond the current hybrid systems.

Epoxy filled with nylon powder—An approach to reduce void formation via fused particle method

AbstractIn the quest for superior materials, especially in industrial applications demanding strength, stiffness, low density, and cost‐efficiency, composite materials have emerged as game changers. Combining a polymer matrix with reinforcement materials, they hold great promise. However, the challenge of particle agglomeration looms large, especially at high loadings. Particle agglomeration disrupts filler distribution and gives rise to voids in polymer composites. This study investigates the fusion behavior of agglomerated Nylon particles and their influence on Nylon/epoxy composites. Using epoxy resin and Nylon SP301, a micron‐sized Nylon 12 powder with a 185°C melting point, composites were prepared at 3%, 9%, and 15% Nylon loading. After curing, these composites underwent controlled heating at 185, 195, and 205°C, with a fusion of 20–100 min. At 185°C, particles initially remain separate, forming slight clumps after 20 min and increasingly sticking together at 60 and 100 min. Shifting to 195°C, particles begin consolidating into a solid mass even after 20 min. The introduction of Nylon decreases composite density compared to pure epoxy, and density changes vary with fusion time, exhibiting complete fusion, partial fusion, and shrinkage‐induced gap formation. Differential scanning calorimetry analysis reveals evolving glass transition temperatures (Tg) influenced by the fusion process, with longer fusion times yielding higher Tg and greater heat capacity.

Influence of curing time on some properties of GNPs/PDMS nanocomposites

Graphene nanoplatelets/polydimethylsiloxane (GNPs/PDMS) nanocomposites foils are obtained by dispersing nanoplatelets of graphene (GNPs) into polydimethylsiloxane (PDMS) at a given GNPs concentration but at different curing times to study the effects of curing time on some their bulk and surface properties. Their appearance and morphology have been examined by optical and scanning electron microscopies, their wettability and roughness by the sessile drop method and profilometry, their bonds by µRaman and ATR-FTIR spectroscopies, their dielectric response by dielectric spectroscopy. In particular, optical and SEM images and roughness measurements indicate a roughened and hydrophobic surface at the shortest curing time that becomes less roughened, more uniform and less hydrophobic as curing time increases. ATR-FTIR and µRaman spectra reveal the absence of chemical interaction between GNPs and PDMS. The behavior of the PDMS real and imaginary parts of dielectric permittivity without and with GNPs and at increasing curing times seems to define the obtained GNPs/PDMS nanocomposites as low-loss materials. The obtained results show that the curing time significantly affects the filler distribution in the PDMS matrix and consequently the properties of the final nanocomposites.

Two-state nanocomposite based on symmetric diblock copolymer and planar nanoparticles: mesoscopic simulation

A method for controlling the distribution and orientation of 2D fillers in the copolymer matrix is presented.

Renewable Compatibilizing Agent for Silica Reinforced Natural Rubber

The main problem in utilizing silica as an alternative reinforcing filler for natural rubber (NR) compounds is a weak rubber-filler interaction and poor filler distribution due to their incompatibility feature. The particles of silica have a strong tendency to filler interactions which leads to form silica agglomeration. To solve this drawback, this work has utilized ethanolamine-modified palm stearin (EMPS) as a renewable compatibilizer agent to improve NR-silica compatibility. The EMPS was prepared by a typical chemical reaction between ethanolamine and refined bleach-deodorized palm stearin (a byproduct of cooking oil production) on a laboratory scale. The influence of the EMPS on the improvement of rubber-filler interaction was investigated by studying the processing characteristics and the tensile properties of silica-reinforced NR compound (silica content was fixed at 30 phr). Compared to the silica-reinforced NR with no EMPS, it was found that EMPS caused a greater coefficient of vulcanization, tensile strength, and reinforcement effect for the silica-reinforced NR. It was due to an active reaction between silanol groups of silica with EMPS which increased the NR-silica compatibility, and the Fourier Transform Infra-Red (FTIR) analysis has confirmed the typical reaction.

Effect of the Interplay between Polymer-Filler and Filler-Filler Interactions on the Conductivity of a Filled Diblock Copolymer System.

We investigate the relative roles of the involved interactions and micro-phase morphology in the formation of the conductive filler network in an insulating diblock copolymer (DBC) system. By incorporating the filler immersion energy obtained by means of the phase-field model of the DBC into the Monte Carlo simulation of the filler system, we determined the equilibrium distribution of fillers in the DBC that assumes the lamellar or cylindrical (hexagonal) morphology. Furthermore, we used the resistor network model to calculate the conductivity of the simulated filler system. The obtained results essentially depend on the complicated interplay of the following three factors: (i) Geometry of the DBC micro-phase, in which fillers are preferentially localized; (ii) difference between the affinities of fillers for dissimilar copolymer blocks; (iii) interaction between fillers. The localization of fillers in the cylindrical DBC micro-phase has been found to most effectively promote the conductivity of the composite. The effect of the repulsive and attractive interactions between fillers on the conductivity of the filled DBC has been studied in detail. It is quantitatively demonstrated that this effect has different significance in the cases when the fillers are preferentially localized in the majority and minority micro-phases of the cylindrical DBC morphology.

Improving the packing and mechanical properties of graphite blocks by controlling filler particle-size distribution

Mechanical qualities play a critical role in increasing the industrial applications of carbon-carbon composite materials as their porosity determines the strength of the material. In this study, carbon blocks with improved packing properties were produced by controlling various particle size distributions of coke particles. Particle-size diversity and geometric packing structure favorably affected the packing properties of the powder. Coke samples with tap densities up to 1.258 g/mL were prepared by controlling the size distribution of the coke particles. The porosity of the carbon block was calculated using three density definitions. The closed pores were reduced by up to 13.68% through the packing density of the particles, and the open pores were controlled by the coke/pitch mixing conditions regardless of the tap density. The carbon block showed a total porosity of 21.61% and a maximum compressive strength of 131 MPa by controlling the tap density of the coke. The proposed technique will be useful in various industries that require appropriate tap density control and will improve the compressive strength of composite materials.

Metallurgical, mechanical and corrosion behavior of Interpulse and pulsed current TIG dissimilar welds of Monel 400 and AISI 316L

This research work explores the weldability, structural integrity, mechanical properties, and corrosion behavior of dissimilar welds of Monel 400 and AISI 316L developed by using Interpulse and pulse arc current modes in TIG welding process. ERNiCrMo-3 filler of 1.6 mm was used to fill the V-groove configuration of 5 mm thick plates in multiple passes. Metallurgical changes were observed in both Interpulse and pulsed current dissimilar weldments using optical and scanning electron microscope techniques. Mechanical properties of the joined structures were evaluated by performing tensile tests on UTM and hardness measurements on weld surfaces using Vickers hardness tester. The resistance against the corrosion especially at the weld area of both welded structures was measured using a cyclic sweep test. From the XRT and visual inspection analyses, the joined structures were free from defects and also seen the uniformity of the filler distribution toward the base metals. The grain structure with well-defined grain structures were identified in PC-TIG weldments whereas fine grains with clear distribution of filler alloying elements were seen in Interpulse-TIG weldments. Interpulse-TIG weldments exhibited with better mechanical and corrosion resistance properties than the PC-TIG weldments vowing to constricted arc mode during the welding process.

A comprehensive study on enhancing effective thermal conductivity of polymer composites with randomly distributed triple fillers

This paper describes a comprehensive study on the effective thermal conductivity (ETC) of triple-filled polymer composites. A very complicated behavior was revealed under various effective factors, such as thermal conductivity (TC), volume fraction (VF), particle distribution, particle size, and filler arrangement. Consequently, some prediction models, which were well validated with numerical results, are first developed. Additionally, the ETC of polymer composite dramatically and non-linearly depends on TC ratios, VF ratios, particle distribution, filler arrangement, and particle size of the triple filler. The mountain shape of the ETC forms and depends on a variety of effective factors. The maximum ETC exists at the given optimum TC ratios ranging from approximately 0.1 to 100. It was also found that the ETC increases with the increase of the VF ratio for a threshold TC ratio; however, this trend changes when TC ratios go beyond the threshold values. Particularly, the ETC of the particle-filled polymer composite also depends on the filler arrangement, even though particles are straightly arranged along the direction of thermal flow. This effect becomes more significant when the difference in VF and TC between particles is larger. The results obtained are very useful in enhancing and maximizing the ETC of polymer composites with triple fillers and even multiple fillers in general.

Rheological and nano-mechanical characteristics of bituminous mastics containing waste and ordinary filler at different temperatures

This study has focused on the effect of cement kiln dust (CKD) as a waste filler on the rheological and nano-mechanical properties of bituminous mastic in comparison with limestone powder (LSP) as an ordinary filler. Mastics were prepared using three filler to bitumen (F/B) ratios including, 0.4, 0.8 and 1.2. The strategic highway research program (SHRP) standard and multiple stress creep recovery (MSCR) test methods were used to evaluate the behavior at high performance temperatures. Also, SHRP standard and time sweep methods were performed to evaluate the fatigue behavior at medium performance temperatures. Low temperature properties were examined by bending beam rheometer. Field emission scanning electron microscopy (FESEM) was used to evaluate the quality of filler distribution in the mastic. Furthermore, the nano-mechanical properties of mastics were examined by atomic force microscopy (AFM) including topography roughness, elastic modulus and adhesion force. Fundamental evaluations with AFM indicated that, at a constant F/B ratio, CKD filler with a higher fineness and specific surface area showed higher elastic modulus and lower adhesion than LSP. Also, the FESEM analysis for filler distribution showed the highest homogeneity coefficient at F/B ratio of 0.8. A significant relationship was observed between SHRP rutting parameter and creep variables in MSCR method. Both methods indicated a superior rutting resistance for CKD than LSP. Although, there was no clear relationship between SHRP fatigue parameter and the time sweep outcomes.

Road performance evaluation of prestressed high-strength concrete pile waste powder as alternative filler in asphalt concrete

As a kind of solid waste, using Prestressed High-Strength Concrete Pile Waste Concrete (PPWC) as the replacement for limestone filler in asphalt concrete can not only reduce the accumulation of PPWC and increase its utilization but also avoid the increased road construction costs and environmental degradation associated with limestone mining. This study aims to investigate the effect of using PPWC filler to replace limestone filler on the road performance of asphalt concrete. Firstly, PPWC was ground into filler particles with a diameter less than 0.075 mm. The particle characteristics such as surface morphology, particle size distribution and chemical composition of PPWC filler and limestone filler were compared. Then, PPWC filler was used to replace limestone filler with different volume fractions to prepare asphalt concrete, and the water damage resistance, high-temperature rutting resistance, low-temperature crack resistance, fatigue resistance and adhesion performance of asphalt concrete were tested. The results showed that PPWC filler has a smaller particle size and rougher surface than limestone filler, and it contains Ca(OH)2 produced by hydration. The addition of PPWC filler can effectively improve the mechanical properties of asphalt concrete without reducing its water damage resistance. PPWC filler can improve the high-temperature rutting resistance and low-temperature crack resistance of asphalt concrete, but reduce its low-temperature fatigue resistance. The low content of PPWC filler will enhance the adhesion between asphalt mortar and aggregate. However, when the content of PPWC filler exceeds 50%, Ca (OH)2 in PPWC will reduce the adhesion between acid asphalt mortar and alkaline basalt aggregate. Therefore, the use of PPWC as filler in asphalt mixtures provides a reliable solution for the sustainable development of road materials.