Interfacial Adhesion Properties Research Articles

Study on Bonding Behavior between High Toughness Resin Concrete with Steel Wire Mesh and Concrete

This paper investigates the interfacial bonding behavior between high toughness resin concrete with steel wire mesh (HTRCS) and concrete. A total of five sets of fifteen double shear specimens were tested for parameters including concrete strength and material properties of HTRCS composites. The test results showed that the failure mode of DS1 specimens was partial debonding and fracture, and the rest of the specimens were the fracture of HTRCS. The concrete strength and reinforcement ratios of HTRCS composites were positively correlated with interfacial adhesion properties. When the concrete strength was increased from C30 to C40 and C50, the ultimate load increased by 43.4% and 43.2%, respectively. The ultimate load capacity increased by 32.1%, with the reinforcement ratio of HTRCS composites increasing from 1.05% to 1.83%. Moreover, the bonding slip model and the bearing capacity formula for the interface between HTRCS composites and concrete were proposed, and the calculation values were in good agreement with the test values, with an average value of 0.978.

Improved interfacial adhesion of carbon fiber‐reinforced polydicyclopentadiene layered composite material by modification of norbornene derivatives

AbstractSurface chemical grafting modifications of carbon fibers (CFs) using 5‐(triethoxysilyl)norbornene (TOS), norbornene carboxylic acid tert‐butyl ester (NB‐TBE), and 5‐norbornene‐2,3‐dicarboxylic anhydride (NA) improved interfacial interactions between CFs and poly(dicyclopentadiene) (PDCPD) resin. The ring‐opening metathesis polymerization (ROMP) of DCPD, catalyzed by Grubbs catalyst II, enabled the fabrication of PDCPD/CF layered composite materials with resin and fibers tightly adhered. The optimal composite exhibited remarkable mechanical properties, with a tensile strength of 654.6 MPa and flexural strength of 510.7 MPa. Excellent thermal stability with a maximum weight loss rate in temperatures above 450°C and good chemical resistance with a weight change of about 1% in both acidic and alkaline media highlight the promising potential of these materials for use in harsh environments. The simple yet efficient approach of TOS, NB‐TBE, and NA‐enhanced layered CF shows great promise as advanced composite materials for industrial applications.Highlights Norbornene derivatives such as TOS, NB‐TBE, and NA are suitable modifiers for CF. ROMP of DCPD and norbornene group onto CFs, fabrication of PDCPD/CF composite materials. The composite exhibited remarkable interfacial adhesion and mechanical properties.

High-Branched Natural Polysaccharide Flaxseed Gum Binder for Silicon-Based Lithium-Ion Batteries with High Capacity.

Silicon-based anodes heavily depend on the binder to preserve the unbroken electrode structure. In the present work, natural flaxseed gum (FG) is used as a binder of silicon nanoparticles (SiNPs) anode for the first time. Owing to a large number of polar groups and a rich branched structure, this material not only anchors tightly to the surface of SiNPs through bonding interactions but also formed a hydrogen bonding network structure among molecules. As a result, the FG binder can endow the silicon electrode with stable interfacial adhesion and outstanding mechanical properties. In addition, FG with a high viscosity facilitates the homogeneous dispersion of the electrode components. When FG is used as a binder, the cycling performance of the Si anode is greatly improved. After one hundred cycles at an applied current density of 1 A g-1, the electrode continues to display remarkable electrochemical properties with a significant cyclic capacity (2213mAh g-1) and initial Coulombic efficiency (ICE) of 89.7%.

Influence of micron-sized oligomeric semisiloxane modification on surface properties of veneer and interfacial adhesion of EVA film/poplar plywood

ABSTRACT Using EVA film as an adhesive to composite with wood veneer can fabricate e formaldehyde-free wood-based panels. In order to improve the interfacial adhesion of the thermoplastic resin plywood, micron-sized oligomeric semisiloxane (MS) solution was prepared and sprayed on the poplar veneer before bonded with the EVA film. The effect of MS solution on the surface properties of poplar and mechanical properties of MS-treated plywood by FTIR, XPS, WCA, and SEM-EDS. The results indicated that MS was successfully grafted onto the surface of veneer by covalent bonding (Si-O-C) and formed a rough hydrophobic coating on the veneer. The WCA of poplar veneer was significantly increased. As a result of the change in surface properties, poplar veneer formed a tight interfacial bonds with EVA film, which improved mechanical performance of plywood. When the MS treatment conditions were 3% silane, 15% neutral silica, and 3 h reaction times, the wet shear tensile strength and dry shear tensile strength reached 1.03 and 1.56 MPa, respectively. Compared with untreated plywood, the wet strength and dry strength were increased by 76% and 39%, respectively. In addition, Reduced gaps between MS-treated poplar veneer and EVA film and formed stronger interlock structures were observed by SEM.

Oxygen Impurity-Tuned Structure and Adhesion Properties of the Cu/SiO2 Interface.

The properties of the Cu/SiO2 interface usually deteriorate in the complex atmospheric environment, which may limit its performance and application in the engineering. Using the reactive molecular dynamics method, we investigate how the mechanical behaviors of the Cu/SiO2 interface change as it interacts with oxygen impurities. The interfacial oxidation degree could be enhanced as O2 penetrates into the interface area. This makes the interfacial structure disordered and is not conducive to the survival of Cu-O-Si bondings, which reduces the tensile and shear strengths of the interface. To improve the abrupt bonding property change at the interface and modify the interfacial adhesion properties, O impurities are introduced at the Cu interstitial sites near the interface. By doing so, the interface strength can be significantly enhanced due to the production of typical O-Cu-O bondings while the regular interfacial structure is retained. Meanwhile, the interfacial oxidation also changes the tensile failure site and shearing sliding mode of the interface, i.e., from inside the oxide to between oxide and Cu. The findings of this work may not only advance the understanding of interaction mechanism between oxygen impurities and the Cu/SiO2 interface but also provide new insights into optimizing the bonding properties of the metal/oxide interface.

Interfacial adhesion properties and debonding mechanisms in rejuvenated asphalt mixtures

The interfacial strength between asphalt and aggregate significantly affects the macroscopic properties of rejuvenated asphalt mixtures. Investigating the interfacial properties of rejuvenated asphalt mixtures contributes to understanding the adhesion mechanisms and debonding behavior, enhancing the service life of rejuvenated asphalt mixtures. In this study, molecular dynamics methods were utilized to construct interface models of virgin, aged, and rejuvenated asphalt-aggregate systems, subsequent to which asphalt-aggregate interface pull-out tests were conducted. The findings revealed that the exponential-type cohesive zone model (CZM) effectively characterize the stress-strain correlations during asphalt-aggregate interface pull-out tests. The combination of adhesive and cohesive failure is the typical damage modes at asphalt-aggregate interface. Cohesive failure tended to be the main failure mode between aged asphalt-aggregate interface, while asphalt oxidation aging notably reduced the interface tensile strength and hence the cracking resistance of asphalt mixtures. The interface failure patterns between rejuvenated and virgin asphalt were similar, demonstrating an adhesive failure at lower temperatures and a shift towards cohesion failure at higher temperatures. The interface failure usually occurred at lower temperatures especially for aged asphalt, while the incorporation of rejuvenator could effectively mitigate the cracking potential asphalt mixtures. This study simulated the interfacial failure behavior for rejuvenated asphalt mixtures, which can be a theoretical basis of using rejuvenator in recycled asphalt mixtures.

Enhanced interfacial bonding of AF/PEEK composite based on CNT/aramid nanofiber multiscale flexible-rigid structure

The application of aramid fiber (AF)/polyetheretherketone (PEEK) composites is currently hindered by the inert surface and poor wettability of AF, resulting in weak interfacial adhesion and poor mechanical properties. Surface coating and the introduction of nanostructures have been proven to be effective approaches to address this problem. Herein, a simple hybrid sizing agent has been developed to modify the AF surface, consisting of soluble polyimide (PI) as a compatibilizer, carboxyl-functionalized carbon nanotubes (CNT-COOH) as a rigid unit, and aramid nanofibers (ANF) as a flexible component. The synergetic effects of PI and the multiscale flexible-rigid structure (CNT-COOH/ANF) contribute to the formation of chemical and physical bonds between AF and PEEK matrix, further improving the interfacial adhesion and stress transfer efficiency. Attributed to the enhanced wettability and roughness of AF, compared with unsized AF, the flexural strength (220.97 MPa), modulus (13.26 GPa), ILSS (13.36 MPa), and storage modulus (12.93 GPa) of the AF/PEEK composite increase by 132.60 %, 99.00 %, 18.97 %, and 82.70 % respectively. Additionally, the flexible-rigid nanonetwork facilitates the penetration of the PEEK resin into pore spaces. This simple and effective approach exhibits promising potential in enhancing the interfacial bonding of AF/PEEK composites.

Wettability and microstructural evolution of copper filler in W and EUROFER brazed joints

In terms of wettability, active systems are characterized by a reduction in interfacial energy as the time at specific conditions is increased. This article aims to investigate the evolution of wettability and microstructure, which undergoes a critical transformation at temperatures and dwell times near brazing conditions due to their significant impact on resultant mechanical properties. The objective is to enhance wettability and prevent the formation of different phases that can occur rapidly within the brazing window conditions. Up to 1105 °C, complete fusion of the filler does not occur. However, once it happens, the expansion of the copper filler in EUROFER increases up to 400%, and the contact angle reduces from 100° to 10°, indicating an active wetting behavior. On the other hand, when copper is used with tungsten, an inert behavior is observed, maintaining the contact angle around 70°. Brazed joints carried out under the most promising wetting conditions demonstrated that at 1110 °C-1 min, various phenomena began to occur. This includes solid-state diffusion of copper in the EUROFER, following the austenitic grain boundaries, and partial dissolution of Fe in the copper braze. Increasing the brazing time from 2 to 5 min achieved high interfacial adhesion properties and controlled the diffusion layer and Fe-rich band formed at the W-braze interface, resulting in the best mechanical results (295 MPa).

Simple surface modification of barium sulfate for improving the interface of polymer composites and its x‐ray shielding properties

AbstractRadiation shielding materials have been researched using Pb and metal oxide particles, and composites of resin and barium sulfate (BaSO4) have been reported. In addition, multiwalled carbon nanotubes (MWCNTs) have often been used as a nanomaterial to improve the mechanical strength of resin–BaSO4 composites. The literature includes no examples of these two materials—BaSO4 and MWCNTs—being used at the interface of composites. We effectively modified the surface of BaSO4 by a simple process involving strong electrostatic interaction between positively charged barium and negatively charged functional groups on the MWCNT surface. The process is simple and can form large amounts of MWCNTs that coat BaSO4 surfaces. As a result, MWCNTs remained on the BaSO4 surface even after the MWCNT‐coated BaSO4 was washed with a solvent and subjected to melt mixing. The physical anchoring of MWCNTs onto the BaSO4 surface improved the interfacial adhesion and mechanical properties of the resultant composites. The originality of this research is that MWCNTs can be coated onto the surface by only electrostatic interaction without using a polymer adhesive. In addition, the x‐ray shielding performance of the MWCNT‐containing composites was the same as that of composites prepared without the MWCNTs.Highlights MWCNTs were coated onto the surface of BaSO4 by electrostatic interaction. Interfacial adhesion of PS composites was improved by coating MWCNTs. The MWCNTs did not affect the x‐ray shielding performance.

Improved adhesion of rubber composites by developing environmentally friendly fiber impregnation coatings with good interfacial modulus transition gradients

Polyester (PET) fibers must undergo impregnation with a resorcinol-formaldehyde-latex (RFL) solution to ensure efficient adhesion with rubber. However, the harmful, carcinogenic resorcinol-formaldehyde (RF) resin in RFL impregnation solution negatively affects human health. In this paper, PET was pretreated with blocked isocyanate and epoxy resins to activate the fibers, and a new environmentally friendly fiber impregnation coating was developed. In the new impregnation coatings, ethylene glycol diglycidyl ether (EGDE) and m-xylylenediamine (MXDA) were applied to replace the resorcinol and formaldehyde. Moreover, glycidyl methacrylate (GMA) containing epoxy groups and double bonds was introduced to enhance interaction with rubber further, and then styrene-butadiene-vinyl-pyridine (VP) latex was mixed. The results show that the peel strength of the impregnated PET/rubber composites with the new impregnation coatings can reach 14.0 N/mm, representing an increase of 30.8 % compared to that of the sample with the pure RFL impregnation coatings, whose peel strength is only 10.7 N/mm. Furthermore, the mechanism for enhancing the interfacial adhesive properties of PET/rubber composites was performed by analyzing the chemical composition and morphological changes of the impregnated PET surface, as well as the change of sulfur content at the interface of the impregnated PET/rubber composites and the transition gradient of interfacial modulus.

A universal strategy for rapid and scalable surface modification of ultra high molecular weight polyethylene fiber

The high performance UHMWPE fiber usually demonstrates extremely poor surface adhesion with resin matrix. Therefore, improving the interfacial adhesion property becomes one of the toughest challenges faced by UHMWPE fibers. In this study, a simple and universal surface welding strategy is promoted to effectively modifying UHMWPE fiber with improved surface adhesion in a short time. The surface welding manufacturing approach is realized by the controllable Joule heating generated from the high contact resistance and rapid thermal response of the conductive nano-material layer coated on UHMWPE surface, which can locally melt the UHMWPE fiber surface and weld the nano materials on UHMWE with a strong and robust mechanical bonding. Since the whole welding process is simple and lasts only for a few seconds, it can be easily applied to the current industrial UHMWPE fiber and fabric manufacturing, enabling a continuous, fast, efficiency and scalable roll-to-roll UHMWPE surface modification process.

Three-dimensional dual-layered conductive binder enables stable and high performance of SiOx/C anodes

Among practical anode materials for next-generation lithium-ion batteries (LIBs), SiOx has garnered substantial attention owing to its relatively low volumetric variation and high theoretical capacity. Nevertheless, the volumetric change of micro-SiOx remains a formidable challenge for existing adhesives. Here, we propose an innovative design strategy that amalgamates both rigidity and flexibility, in which rigid anion gum Arabic (GA), flexible acrylic random copolymer (ARC), and carbon nanotubes (CNTs) interwoven into a 3D network with strong interfacial adhesion and excellent mechanical properties. These attributes effectively restrict SiOx particles and favor a stable solid electrolyte interphase (SEI) layer formed on SiOx. Here, GA plays a pivotal role in dispersing CNTs and maintaining their consistent proximity to SiOx, thereby establishing stable electron conduction networks. The SiOx electrode still sustains a specific capacity of 760 mAh g−1 after 350 cycles under a high current of 1C. Additionally, at 0.2C, the SiOx electrode attains a notably high capacity of 1105 mAh g−1 with a capacity retention of 72.9 % at the 300th cycle, while exhibiting an excellent areal capacity of 1.4 mAh cm−2 even after 400 cycles. This work develops a straightforward yet highly efficacious approach for fabricating high areal capacity electrodes and offers promising prospects for improving the stableness of Si-based anodes.

Theoretical study of the effects of alloying elements on TiO2/Ti2AlNb interface adhesion properties.

Ti2AlNb-based alloys are expected to be applied in the manufacture of parts of aeroengines to achieve the goal of increasing the thrust-to-weight ratio. However, the poor high temperature oxidation resistance of these alloys may hinder their applications. Alloying has been proven to be effective in improving oxidation resistance properties. However, the selection of alloying elements and their influence mechanisms are rarely studied. The TiO2/Ti2AlNb interface bonding interactions and the effects of alloying elements of Si, Sc, Y, Zr, Mo and Hf were investigated via first principles calculations. The separation energy and electronic structure were studied to explore the bonding interactions between the oxide scale and Ti2AlNb matrix. When Zr and Hf are used to replace Al, the bonding properties of the TiO2/Ti2AlNb interface are improved. The tensile and shear deformations of the interfacial zones are applied to study the influence of alloying elements on the TiO2 oxide spalling on Ti2AlNb. The tensile strength is increased by more than 2 GPa when Nb is substituted by the Sc, Zr and Hf elements. Therefore, Sc, Zr, and Hf are beneficial for inhibiting oxide spalling and will have great potential to improve the oxidation resistance properties.

Adhesion properties of MoS<sub>2</sub>/SiO<sub>2 </sub>interface: Size and temperature effects

The interface adhesion properties are crucial for designing and fabricating two-dimensional materials and related nanoelectronic and nanomechanical devices. Although some progress of the interface adhesion properties of two-dimensional materials has been made, the underlying mechanism behind the size and temperature dependence of interface adhesion energy and related physical properties from the perspective of atomistic origin remain unclear. In this work, we investigate the effects of size and temperature on the thermal expansion coefficient and Young’s modulus of MoS<sub>2</sub> as well as interface adhesion energy of MoS<sub>2</sub>/SiO<sub>2</sub> based on the atomic-bond-relaxation approach and continuum medium mechanics. It is found that the thermal expansion coefficient of monolayer MoS<sub>2</sub> is significantly larger than that of its few-layer and bulk counterparts under the condition of ambient temperature due to size effect and its influence on Debye temperature, whereas the thermal expansion coefficient increases with temperature going up and almost tends to a constant as the temperature approaches the Debye temperature. Moreover, the variations of bond identity induced by size effect and temperature effect will change the mechanical properties of MoS<sub>2</sub>. When the temperature is fixed, the Young’s modulus of MoS<sub>2</sub> increases with size decreasing. However, the thermal strain induces the volume expansion, resulting in the Young’s modulus of MoS<sub>2</sub> decreasing. Furthermore, the size and temperature dependence of lattice strain, mismatch strain of interface, and Young’s modulus will lead the van der Waals interaction energy and elastic strain energy to change, resulting in the change of interface adhesion energy of MoS<sub>2</sub>/SiO<sub>2</sub>. Noticeably, the interface adhesion energy of MoS<sub>2</sub>/SiO<sub>2</sub> gradually increases with MoS<sub>2</sub> size decreasing, while the thermal strain induced by temperature causes interface adhesion energy of MoS<sub>2</sub>/SiO<sub>2</sub> to decrease with temperature increasing. In addition, we predict the conditions of the interface separation of MoS<sub>2</sub>/SiO<sub>2</sub> under different sizes and temperatures. Our results demonstrate that increasing both size and temperature can significantly reduce the interface adhesion energy, which is of great benefit in detaching MoS<sub>2</sub> film from the substrate. Therefore, the proposed theory not only clarifies the physical mechanism regarding the interface adhesion properties of transition metal dichalcogenides (TMDs) membranes, but also provides an effective way to design TMDs-based nanodevices for desirable applications.

Synthesis of polyelectrolyte-decorated polydopamine nanoparticles via surface reconstruction for enhancing oil-based lubrication

Polydopamine nanoparticles (PDA NPs) show bright prospects in the field of lubricant additives due to their high interface adhesion and reaction properties. However, the synthesis of PDA NPs with excellent dispersibility and lubricity in lubricating oils remains a great challenge. In this work, a class of polyelectrolyte-decorated PDA NPs (PPDA NPs) were synthesized by surface reconstruction of PDA NPs. The lipophilic PPDA NPs can be stabilized in PEG200 base oil without any sediments over 6 months. Compared with PEG200 base oil, the PPDA NPs (1.0 wt%)/PEG200 dispersion not only reduced the friction coefficient (COF) by 37.3 % and wear volume by 51.6 % but also performed well under heavy loads, high speeds, and long duration. Wear surface analyses confirmed that the structural evolution from PPDA NPs to nanosheets induced the formation and deposition of hybrid tribofilm with robust tribological behaviors, enabling desirable oil lubrication. Overall, the synergistic effects between PDA cores and PPDA shells contributed to the superior lubricity of PPDA NPs. This study provides a promising protocol for designing and synthesizing oil-dispersible PPDA NPs, brightening the application prospect of organic polymer NPs in tribology.

Biofouling resistant materials based on micro‐structured surfaces with liquid‐repellent properties

AbstractAdhesion of contaminants on various polymer‐based devices during fluid‐substrate interactions is a common problem that can cause biofouling and corrosion. In this study, hierarchical structures with submicron features on polypropylene (PP), high‐density polyethylene (HDPE), and polycarbonate (PC) are fabricated by femtosecond laser ablation. The effect of the hierarchical structures on surface wettability, droplet impact, and bacterial attachment has been examined. Our results demonstrate that the structured polymeric substrates facilitate large contact angles and minimal interfacial adhesion, allowing droplets to roll off at a low angle of inclination below 5°. Further, rendering the hierarchical structures with a low‐surface‐energy coating can enable the surfaces to exhibit superamphiphobic properties. The low interfacial adhesion properties, as accounted by the large contact angles and small contact angle hysteresis, of such surfaces prevent bacterial attachment and biofilm formation. The findings provide a design principle for creating affordable biofouling resistant surfaces with a submicron topography that can be used for engineering and biomedical devices.

Comparative study of different bonding interactions on the interfacial adhesion and mechanical properties of MXene-decorated carbon fiber/epoxy resin composites

Interfacial adhesion determines the mechanical performance of the carbon fibers-reinforced polymers composites (CFRPs), and different bonding interactions could lead to different degrees of interfacial adhesion and mechanical properties of CFRPs. In order to survey specific influence of different bonding interactions on the interface bonding, further boost the mechanical properties of CFRPs, MXene is decorated onto carbon fiber (CF) surface via Van der Waals force or hydrogen bonds (CF-v-MXene), ionic bonds (CF-i-MXene), and covalent bonds (CF-c-MXene), respectively. Besides, detailed interaction mechanisms of various bonding interactions are also comprehensively investigated. The results indicate that the introduction of MXene is obviously efficient for improving the interface adhesion and mechanical properties of CF/epoxy (CF/EP) composites, and the composites reinforced by CF-c-MXene exhibit the optimal properties. Tremendous improvements of 90.1 % and 110.3 % for the impact strength and interfacial shear strength (IFSS) are achieved compared with the composites reinforced by the unsized CF. The microscopic interfacial structure and fracture failure mode are further observed and analyzed to explore the enhancement mechanisms. This work provides effective guidance and reference for the application of MXene and other similar 2D layered materials, such as Transition Metal Dichalcogenides (TMDCs), to design and manufacture high-quality interface for CFRPs with excellent interfacial and mechanical properties.

High filler content acrylonitrile‐butadiene‐styrene composites containing tungsten and bismuth oxides for effective lead‐free x‐ray radiation shielding

AbstractAcrylonitrile‐butadiene‐styrene (ABS) based composites with a high content of tungsten and bismuth oxide were developed using an innovative process to obtain lead‐free x‐ray shielding materials. ABS was chosen for its good mechanical properties and its widespread availability as a recycled material. The composites underwent flexural tests, Shore D hardness tests, thermogravimetric and morphological analysis, and their x‐ray attenuation properties were determined through numerical simulations and experimental measurements. Despite their high filler content (up to 75 wt%), the composites showed good filler dispersion within the polymeric matrix and maintained their mechanical properties. Across the investigated energy range (50–150 kV), the lead equivalence for x‐ray shielding was achieved with composite plates containing 75 wt% of tungsten and bismuth oxide, at thickness values corresponding to a weight increase of only 29% and 36%, respectively, in comparison to lead. These findings pave the way for a new generation of lead‐free x‐ray shielding materials. Moreover, their mechanical properties, including flexibility for potential application in wearable personal protective equipment, can be tailored by adjusting the filler content.Highlights High filler content lead‐free ABS composites with WO3 and Bi2O3 were developed. They show good polymer/filler interfacial adhesion and flexural properties. Numerical simulations of their x‐ray shielding properties were performed. Experimental tests with polychromatic sources confirmed good x‐ray attenuation. Results pave the way for the development of new lead‐free x‐ray shielding systems.

Strong adhesion using a simple dopamine-based homopolymer

The underwater adhesive materials inspired by marine mussels have been a research hotspot. As is known to all, interface adhesion properties, mechanical properties, rapid response properties are important indicators for the application of underwater adhesive materials. In this study, we report that Poly(N-(3,4-Dihydroxyphenethyl) methacrylamide) (PDMA), a simple dopamine-based homopolymer, replaces complex binary or multiple copolymers as an underwater adhesive material. The influence factors of PDMA were investigated by universal tensile dynamometer, water contact angle tester, X-ray photoelectron spectroscopy (XPS) and Fourier transform infrared reflection (FTIR). Meanwhile, the underwater self-assembly performance of PDMA was performed. Compared with the air group, there are more phenolic hydroxyl groups on the surface of the adhesive in the underwater group, and the adhesive performance is better. In summary, PDMA can be regarded as an alternative substitution material for underwater adhesives.

Characterization of Waste Micro and Nano Tungsten Carbide Powder Reinforced Polyamide 66 Matrix Composites

Polyamide 66 (PA 66) or Nylon 66 is a strong, easily processed polymer with high thermal resistance and excellent mechanical properties. Tungsten carbide (WC/Co-Cr 86/10-4), known for its exceptional hardness and elasticity, is commonly used for coatings in the thermal spraying and coating industry. In this study, we examined the microstructural, mechanical, and thermal properties of composites made from waste micro and nano WC/Co-Cr 86/10-4 powder and a PA66 matrix. PA66 was reinforced with varying ratios of 3, 6, and 10 wt.% WC/Co-Cr 86/10-4. The composite specimens were created by mechanically mixing granular PA66 and micro and nano WC/Co-Cr 86/10-4 powders and molding them under controlled temperature. Mechanical properties were evaluated through ductility and hardness tests, while thermal properties were determined through DSC analysis. The SEM observation revealed the distribution of WC/Co-Cr 86/10-4 within the polymer matrix. The DSC analysis indicated that the composite had a slightly higher melting temperature than pure PA66, and the thermal conductivity also increased slightly. The experimental results demonstrated that the mechanical properties of the composite improved as the WC/Co-Cr 86/10-4 content increased, specifically in terms of tensile strength and hardness. Additionally, the composite exhibited enhanced interfacial adhesion, mechanical behavior, and thermal properties. This composite, utilizing WC/Co-Cr 86/10-4 waste and recycled PA66, allows for the repurposing of industrial waste.