Recycled Carbon Fiber Research Articles

Study on recycled carbon fiber obtained by thermal activated oxide semiconductor and mechanical properties of its reinforced polymer composites

Study on recycled carbon fiber obtained by thermal activated oxide semiconductor and mechanical properties of its reinforced polymer composites

Upcycling end-of-life carbon fiber in high-performance CFRP composites by the material extrusion additive manufacturing process

Each year, a significant amount of waste is produced from carbon fiber polymer composites at the end of its lifecycle due to extensive use across various applications. Utilizing regenerative carbon fiber as a feedstock material offers a promising and sustainable approach to additive manufacturing based on materials. This study proposes the additive manufacturing of recycled carbon fiber with a polyamide-12 polymer composite. Filaments of recycled carbon fiber-reinforced polyamide-12 (rCF-PA12) with different recycled carbon fiber contents (0%, 10%, and 15% by weight) in the polyamide-12 matrix are developed. These filaments are utilized for 3D printing of specimens by using various infill density parameters (80% and 100%) on a fused deposition modeling 3D printer. The study examined how the fiber content and infill densities influenced the flexural performance of the printed specimens. Notably, the part containing 15 wt% recycled carbon fiber (rCF) composites showed a significant improvement in flexural performance due to enhanced interface bonding and effective fiber alignment. The results indicated that reinforcing the printed part with 10% and 15 wt% recycled carbon fiber (rCF) improved the flexural properties by 49.86% and 91.75%, respectively, compared to the unreinforced printed part under the same infill density and printing parameters. The investigation demonstrates that the additive manufacturing-based technique presents a potential approach to use carbon fiber-reinforced polymers waste and manufacture high-performance engineering, economic, and environmentally friendly industrial applications with the complicated design using different polymer matrices.

Novel insights into the correlation composition-structure-property of recyclable carbon fiber reinforced thermosetting resin composites

As widely used lightweight and high-strength materials, the sustainable development of thermosetting composites is hampered by their limited recyclability. Developing simple methods for the efficient and upgraded recycling is desirable but challenging. Herein, carbon fiber reinforced degradable thermosetting resin composites were prepared, and the effects of resin degradation process and its derivatives on the sustainable recycling of carbon fiber were studied. Through the tunable departure and re-adsorption of degradation derivatives in cleaning post-treatment, recycled carbon fibers achieved not only non-destructive recovery but also simultaneously improvements in tensile strength from 3.0 GPa to 3.7 GPa and surface energy from 47.2 mN/m to 66.7 mN/m. The adhered derivatives, rich in -NH- and oxygen-containing groups, exhibited good interactions with the fiber surface and epoxy resin. Benefiting from this, the inter laminar shear strength of recycled carbon fibers reinforced epoxy composite effectively improved 24.3 %. In this work, directly reusing resin degradation products for the recycling of reinforced fibers was proposed and the key role of the composition and distribution of degradation products in recycling properties was revealed. The strategy of integrating characteristics of components to enhance material recyclability is expected to have widespread applicability, promoting the sustainable transition for thermosetting composites.

Enhancing flame retardancy in 3D printed polyamide composites using directionally arranged recycled carbon fiber

Combining recycled carbon fiber (rCF) and 3D printing technology has shown great potential for fabricating functional prototypes and production parts used in the aerospace and automotive industries. However, it is still a challenge to design flame-retardant 3D printed parts with high mechanical properties and flame-retardant rating. In the work, a flame-retardant polyamide (PA)-based composite for material extrusion 3D printing was prepared by utilization of rCF, polyhedral oligomeric silsesquioxanes (POSS), and 9,10-Dihydro-9-oxa-10-phosphaphenanthrene (DOPO)-based flame retardant. The 3D-printed composites have high thermal stability, mechanical properties, and excellent flame retardancy with a V-0 rating. With the benefits of material extrusion 3D printing, directionally arranged rCF in 3D printed composites could effectively inhibit the fire spread, extend the time to ignition (TTI), reduce the total heat release (THR) and total smoke release (TSR) of 3D printed composites. The directional flame-retardant mechanism is mainly the thermal conductivity mechanism of the condensed phase and the promotion of stable ordered carbon layer formation. It provides a promising path for designing high-performance flame-retardant materials.

Investigation of pull-out and mechanical performance of fibre reinforced concrete with recycled carbon fibres

This paper presents the pull-out bonding behaviour and mechanical performance of recycled carbon fibre (rCF) reinforced concrete based on the recent investigation of fibre reinforced concrete (FRC) with rCF recovered from pyrolysis. Single fibre pull-out tests have been carried out to identify the apparent interfacial shear strength of different types of rCF and virgin carbon fibre (vCF) to identify the fibre matrix connection. Furthermore, a series of tests have been carried out to identify the workability, compressive strength and tensile strength of FRC. Besides rCF, also vCF and steel fibre were used for fabrication of FRC test specimens. rCF have shown the same adhesion behaviour and strength like vCF. Furthermore, the use of unsized or acrylate-based sized rCF creates an adhesion between fibre and matrix material. During the pull-out tests, the failure does not occur as an adhesive crack between fibre and cement matrix, but as a cohesive crack in the cement matrix. The mechanical performance of FRC with rCF was compared with mortar and FRC with vCF and steel fibres. The results of compressive test conducted for FRC with vCF and rCF indicated that the influence of vCF and rCF on the compressive strength of FRC was insignificant. On the other hand, the results of tensile test conducted for FRC with vCF and rCF indicated that the tensile strength of FRC with rCF was at least 14.9% greater than that of FRC with vCF.

Piezoresistive response and self-sensing properties of UHPC reinforced with recycled carbon fibers

This research explores Ultra-High-Performance Concrete (UHPC) reinforced with recycled carbon fibers to verify its potential application in self-sensing concrete for structural health monitoring. The improved electrical conductivity due to the inclusion of carbon fibers enables the emergence of piezoresistivity, transforming UHPC into a sensitive sensor for detecting mechanical stresses. By incorporating various characterization tests alongside investigations into fiber type (loose versus fibrillated sheets) and content variations, the study aims to establish a correlation between the electrical properties and the resulting piezoresistive response. Resistivity will be measured using impedance scanning, while piezoresistivity will be determined through loading and unloading cycles with a datalogger recording the variations in electrical resistance. The inclusion of carbon fibers suggests an improvement in mechanical performance, up to 42 % in flexural strength and 26 % in compression compared to UHPC without fibers. Resistivity ranges from 1 to 2 Ω⋅m and gauge factor reach 38. These results are comparable to those reported in other studies on UHPC with carbonaceous additions, highlighting the potential of recycled carbon fibers as a sustainable and effective reinforcement strategy.

Nano-micro pore structure characteristics of carbon black and recycled carbon fiber reinforced alkali-activated materials

Microscopic scrutiny aids in alkali-activated materials’ (AAM) application in construction industry. This study delves into the pore structure and properties of one-part alkali-activated slag (AAS) mortar modified by carbon black (CB) and recycled carbon fiber (rCF). The additives enhanced flexural strength by 51.82% (12.16 MPa) with lower water absorption (10.24%). Refinement of pore size and reduction of connectivity are key factors in improving properties. The densification effect of CB and the strong interface between rCF and gel were observed. Furthermore, AAS mortars exhibited multifractal characteristics within the range of micropores and capillary pores. Despite altering fractal regions, the additives did not affect its size dependence. The backbone fractal dimension increases with the addition of CB and rCF, exhibiting strong correlations with various macro properties, thus serving as a comprehensive parameter to characterize pore shape and distribution. This study deepens understanding of AAM composites, facilitating their adoption of low-carbon building materials.

Thermal and mechanical behaviour of recycled short milled carbon fibre reinforced polypropylene and recycled polypropylene composites: A comparative study

Environmental and economic factors have driven research into the recycling and applications of recycled carbon fibres (rCF). This paper presents a comparative study characterizing and comparing the mechanical and thermal performance of recycled short milled carbon fibre (rSMCF) on virgin and recycled polypropylene composites. The effects of rSMCF on VPP and RPP on mechanical performance were analysed and compared. At 5 wt% rSMCF, recycled polypropylene achieved 52.3% and 47.3% improvement on tensile and flexural modulus, while at the same rSMCF loading, virgin polypropylene only improved 37.7% and 17.5%, respectively. The un-notched impact strength of RPP-based composites reduced from 83.2 kJ/m2 to 60.1 kJ/m2 when rSMCF content increased from 1 wt% to 5 wt%, indicating future work should enhance the fibre/polymer interface performance. Crystal contents (χ0) of the PP/rSMCF composites were investigated by differential scanning calorimetry (DSC), and the results were analysed and mapped to the mechanical performance. The results of this study propose a novel scalable method for the production of high-performance VPP/RPP composite materials using rSMCF.

Experimental Investigation into the Mechanical and Piezoresistive Sensing Properties of Recycled Carbon-Fiber-Reinforced Polymer Composites for Self-Sensing Applications.

This study investigates the mechanical and piezoresistive sensing properties of recycled carbon-fiber-reinforced polymer composites (rCFRPs) for self-sensing applications, which were prepared from recycled carbon fibers (rCFs) with fiber lengths of 6, 12, 18, and 24 mm using a vacuum infusion method. Mechanical properties of the rCFRPs were examined using uniaxial tensile tests, while sensing characteristics were examined by monitoring the in situ electrical resistance under cyclic and low fatigue loads. Longer fibers (24 mm) showed the superior tensile strength (92.6 MPa) and modulus (8.4 GPa), with improvements of 962.1% and 1061.1%, respectively. Shorter fibers (6 mm) demonstrated enhanced sensing capabilities with the highest sensitivity under low fatigue testing (1000 cycles at 10 MPa), showing an average maximum electrical resistance change rate of 0.7315% and a gauge factor of 4.5876. All the composites displayed a stable electrical response under cyclic and low fatigue loadings. These results provide insights into optimizing rCF incorporation, balancing structural integrity with self-sensing capabilities and contributing to the development of sustainable multifunctional materials.

Developing hybrid C-sections from waste and recycled composite materials

This paper investigates the performance of hybrid composites made from mixed waste plastics (wMP), recycled carbon fibre (rCF), and waste glass fibre (wGF). Two lay-up configurations with varying wGF and rCF contents were considered: one with approximately 7 vol% rCF (25 vol% wGF) and another with approximately 15 vol% rCF (9.4 vol% wGF). The tensile, compressive, and flexural performance of standard coupon specimens for both configurations were assessed, revealing that specimens with increased rCF content exhibited superior performance. Additionally, three hybrid C-sections, containing 15 vol% rCF, were thermoformed and subjected to axial compression. All three C-sections failed due to bearing failure, accompanied by some interlaminar delamination and material crushing at the loading ends. Their weight-specific load capacity surpassed that of similar sections published in the literature, such as ultra-thin-walled steel C-sections, by almost 95 %. A finite element model (FEM) of the C-section was developed and was able to predict reasonably well the stress versus strain response. These findings demonstrate that waste and recycled composite materials could serve as sustainable alternatives to ultra-thin-walled steel C-sections and other conventional materials commonly used in construction.

Effect of Carboxymethyl Cellulose and Polyvinyl Alcohol on the Dispersibility and Chemical Functional Group of Nonwoven Fabrics Composed of Recycled Carbon Fibers.

In this study, recycled carbon fibers (rCFs) recovered from waste carbon composites were used to manufacture wet-laid nonwoven fabrics. The aim was to improve dispersibility by investigating the changes in the dispersibility of carbon fibers (CFs) based on the content of the dispersant carboxymethyl cellulose (CMC) and the binder polyvinyl alcohol (PVA), and the length and basis weight of the CFs. In addition, the chemical property changes and oxygen functional group mechanisms based on the content of the CMC dispersant and PVA binder were investigated. The nonwoven fabrics made with desized CFs exhibited significantly improved dispersibility. For nonwoven fabrics produced with a fixed binder PVA content of 10%, optimal dispersibility was achieved at a dispersant CMC concentration of 0.4%. When the dispersant CMC concentration was fixed at 0.4% and the binder PVA content at 10%, the best dispersibility was observed at a CF length of 3 mm, while the maximum tensile strength was achieved at a fiber length of 6 mm. Dispersibility remained almost consistent across different basis weights. As the dispersant CMC concentration increased from 0.2% to 0.6%, the oxygen functional groups, such as carbonyl group (C=O), lactone group (O=C-O), and natrium hydroxide (NaOH), also increased. However, hydroxyl group (C-O) decreased. Moreover, the contact angle decreased, while the surface free energy increased. On the other hand, when the dispersant CMC concentration was fixed at 0.4%, the optimal binder PVA content was found to be 3%. As the binder PVA content increased from 0% to 10%, the formation of hydrogen bonds between the CMC dispersant and the PVA binder led to an increase in C=O and O=C-O bonds, while C-O and NaOH decreased. As the amount of oxygen increased, the contact angle decreased and the surface free energy increased.

Thermal Recycling Process of Carbon Fibers from Composite Scrap—Characterization of Pyrolysis Conditions and Determination of the Quality of Recovered Fibers

In this study, we took a closer look at the thermal recyclability of CFRP composites used in the manufacture of high-pressure cylinders. Thermal analysis was used to determine the minimum temperature at which stable resin decomposition begins. The aim was to find temperature parameters and retention times with which the pyrolysis process is as economically viable as possible, and the recovered fibers retain optimum mechanical properties. The surface morphology of fibers annealed in both inert and oxidizing atmospheres was examined. In addition, the mechanical strengths under static as well as dynamic conditions of the newly manufactured laminates containing the recovered fibers were investigated. During research, it was found that reusing fibers is very difficult. The recycled carbon fibers were successfully compressed in an epoxy matrix in the form of a pre-impregnated carbon mat with the presence of air. The presence of oxygen during the thermal degradation of the composite severely damaged the surface and structure of the carbon fiber, causing composites made from these fibers to be mechanically weaker by more than 247%.

Driving sustainability and performance: 3D-printing of lightweight functional components using recycled carbon fiber reinforced polyphenylene sulfide composites for automotive industry

Driving sustainability and performance: 3D-printing of lightweight functional components using recycled carbon fiber reinforced polyphenylene sulfide composites for automotive industry

Study on recycling carbon fibers from carbon fiber reinforced polymer waste by microwave molten salt pyrolysis

The extensive application of carbon fiber reinforced polymers (CFRP) has led to a sharp rise in the waste generated from CFRP, which poses a significant issue in sustainability that needs to be addressed. This work presents an efficient treatment method to recycle CFRP waste. Under the combined action of microwave heating and ZnCl2/NaCl molten salt, the epoxy resin matrix was rapidly degraded at 300 ℃ in 20 min. Then the pyrolytic carbon produced on the surface of carbon fibers from this process was removed by oxidation procedure in an air atmosphere. The results showed that the surface morphology and microstructure of the recycled carbon fibers (RCF) had no obvious changes, and the tensile strength and tensile modulus of RCF remained at 87.8 % and 94.6 % of the virgin carbon fibers, respectively. The degradation of epoxy resin by microwave molten salt pyrolysis increased the output of H2, which reached 65.35 % of total pyrolysis gases. Furthermore, the epoxy resin can be transformed directionally. The main components of the pyrolysis oils were phenol and p-isopropyl phenol, which had a high utilization value. Therefore, this study designed a new and efficient process to recycle carbon fibers from CFRP waste, which has important application prospect.

Solvolysis Process for Recycling Carbon Fibers from Epoxy‐Based Composites

AbstractFiber reinforced polymers boast exceptional mechanical performance coupled with low material density. Over recent decades, their usage has been steadily increasing and is poised to accelerate in the future. These materials typically have a lifespan of around 25–30 years, so at present time lots of tons of polymer composites are next to their end of life and this volume continues to grow. Currently, a significant portion of these materials is either incinerated or landfilled, resulting in substantial environmental impacts. Numerous studies have aimed to identify optimal recycling approaches, one of which involves solvolysis: the chemical dissolution of the polymer matrix. In this study, a solvolysis method has been devised and refined to effectively recover carbon fibers from composites while minimizing property degradation. The process begins with the identification of a suitable solvolysis fluid, specifically an aqueous sulfuric acid solution. Subsequently, key solvolysis parameters including solution concentration, temperature, residence time, and fluid agitation are meticulously optimized. The chemical and morphological impacts of this process are thoroughly examined using Fourier‐transform infrared spectroscopy analysis and scanning electron microscope observations.

Sustainable Electrically Conductive Bio-Based Composites via Radical-Induced Cationic Frontal Photopolymerization.

Diglycidylether of vanillyl alcohol (DGEVA), in combination with mechanically recycled carbon fibers (RCFs), was used to make, via Radical-Induced Cationic Frontal Photopolymerization (RICFP), fully sustainable and bio-based conductive composites with good electrical conductivity and consequent Joule effect proprieties. Three different fiber lengths, using three different sieve sizes during the mechanical recycling process (0.2, 0.5, and 2.0 mm), were used in five different amounts (ranging from 1 to 25 phr). The samples were first characterized by dynamic mechanical thermal analysis (DMTA), followed byelectrical conductivity and Joule heating tests. More specifically, the mechanical properties of the composites increased when increasing fiber content. Furthermore, the composites obtained with the longest fibers showed the highest electrical conductivity, reaching a maximum of 11 S/m, due to their higher aspect ratio. In this context, the temperature reached by Joule effect was directly related to the electrical conductivity, and was able to reach an average and maximum temperatures of 80 °C and 120 °C, respectively, just by applying 6 V.

Reinforcing Efficiency of Recycled Carbon Fiber PLA Filament Suitable for Additive Manufacturing.

The use of 3D printing technology for manufacturing new products based on sustainable materials enables one to take advantage of secondary raw materials derived from recycling. This work investigates the structural performances of 3D printing composite filaments based on polylactic acid (PLA), as a matrix, reinforced by recycled carbon fiber (rCF). Carbon fibers were recovered from industrial scraps by a patented thermal process and used to produce thermoplastic composite filaments for additive manufacturing without any additional treatment and additives. The influence of the recovered carbon fiber (rCF) content on the thermal properties, mechanical properties and microstructure of the composites was studied in the range of 3-20 wt%. The recorded TGA curves exhibited a one-stage weight loss within the temperature range 290-380 °C for all samples and the residual rCF content was in good agreement with the theoretical fiber loading. The Young modulus of the extruded filaments strongly increased below a critical content (5 wt%), while at higher content the improvement was reduced. An increase in the storage modulus of 54% compared to neat PLA 3D printed sample resulted in a printed specimen with a higher rCF content. SEM images highlighted a strong rCF prevailing alignment in the direction of the extrusion flow, creating almost unidirectional reinforcement inside the filament. These findings suggest that homogeneous composite filaments reinforced with well-dispersed recycled CF without additional chemical modification and additives are suitable materials for additive manufacturing. The effect of rCF topological distribution within the material on the mechanical performances has been discussed, highlighting that the isolated fibers could efficiently transfer loads with respect to the percolated 3D network and have been correlated with the microstructure.

Capacitive Sensors Based on Recycled Carbon Fibre (rCF) Composites.

Recycled carbon fibre (rCF) composites are increasingly being explored for applications such as strain sensing, manufacturing of automobile parts, assistive technologies, and structural health monitoring due to their properties and economic and environmental benefits. The high conductivity of carbon and its wide application for sensing makes rCF very attractive for integrating sensing into passive structures. In this paper, capacitive sensors have been fabricated using rCF composites of varying compositions. First, we investigated the suitability of recycled carbon fibre polymer composites for different sensing applications. As a proof of concept, we fabricated five touch/proximity sensors and three soil moisture sensors, using recycled carbon fibre composites and their performances compared. The soil moisture sensors were realised using rCF as electrodes. This makes them corrosion-resistant and more environmental-friendly, compared to conventional soil moisture sensors realised using metallic electrodes. The results of the touch/proximity sensing show an average change in capacitance (ΔC/C~34) for 20 mm and (ΔC/C~5) for 100 mm, distances of a hand from the active sensing region. The results of the soil moisture sensors show a stable and repeatable response, with a high sensitivity of ~116 pF/mL of water in the linear region. These results demonstrate their respective potential for touch/proximity sensing, as well as smart and sustainable agriculture.

A novel overflow extrusion‐annealing process for preparing high performance recycled carbon fiber reinforced Nylon 6 composites

A novel overflow extrusion‐annealing process for preparing high performance recycled carbon fiber reinforced <scp>Nylon 6</scp> composites

Smart electroactive self-repairable coating involving end-of-life aircraft prepregs by mechanical recycling

The environmental impact of the Carbon Fiber Reinforced Polymers (CFRPs) industry, particularly due to waste generation during manufacturing and end-of-life phases, is compelling major industrial entities to reconsider a circular economy approach for their materials and to comply with emerging regulations. This study explores the potential of recycled carbon fibers (rCFs) derived from the mechanical recycling of prepreg waste. Mechanical recycling was selected for its cost-effectiveness and moderate environmental impact, recovering short rCFs with lengths below 200 μm. These rCFs, which retain excellent electrical properties, are incorporated into an epoxy matrix with Polycaprolactone (PCL) to create a multifunctional coating with self-healing capabilities. The resulting composite material exhibited significant improvements in electrical conductivity, achieving up to 16.50 S/m, and demonstrated effective Joule effect heating, exceeding 200 °C with 20 V applied for a composite containing 15 wt% rCF. The self-healing efficiency for surface cracks, activated by the Joule effect, reached 80–90 %, resulting in a 99 % reduction in energy consumption compared to conventional oven heating. Notably, the self-healing mechanism was characterized in real-time within a scanning electron microscope for the first time, providing a comprehensive evaluation of the process. This innovative coating offers promising applications in aviation for anti-icing, deicing, and maintenance reduction, as well as in residential settings as an energy-efficient floor heating solution. This research underscores the potential of mechanically recycled CFRPs to produce high-value, sustainable materials, promoting a circular economy and reducing the environmental footprint of the aeronautical sector.