Circular Production, Designing, and Mechanical Testing of Polypropylene-Based Reinforced Composite Materials:...

Area of Science:

• Materials Science
• Polymer Engineering
• Sustainable Materials

Background:

• Polymer waste circularity is a growing research area in Europe.
• Polypropylene (PP)-based composites are being explored for enhanced properties.
• Utilizing post-consumer fibers offers a sustainable approach to polymer recycling.

Purpose of the Study:

• To evaluate the thermal, surface, mechanical, and tribological properties of PP composites reinforced with cotton, synthetic polyester, and polyethylene terephthalate post-consumer fibers.
• To determine the effect of varying fiber content (10%, 30%, 40% wt.) on composite performance.
• To assess the suitability of these composites for commercial applications.

Main Methods:

• Injection molding was used to produce PP-based composites.
• Direct extrusion combined with injection molding techniques were employed for fiber incorporation.
• Mechanical testing (tensile, flexural, impact), surface analysis (roughness), and tribological testing (abrasive, erosive wear) were conducted.
• Single-step analysis of variance was used to predict commercial applicability.

Main Results:

• PP-PCPESF-10% wt. showed the highest tensile strength (29 MPa).
• Increased fiber content led to reduced tensile and flexural strain due to micro-defects, but enhanced modulus and strength.
• PP-PCCF-40% wt. exhibited the highest flexural strength (57 MPa) and constant (2780 MPa).
• Higher fiber loadings increased micro-defects, surface roughness, abrasive wear, and coefficient of friction.
• Pure PP had the lowest abrasive wear (3.09 × 10^-6 mm³/Nm), while PP-PCCF 40% wt. showed significantly higher erosive wear (2-17 times).

Conclusions:

• Polypropylene composites reinforced with post-consumer fibers offer improved mechanical strength.
• The trade-off between enhanced strength and increased wear/defects needs careful consideration for specific applications.
• Analysis suggests potential for commercial application, contingent on managing defect formation and wear characteristics.