Improving the Mechanical Properties of Recycled Carbon Fiber Nonwoven Thermoplastic Composites by Pretreating the Nonwoven with a Sizing Formulation

The excellent properties of carbon fibers, in combination with the high price of carbon fibers, makes it interesting to recycle these fibers. Pyrolysis is already an established recycling method to recover the carbon fibers, but in this process also the sizing is removed which could result in lower mechanical properties because of bad adhesion between the fiber and matrix. In this study, recycled carbon nonwoven reinforcements made from pyrolyzed carbon fibers were pre-treated in order to improve the mechanical properties of recycled carbon polyamide and recycled carbon polypropylene composites. The pre-treatment involves applying a to the matrix adapted primer coating to the nonwoven by spraying. Via compression molding, polyamide and polypropylene composites were prepared with and without pretreatment. The tensile and interlaminar shear strength of these composites were measured to determine the effect of the pretreatment. Results revealed that both strengths could be increased by pretreatment of the carbon nonwoven and the increase was largest for the PP composites.