Effect of needle-punching on the internal morphology and mechanical properties of recycled non-woven carbon fiber reinforced thermoplastics with tailored anisotropic ratio

IF 12.7 1区材料科学 Q1 ENGINEERING, MULTIDISCIPLINARY

Composites Part B: Engineering Pub Date : 2025-07-18 DOI:10.1016/j.compositesb.2025.112822

Sang Won Lim , Fan Zhang , Cheng Jin , Haruna Maruko , Yi Wan , Jun Takahashi

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Abstract

The ongoing environmental crisis and growing demand for sustainability pose significant challenges to the widespread adoption of carbon fiber composites. Regulations aimed at reducing carbon emissions emphasize the importance of incorporating recycled carbon fiber (rCF). This study investigates the internal morphology and mechanical behavior of needle-punched non-woven carbon fiber reinforced thermoplastics (NW-CFRTP) using rCF as reinforcing substrate and polyamide-6 as base matrix. NW-CFRTP offer a promising alternative to continuous composites as they enable tailoring of mechanical performance by anisotropic ratio. Needle-punching is a widely employed process to improve material handling, property stabilization, and flow deterrence – key considerations for large-scale production. However, there are concerns regarding its potential adverse effects on the high in-plane mechanical properties. The NW-CFRTP in this study utilized orientation tailored rCF to enhance directional mechanical properties, making it more suitable for structural members in automotive applications. Internal morphology was analyzed through X-ray micro-computed tomography scanning to evaluate tensorial anisotropy and flow behavior. Mechanical properties were experimentally assessed and further analyzed through multi-scale modelling approach to estimate engineering constants. Results indicate that needle-punching effectively mitigates turbulent flow while preserving fiber orientation and planarity, with minimal compromise in mechanical performance. The tailored NW-CFRTP in this study, to the best of the author's knowledge, achieved the highest reported performance for recycled discontinuous CFRTP with fiber volume fraction below 30 %, demonstrating exceptional fiber utilization efficiency. Finally, the theoretical properties derived through multi-scale modelling provide a solid foundation for finite element analysis to support adoption of the material on a larger scale.

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针刺对各向异性比定制再生无纺布碳纤维增强热塑性塑料内部形貌和力学性能的影响

持续的环境危机和不断增长的可持续性需求对碳纤维复合材料的广泛采用提出了重大挑战。旨在减少碳排放的法规强调了纳入再生碳纤维（rCF）的重要性。研究了以rCF为增强基材，聚酰胺-6为基体的针刺碳纤维增强热塑性塑料（NW-CFRTP）的内部形貌和力学行为。NW-CFRTP为连续复合材料提供了一种很有前途的替代方案，因为它们可以通过各向异性比率来定制机械性能。针刺是一种广泛应用的工艺，用于改善物料处理，性能稳定和流动威慑-大规模生产的关键考虑因素。然而，人们担心其对高平面内力学性能的潜在不利影响。本研究中的NW-CFRTP利用定向定制的rCF来增强定向力学性能，使其更适合于汽车结构部件的应用。通过x射线显微计算机断层扫描分析内部形态，以评估张拉各向异性和流动行为。通过多尺度建模方法估算工程常数，对其力学性能进行了实验评估和进一步分析。结果表明，针刺有效地缓解了湍流，同时保持了纤维的取向和平面性，而力学性能的损害最小。据作者所知，本研究中定制的NW-CFRTP在纤维体积分数低于30%的情况下，获得了最高的再生不连续CFRTP性能，显示出卓越的纤维利用效率。最后，通过多尺度建模得出的理论特性为有限元分析提供了坚实的基础，以支持该材料在更大尺度上的应用。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Composites Part B: Engineering 工程技术-材料科学：复合

CiteScore

24.40

自引率

11.50%

发文量

784

审稿时长

21 days

期刊介绍： Composites Part B: Engineering is a journal that publishes impactful research of high quality on composite materials. This research is supported by fundamental mechanics and materials science and engineering approaches. The targeted research can cover a wide range of length scales, ranging from nano to micro and meso, and even to the full product and structure level. The journal specifically focuses on engineering applications that involve high performance composites. These applications can range from low volume and high cost to high volume and low cost composite development. The main goal of the journal is to provide a platform for the prompt publication of original and high quality research. The emphasis is on design, development, modeling, validation, and manufacturing of engineering details and concepts. The journal welcomes both basic research papers and proposals for review articles. Authors are encouraged to address challenges across various application areas. These areas include, but are not limited to, aerospace, automotive, and other surface transportation. The journal also covers energy-related applications, with a focus on renewable energy. Other application areas include infrastructure, off-shore and maritime projects, health care technology, and recreational products.