Search Results (11)

Recycling carbon-fiber-reinforced plastics (CFRPs) is crucial for sustainable material utilization, particularly in aerospace applications, where large quantities of prepreg waste are generated. This study investigated the mechanical properties of highly oriented recycled CFRP (rCFRP) molded using vacuum-assisted resin transfer molding (VaRTM), wet-layup, and traditional RTM methods. Recycled carbon fibers (rCFs) obtained via solvolysis and pyrolysis were processed into nonwoven preforms to ensure fiber alignment through carding. The influence of molding methods, fiber recycling techniques, and fiber orientation on mechanical performance was examined through tensile tests, fiber volume fraction (Vf) analysis, and scanning electron microscopy observations. The results indicated that the solvolysis-recycled rCF exhibited superior interfacial adhesion with the resin, leading to a higher tensile strength and stiffness, particularly in the RTM process, where a high Vf was achieved. Wet-layup molding effectively reduced the void content owing to autoclave curing, maintaining stable properties even with pyrolyzed rCF. VaRTM, while enabling vacuum-assisted resin infusion, exhibited a higher void content, limiting improvements in mechanical performance. This study highlights that tailoring the molding method according to the desired performance, such as increasing stiffness potential by enhancing Vf in RTM or improving tensile strength by improving fiber–matrix adhesion in wet-layup molding, is critical for optimizing rCFRP properties, providing important insights into sustainable CFRP recycling and high-performance material design. Full article

The increasing demand for high-performance materials has led to an increase in the use of carbon fibre-reinforced plastics (CFRPs) in recent decades, increasing the waste from end-of-life materials and off-cuts. The recycling of CFRPs, especially when thermosetting matrices are used, still remains an open challenge for academia and industry, with chemical, thermal and mechanical strategies being explored. Among them, mechanical methods have garnered growing interest since they do not require high specific energy consumption or expensive apparatus. However, from the literature it was observed that when using these methods, traces of old matrix remain on the fibre’s surface, compromising the fibre–matrix adhesion efficiency and limiting their use in recycled composites. On the other hand, solvothermal methods are known for their high matrix dissolution efficiency that in turn improves the fibre–matrix adhesion. Therefore, in this paper, end-of-life CFRPs from the aeronautic sector were machined using a milling-based mechanical recycling method, while to remove the residual matrix from the fibre surface, the recovered chips were chemically treated with a two-step treatment at low temperature. Then, two types of recycled composite laminates were manufactured using the compression moulding technique: the first using recycled fibres only from the mechanical recycled method, and the second one using recycled fibres deriving from both recycling methods. The feasibility of the process was analysed observing that the additional chemical treatment led to a mass loss of almost 24% in the recycled fibres. FTIR analysis revealed the complete matrix dissolution since no spectra of epoxy resin groups were detected. Finally, the flexural behaviour of the recycled composites was investigated, revealing an increase in the flexural strength and modulus of the second sample typology, respectively, of almost 42% and 76% thanks to the improved fibre–matrix adhesion as a consequence of the solvothermal treatment. Full article

The growing use of fibre-reinforced polymers (FRPs) is driving a demand for the development of sustainable end-of-life strategies. Solvolysis, a chemical recycling method using solvents to decompose the polymer matrix, has emerged as a promising approach for reclaiming both fibres and organic compounds from FRP waste. This work provides a comprehensive overview of solvolysis techniques by discussing the environmental benefits and economic opportunities of this technology, summarising the process conditions, and evaluating the characteristics of the recovered products. The economic viability of solvolysis lies in recovering high-value components; predominantly carbon fibres from CFRPs and organic products from GFRPs, which are suitable for reuse or as a feedstock for new composites. Solvolysis can operate under low temperature and pressure (LTP) or high temperature and pressure (HTP) conditions. The choice of solvent, catalyst, reaction time, and temperature is crucial to achieving high resin decomposition while preserving fibre properties. To achieve an economically viable and environmentally beneficial process, it will be essential to optimise these parameters. A key challenge is maintaining the strength and surface properties of the recovered fibres, as degradation in their performance can limit their suitability for high-performance applications. The implication of this is that, without careful consideration of the recycling process, FRPs cannot be fully circular. They will be continuously downgraded into low-value applications and ultimately incinerated or landfilled. This review further explores the diversity of organic products obtained, which can range from monomers to oligomers to complex mixtures. Efficient separation and upgrading techniques, such as distillation and liquid–liquid extraction, are essential to maximise the value of the recovered organics. These additional processing steps are likely to result in greater financial and resource costs within a commercial recycling system. This review concludes with a summary of commercial solvent-based recycling ventures and an outlook on future research directions, which includes the need to develop processes capable of recovering high-value, long carbon fibres. Successful development of such a process would represent a step-change in the value proposition of a carbon fibre recycling industry. Full article

The recycling of carbon-fiber reinforced polymers (CFRPs) presents significant challenges due to their thermosetting matrix, which complicates end-of-life management and often results in energy-intensive disposal or significant waste accumulation. Despite advancements in recycling methods, knowledge gaps remain regarding their sustainability and economic viability. This study undertakes a comprehensive Life Cycle Assessment and Environmental Life Cycle Costing analysis of four key recycling techniques: mechanical recycling, pyrolysis, solvolysis, and high-voltage fragmentation (HVF). By using the SimaPro software, this study identifies mechanical recycling and HVF as the most sustainable options, with the lowest cumulative energy demand (CED) of 5.82 MJ/kg and 4.97 MJ/kg and global warming potential (GWP) of 0.218 kg CO₂eq and 0.0796 kg CO₂eq, respectively. In contrast, pyrolysis imposes the highest environmental burdens, requiring 66.3 MJ/kg and emitting 2.84 kg CO₂eq. Subcritical solvolysis shows more balanced environmental impacts compared to its supercritical counterpart. Cost analysis reveals that for mechanical recycling and pyrolysis, material costs are negligible or zero. In contrast, solvolysis and HVF incur material costs primarily due to the need for deionized water. Regarding energy costs, pyrolysis stands out as the most expensive method due to its high energy demands, followed closely by solvolysis with supercritical water. Full article

The recycling of Carbon Fibre-Reinforced Polymers (CFRPs) is becoming increasingly crucial due to the growing demand for sustainability in high-performance industries such as automotive and aerospace. This study investigates the impact of two chemical recycling techniques, chemically assisted solvolysis and plasma-enhanced solvolysis, on the morphology and properties of carbon fibres (CFs) recovered from end-of-life automotive parts. In addition, the effects of fibre sizing are explored to enhance the performance of the recycled carbon fibres (rCFs). The surface morphology of the fibres was characterised using Scanning Electron Microscopy (SEM), and their structural integrity was assessed through Thermogravimetric Analysis (TGA) and Raman spectroscopy. An automatic analysis method based on optical microscopy images was also developed to quantify filament loss during the recycling process. Mechanical testing of single fibres and yarns showed that although rCFs from both recycling methods exhibited a ~20% reduction in tensile strength compared to reference fibres, the application of sizing significantly mitigated these effects (~10% reduction). X-ray Photoelectron Spectroscopy (XPS) further confirmed the introduction of functional oxygen-containing groups on the fibre surface, which improved fibre-matrix adhesion. Overall, the results demonstrate that plasma-enhanced solvolysis was more effective at fully decomposing the resin, while the subsequent application of sizing enhanced the mechanical performance of rCFs, restoring their properties closer to those of virgin fibres. Full article

The extensive use of carbon fiber-reinforced plastics (CFRP) in aerospace, civil engineering, and other fields has resulted in a significant amount of waste, leading to serious environmental issues. Finding appropriate methods for recycling CFRP waste and effectively reusing recycled carbon fibers (rCFs) has become a challenging task. This paper presents an overview of the current status of CFRP waste and provides a systematic review and analysis of recycling technologies. In addition to discussing mechanical recycling, thermal decomposition, and chemical solvent degradation methods, the organic alkali/organic solvent method for recycling resins is also elucidated. By introducing the recycling conditions and outcomes of the organic alkali/organic solvent method, the study highlights its significance as a reference for carbon fiber recycling. Furthermore, the paper reviews the current state of rCFs utilization based on its application domains, focusing on research advancements in fiber composites and cementitious composites. Based on these findings, the paper summarizes the existing research limitations and identifies specific areas that require further attention in recycling techniques and rCFs utilization. Lastly, this review provides a prospect on the future of recycling and reusing CFRP waste. Full article

The application of adhesively bonded joints in aerospace structural parts has increased significantly in recent years and the general advantages of their use are well-documented. One of the disadvantages of adhesive bonding is the relevant permanence, when compared to traditional mechanical fastening. End-of-life processes generally require the separation of the adherents for repair or recycling, and usually to achieve this, they combine large mechanical forces with a high temperature, thus damaging the adherents, while consuming large amounts of energy. In this work, a novel disassembly technique based on laser-induced shock waves is proposed for the disassembly of multi-material adhesively bonded structures. The laser shock technique can generate high tensile stresses that are able to break a joint, while being localized enough to avoid damaging the involved adherents. The process is applied to specimens made from a 3D-woven CFRP core bonded to a thin Ti layer, which is a common assembly used in state-of-the-art aircraft fan blades. The experimental process has been progressively developed. First, a single-sided shot is applied, while the particle velocity is measured at the back face of the material. This method proves ineffective for damage creation and led to a symmetric laser configuration, so that the tensile stress can be controlled and focused on the bond line. The symmetric approach is proved capable of generating a debonding between the Ti and the CFRP and propagating it by moving the laser spot. Qualitative assessment of the damage that is created during the symmetric experimental process indicates that the laser shock technique can be used as a material separation method. Full article

This paper presents a review of waste disposal methods for fibre reinforced polymer (FRP) materials. The methods range from waste minimisation, repurposing, reusing, recycling, incineration, and co-processing in a cement plant to dumping in a landfill. Their strength, limitations, and key points of attention are discussed. Both glass and carbon fibre reinforced polymer (GFRP and CFRP) waste management strategies are critically reviewed. The energy demand and cost of FRP waste disposal routes are also discussed. Landfill and co-incineration are the most common and cheapest techniques to discard FRP scrap. Three main recycling pathways, including mechanical, thermal, and chemical recycling, are reviewed. Chemical recycling is the most energy-intensive and costly route. Mechanical recycling is only suitable for GFRP waste, and it has actually been used at an industrial scale by GFRP manufacturers. Chemical and thermal recycling routes are more appropriate for reclaiming carbon fibres from CFRP, where the value of reclaimed fibres is more than the cost of the recycling process. Discarding FRP waste in a sustainable manner presents a major challenge in a circular economy. With strict legislation on landfill and other environmental limits, recycling, reusing, and repurposing FRP composites will be at the forefront of sustainable waste-management strategies in the future. Full article

During the production process of commercial carbon fiber reinforced polymers (CFRPs), a silane coupling agent is added to the carbon fiber at the sizing step as a binder to enhance the product’s physical properties. While improving strength, the silane coupling agent results in a silane residue on recovered carbon fibers (rCF) after recycling, which is a disadvantage when using recovered carbon fibers in the manufacture of new materials. In this study, the rCF is recovered from waste carbon fiber reinforced polymers (CFRPs) from the bicycle industry by a microwave pyrolysis method, applying a short reaction time and in an air atmosphere. Moreover, the rCF are investigated for their surface morphologies and the elements present on the surface. The silicon element content changes with pyrolysis temperature were 0.4, 0.9, and 0.2%, respectively, at 450, 550, and 650 °C. Additionally, at 950 °C, silicon content can be reduced to 0.1 ± 0.05%. The uniformity of microwave pyrolysis recycle treatment was compared with traditional furnace techniques used for bulk waste treatment by applying the same temperature regime. This work provides evidence that microwave pyrolysis can be used as an alternative method for the production of rCFs for reuse applications. Full article

Carbon Fibre Reinforced Polymers (CFRPs) are commonly used materials in manufacturing components and products in the automotive, aerospace, and wind energy industries generating thousands of tons of waste, thus creating a threat to the environment if not recycled. Therefore, it is important for both academia and industry to investigate various ways of recycling this material. However, there is an urgent need for a reliable cost predication system to assist in making informed decisions, planning sustainable treatment, and developing pricing strategies for different waste treatment scenarios. This research paper presents the development of a fuzzy logic-based system to perform cost estimation of recycling processes of the CFRP. The developed system has taken into consideration uncertainties such as the characteristics of End of Life (EoL) material including its size and weight, its origin and diversity of existing recycling methods, and quantity of recycling waste. Cost drivers were divided into categories such as dismantling, transportation, operation, and capital cost. The system was developed by creating 243 fuzzy rules and three levels of fuzzy sets. Moreover, an interactive user-friendly interface was developed to enable the user to use the system easily and efficiently. Finally, case study results were examined to compare the whole life recycling cost of four different recycling technologies in various scenarios of waste treatment. The developed fuzzy logic-based system has the capability in evaluating the cost structure of CFRP recycling techniques and take into consideration uncertainty factors. Hence, a major contribution of the developed system is its provision of the heuristic rules that aid the decision-making process for selecting a cost-effective recycling method. The visualisation facility of the developed system is also a useful tool in enabling potential users to forecast the cost of the CFRP recycling techniques upfront. Full article

Cost-effective and environmentally responsible ways of carbon fiber-reinforced composite (CFRP) recycling are increasingly important, owing to the rapidly increasing use of these materials in many industries such as the aerospace, automotive and energy sectors. Product designers need to consider the costs associated with manufacturing and the end-of-life stage of such materials to make informed decisions. They also need to understand the current methods of composite recycling and disposal and their impact on the end-of-life costs. A comprehensive literature review indicated that there is no such tool to estimate CFRP recycling costs without any prior knowledge and expertise. Therefore, this research paper proposed a novel knowledge-based system for the cost modelling of recycling CFRP that does not require in-depth knowledge from a user. A prototype of a cost estimation system has been developed based on existing CFRP recycling techniques such as mechanical recycling, pyrolysis, fluidized bed, and supercritical water. The proposed system has the ability to select the appropriate recycling techniques based on a user’s needs with the help of an optimization module based on the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). Estimating recycling costs has taken into consideration various factors such as different material types in different industries, transportation, and dismantling costs. The developed system can be employed to support early-stage designers and decision-making stakeholders in terms of understanding and predicting recycling costs easily and quickly. Full article