This review thoroughly investigates the mechanical recycling of carbon fiber-reinforced polymer composites (CFRPCs), a critical area for sustainable material management. With CFRPC widely used in high-performance areas like aerospace, transportation, and energy, developing effective recycling methods is essential for tackling environmental and economic issues. Mechanical recycling stands out for its low energy consumption and minimal environmental impact. This paper reviews current mechanical recycling techniques, highlighting their benefits in terms of energy efficiency and material recovery, but also points out their challenges, such as the degradation of mechanical properties due to fiber damage and difficulties in achieving strong interfacial adhesion in recycled composites. A novel part of this review is the use of finite element analysis (FEA) to predict the behavior of recycled CFRPCs, showing the potential of recycled fibers to preserve structural integrity and performance. This review also emphasizes the need for more research to develop standardized mechanical recycling protocols for CFRPCs that enhance material properties, optimize recycling processes, and assess environmental impacts thoroughly. By combining experimental and numerical studies, this review identifies knowledge gaps and suggests future research directions. It aims to advance the development of sustainable, efficient, and economically viable CFRPC recycling methods. The insights from this review could significantly benefit the circular economy by reducing waste and enabling the reuse of valuable carbon fibers in new composite materials.

Acrylonitrile butadiene styrene (ABS) is the most commonly used thermoplastic printing material for fused deposition modelling (FDM). FDM ABS can be used in a variety of complex working environments. Notably, the thermo-mechanical coupled loads under complex operating conditions may lead to cracking and ultimately catastrophic structural failure. Therefore, it is crucial to determine the crack depth and location before a structural fracture occurs. As these parameters affect the dynamic response of the structure, in this study, the fundamental frequency and displacement amplitude response of a cracked 3D-printed ABS cantilever beam in a thermal environment were analytically and experimentally investigated. The existing analytical model, specifically the torsional spring model used to calculate the fundamental frequency change to determine the crack depth and location was enhanced by the proposed Khan-He model. The analytical relationship between the displacement amplitude and crack was established in Khan-He model and validated for the first time for FDM ABS. The results show that a reduced crack depth and location farther from the fixed end correspond to a higher fundamental frequency and displacement amplitude. An elevated ambient temperature decreases the global elastic modulus of the cracked beam and results in a lower fundamental frequency. Moreover, a non-monotonic relationship exists between the displacement amplitude and ambient temperature. The displacement amplitude is more sensitive to the crack change than the fundamental frequency in the initial stages of crack growth.

The advantage of mesophase pitch-based carbon fibres is their high modulus, but pitch-based carbon fibres and precursors are very brittle. This paper reports the development of a unique manufacturing method using a blend of pitch and linear low-density polyethylene (LLDPE) from which it is possible to obtain precursors that are less brittle than neat pitch fibres. This study reports on the structure and properties of pitch and LLDPE blend precursors with LLDPE content ranging from 5 wt% to 20 wt%. Fibre microstructure was determined using scanning electron microscopy (SEM), which showed a two-phase region having distinct pitch fibre and LLDPE regions. Tensile testing of neat pitch fibres showed low strain to failure (brittle), but as the percentage of LLDPE was increased, the strain to failure and tensile strength both increased by a factor of more than 7. DSC characterisation of the melting/crystallization behaviour of LLDPE showed melting occurred around 120 °C to 124 °C, with crystallization between 99 °C and 103 °C. TGA measurements showed that for 5 wt%, 10 wt% LLDPE thermal stability was excellent to 800 °C. Blend pitch/LLDPE carbon fibres showed reduced brittleness combined with excellent thermal stability, and thus are a candidate as a potential precursor for pitch-based carbon fibre manufacturing.

A high modulus of elasticity is a distinctive feature of carbon fibres produced from mesophase pitch. In this work, we expand our previous study of pitch/linear low-density polyethylene blend fibres, increasing the concentration of the linear low-density polyethylene in the blend into the range of from 30 to 90 wt%. A scanning electron microscope study showed two distinct phases in the fibres: one linear low-density polyethylene, and the other pitch fibre. Unique morphologies of the blend were observed. They ranged from continuous microfibres of pitch embedded in linear low-density polyethylene (occurring at high concentrations of pitch) to a discontinuous region showing the presence of spherical pitch nodules (at high concentrations of linear low-density polyethylene). The corresponding mechanical properties—such as tensile strength, tensile modulus, and strain at failure—of different concentrations of linear low-density polyethylene in the pitch fibre were measured and are reported here. Thermogravimetric analysis was used to investigate how the increased linear low-density polyethylene content affected the thermal stability of linear low-density polyethylene/pitch fibres. It is shown that selecting appropriate linear low-density polyethylene concentrations is required, depending on the requirement of thermal stability and mechanical properties of the fibres. Our study offers new and useful guidance to the scientific community to help select the appropriate combinations of linear low-density polyethylene/pitch blend concentrations based on the required mechanical property and thermal stability of the fibres.

The current paper reports on the quantification of the effect of magnetic fields on the mechanical performance of ferromagnetic nanocomposites in situ during basic standard tensile testing. The research investigates altering the basic mechanical properties (modulus and strength) via the application of a contact-less magnetic field as a primary attempt for a future composites strengthening mechanism. The nanocomposite specimens were fabricated using filament-based 3D printing and were comprised of ferromagnetic nanoparticle-embedded thermoplastic polymers. The nanoparticles were iron particles dispersed at 21 wt.% (10.2 Vol.%) inside a polylactic acid (PLA) polymer, characterised utilising optical microscopy and 3D X-ray computed tomography. The magnetic field was stationary and produced using permanent neodymium round-shaped magnets available at two field strengths below 1 Tesla. The 3D printing was a MakerBot Replicator machine operating based upon a fused deposition method, which utilised 1.75 mm-diameter filaments made of iron particle-based PLA composites. The magnetic field-equipped tensile tests were accompanied by a real-time digital image correlation technique for localized strain measurements across the specimens at a 10-micron pixel resolution. It was observed that the lateral magnetic field induces a slight Poisson effect on the development of extrinsic strain across the length of the tensile specimens. However, the effect reasonably interferes with the evolution of strain fields via the introduction of localised compressive strains attributed to accumulated magnetic polarisation at the magnetic particles on an extrinsic scale. The theory overestimated the moduli by a factor of approximately 3.1. To enhance the accuracy of its solutions for 3D-printed specimens, it is necessary to incorporate pore considerations into the theoretical derivations. Additionally, a modest 10% increase in ultimate tensile strength was observed during tensile loading. This finding suggests that field-assisted strengthening can be effective for as-received 3D-printed magnetic composites in their solidified state, provided that the material and field are optimally designed and implemented. This approach could propose a viable method for remote field tailoring to strengthen the material by mitigating defects induced during the 3D printing process.