In the context of increasing resource scarcity and environmental concerns, the development of green composite materials is essential for promoting sustainability in the automotive industry. However, poor interfacial compatibility between plant fibers and polypropylene (PP), as well as the performance deterioration under complex environmental aging conditions, severely limits their engineering applications. In this study, a synergistic interfacial modification strategy combining alkali treatment of hemp fibers (HFs) with polypropylene grafted maleic anhydride (PP-g-MAH) was employed to enhance fiber–matrix interaction. Hemp fiber-reinforced polypropylene composites (HFRPs) with varying fiber contents (7.5–30 wt%) were fabricated via injection molding. Accelerated aging tests were conducted on the compatibilized HFRPs for up to 2400 h under ultraviolet–thermal–moisture coupled conditions, in accordance with the SAE J2527 standard. The evolution of surface color, mechanical properties, chemical structure, and microstructure was systematically characterized. After aging, surface whitening of the composites was observed. Tensile strength and impact strength decreased by 9.57–22.12% and 38.68–46.03%, respectively, while flexural strength remained relatively stable due to the supporting effect of the fiber skeleton. The aging of compatibilized HFRPs follows an outside-in progressive degradation mechanism, characterized by a stepwise cascade of surface oxidation, crack propagation, moisture ingress, interfacial degradation, and mechanical performance deterioration. These findings offer valuable insights into the long-term durability of natural fiber-reinforced thermoplastic composites and provide theoretical and practical guidance for their structural design and application in demanding service environments.

In order to study the conductive and microwave absorption performance of multi-dimensional multiphase filler conductive foam composites, carbon nanotubes (CNTs)/carbon black (CB)/polymethyl methacrylate (PMMA) nanocomposites with different porosity were fabricated via supercritical carbon dioxide (ScCO₂) one-step physical constraint foaming technology. The effects of filler component and porosity on the conductivity and absorbing properties of CNTs/PMMA/CB composite foam were studied. The Monte-Carlo method was used to study the percolation of composites and the effect of introduced microcells on the conductive network of multi-dimensional fillers. The results revealed that the volume conductivity of CNTs(3 vol%)/PMMA composites increased from 0.88 S m⁻¹ to 3.31 S m⁻¹ after the addition of 1 vol% CB. CNTs and CB had obvious synergistic effect on improving the conductivity of the composites, and the microwave absorption efficiency rose from 12.6 dB to 17.2 dB. With the increase of porosity, the electromagnetic wave absorption peak of CNTs/CB/PMMA composite foam moved to low frequency, while the conductivity showed a first rise and then a decline. The simulated percolation probability obtained by representative volume element (RVE) with different porosity also showed a similar trend, which turned out that with the increase of porosity, the effect of microcells on the convertion of conductive network construction from promoting to inhibiting.

Polypropylene (PP)-composite foams were prepared by a combination process of microcellular injection molding (MIM) and in-mold decoration (IMD). The effect of ethylene propylene diene monomer (EPDM) on the crystallization properties, rheological properties, microstructure, and mechanical properties of PP-composite foams was studied. The effect of the additives on the strength and toughness of PP-composite foam as determined by the multiscale simulation method is discussed. The results showed that an appropriate amount of EPDM was beneficial to the cell growth and toughening of the PP blends. When the content of EPDM was 15 wt%, the PP-composite foams obtained the minimum cellular size, the maximum cellular density, and the best impact toughness. At the same time, the mesoscopic simulation shows that the stress concentration is the smallest, which indicates that 15 wt% EPDM has the best toughening effect in these composite materials.