Mechanical Characterization of Forged Carbon Composites from Waste Prepreg

Information from the abstract

The increasing use of carbon fiber reinforced polymers (CFRPs) in aerospace and automotive has led to a growing volume of prepreg waste, creating economic and environmental challenges. This study investigates the feasibility of repurposing expired carbon fiber prepreg waste into Forged Carbon Fiber (FCF) composites through compression molding. Chopped fibers recovered from ambient-aged unidirectional T700 prepreg were used to manufacture waste forged carbon fiber composites (WFCF) and were compared with forged composites made from new chopped fibers (NFCF) and from mixed WFCF/NFCF formulations. Thermal analysis by differential scanning calorimetry confirmed that the waste prepreg fibers had undergone partial curing during storage, resulting in a modified resin structure before reprocessing. Mechanical performance was evaluated using tensile, three-point bending, and Charpy impact tests. The WFCF composites exhibited low tensile strength and modulus, but a relatively high flexural modulus, highlighting a strong dependence on loading mode. In contrast, NFCF composites reached higher tensile strengths. These results demonstrate that although 100% waste prepreg fibers are unsuitable for structural applications, their use in forged carbon composites becomes viable when blended with virgin fibers. This approach offers a practical pathway to valorize prepreg waste and support a more sustainable circular economy for advanced composite materials.

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Related topics: Fiber-reinforced polymer composites · Epoxy Resin Curing Processes · Smart Materials for Construction