Technologies for Mechanical Recycling of Carbon Fiber-Reinforced Polymers (CFRP) Composites: End Mill, High-Energy Ball Milling, and Ultrasonication

Abstract

Carbon fiber reinforced polymer (CFRP) composites have very high specific properties, which is why they are used in the aerospace, wind power, and sports sectors. However, the high consumption of CFRP compounds leads to a high volume of waste, and it is necessary to formulate mechanical recycling strategies for these materials at the end of their useful life. The recycling differences between cutting-end mills and high-energy ball milling (HEBM) were evaluated. HEBM recycling allowed us to obtain small recycled particles, but separating their components, carbon fiber, epoxy resin, and CFRP particles, was impossible. In the case of mill recycling, these were obtained directly from cutting a CFRP composite laminate. The recycled materials resulted in a combination of long fibers and micrometric particles—a sieving step allowed for more homogeneous residues. Although long, individual carbon fibers can pass through the sieve. Ultrasonication did not significantly affect HEBM recyclates because of the high energy they are subjected to during the grinding process, but it was influential on end mill recyclates. The ultrasonication amplitude notably impacted the separation of the epoxy resin from the carbon fiber. The end mill and HEBM waste production process promote the presence of trapped air and electrostatics, which allows recyclates to float in water and be hydrophobic.

Keywords

• mechanical recycling
• carbon fiber-reinforced polymers
• end milling
• high-energy ball milling
• ultrasonication