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Study on the Effect of Surface Energy of Polypropylene/Polyamide12 Polymer Hybrid Matrix Reinforced with Virgin and Recycled Carbon Fiber

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Study on the Effect of Surface Energy of Polypropylene/Polyamide12 Polymer Hybrid Matrix Reinforced with Virgin and Recycled Carbon Fiber Study on the Effect of Surface Energy of Polypropylene/Polyamide12 polymer Hybrid Matrix Reinforced with Virgin and Recycled Carbon Fiber. by Bruno Sena Maia A thesis submitted in conformity with the requirements for the degree of Master of Science in Forestry Faculty of Forestry University of Toronto © Copyright by Bruno Sena Maia 2017 Study on the Effect of Surface Energy of Polypropylene/Polyamide12 polymer Hybrid Matrix Reinforced with Virgin and Recycled Carbon Fiber. Bruno Sena Maia Master of Science in Forestry Faculty of Forestry University of Toronto 2017 Abstract The presented work is focused on characterization of thermal treated recycled and virgin carbon fibers. Their thermal performances, chemical surface composition and its influence on interfacial adhesion phenomena on PP/PA12 hybrid matrix were compared using TGA, FTIR and XPS analysis. Additionally, differences between hybrid matrix structural performances of PP/PA12 using both surface modifiers PMPPIC and MAPP were investigated. Final mechanical properties improvements between 8% up to 17% were reached by addition of PMPPIC in PP/PA12 hybrid matrix. For PP/PA12 matrix reinforcement using virgin and recycled carbon fibers, impact energy was improved up to 98% compared with MAPP modified matrix leading to a novel composite with good energy absorption. Finally, wettability studies and surface free energy analysis of all materials studied support the effect of the addition of PMPPIC, MAPP and carbon fibers in final composite surface thermodynamics bringing important data correlation between interfacial adhesion mechanisms and final composite performance. ii Acknowledgments My special thanks to Professor Mohini Sain and Professor Jimi Tjong for accepting me as part of the Centre for Biocomposites and Biomaterials Processing group. It meant a lot that they believed in my skills and capacity. Their valuable technical insights, critical perspectives, and overall support made this research possible. In addition, I would like to thank Professor Chandra Veer Singh for his prompt and excellent contribution, feedback and support during this research. Finally, Suhara Panthapulakkal, Shiang Law, Muhammad Pervaiz, Samir K. Konar, Javad Sameni and Tony Ung deserve a special thank you for their research support jointly with all Faculty of Forestry Staff that work hard to achieve excellent results in all aspects. My sincere thanks also goes to Cristiane Gonçalves at Ford Brazil, who through her trust and confidence in my work, opened up the door to the possibility of graduate studies at the University of Toronto. Thanks to my professional CBBP colleagues Antimo Graziano, Ahmed Sobh, Birat KC, Masoud Akhshik and Otavio Titton Dias. I hope we can meet in the future to remember all the challenges and professional experiences we went through together. I must not forget to thank my Canadian friends Emilia Melo, Fabio Rocha (and the little Enzo!), Claudio Lopes and his family for all the support they gave me during my first days here. To everyone that directly or indirectly supported me during my path, thank you very much. I would like to acknowledge the collaborative institutions that honored all my research funding support: MITACS Accelerate Program, Automotive Partnership Canada Program promoted by Natural Sciences and Engineering Research Council of Canada (NSERC), Ford Motor Company Canada and all professors and staff from University of Toronto, Faculty of Forestry. Extra thanks for Prof. Peter M. Brodersen, Prof. Edgar A. Costa and PhD. candidate Aurelio Stammitti from Chemical Engineering Faculty of University of Toronto for their patience, skilled support and advice. Finally, this achievement could not have been accomplished without the support of my family. My character and principles are largely based on their guidance and support. Maria Alice Leal Sena Maia, Divanildo Branco Maia, thank you! To my sister, Ravena Sena Maia, for her advice and guidance through stressful periods. Most importantly, a special thank you to my wife Daniela Gonzalez de Freitas, who iii accepted the challenge to live by my side. The Canadian winters and transition to student life have been a challenge to her. I could not be here without you my love and partner, thank you! iv Table of Contents Acknowledgments .......................................................................................................................... iii Table of Contents .............................................................................................................................v List of Tables ............................................................................................................................... viii List of Figures ................................................................................................................................ xi List of Appendices ..................................................................................................................... xviii List of Symbols ............................................................................................................................ xix List of Abbreviations ................................................................................................................... xxi Chapter 1 ..........................................................................................................................................1 1 Research Background and Literature Review .............................................................................1 1.1 Background ..........................................................................................................................1 1.2 Carbon Fibers (CF) and Recycled Carbon Fibers (RCF) Overview ....................................6 1.2.1 Carbon Fibers ...........................................................................................................6 1.2.2 Recycled Carbon Fibers .........................................................................................16 1.3 Recycled Carbon Fiber (RCF): Reclaiming Processes and RCFRP-Recycled Carbon Fiber Reinforced Plastic Manufacturing .....................................................................................18 1.4 Material Characterization Techniques for Carbon Fibers ..................................................20 1.4.1 Thermogravimetric Analysis (TGA) ......................................................................21 1.4.2 Fourier Transformed Infrared Spectroscopy (FTIR) .............................................24 1.4.3 X-Ray Photoelectron Spectroscopy .......................................................................28 1.5 Surface Energy and Wetting Studies in Composite Materials ...........................................30 1.5.1 Contact Angle and Surface Free Energy ................................................................32 1.5.2 Carbon Fiber Surface Energy Studies ....................................................................34 1.5.3 Sessile drop techniques on polymer blends and composite materials ...................36 v 1.6 Surface modifiers for polymer blends and fiber reinforced polymers ...............................38 1.6.1 Maleic Anhydride Polypropylene – MAPP ...........................................................39 1.6.2 Poly[methylene(Polyphenyl) Isocyanate] – PMPPIC ............................................44 Chapter 2 ........................................................................................................................................47 2 Research Motivation, Scope and Objectives .............................................................................47 2.1 Research Motivation ..........................................................................................................47 2.2 Research Scope ..................................................................................................................48 2.2.1 Recycled Carbon Fibers Characterization .............................................................48 2.2.2 Reacted PP/PA12 Polymer Blend and Recycled Carbon Fiber Polymer Hybrid Composite ..............................................................................................................48 2.2.3 Wettability and Surface Energy Studies in Recycled Carbon Fibers Hybrid Polymers ................................................................................................................................49 2.3 Research Objective ............................................................................................................50 Chapter 3 ........................................................................................................................................51 3 Research Methodology .............................................................................................................51 3.1 Materials Description .........................................................................................................51 3.2 Material Compounding and Processing .............................................................................53 3.2.1 Material preparation ...............................................................................................53 3.2.2 Extrusion Process ...................................................................................................55 3.2.3 Injection molding process ......................................................................................56 3.3 Research Test
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