Baskan-Bayrak Havva, Yahyapour Ramisa, Yagci Yavuz Emre, Saner Okan Burcu
Sabanci University Integrated Manufacturing Technologies Research and Application Center & Composite Technologies Center of Excellence, Teknopark Istanbul, Pendik 34906, Istanbul, Turkey.
Faculty of Engineering and Natural Sciences, Materials Science and Nanoengineering, Sabanci University, Tuzla 34956, Istanbul, Turkey.
ACS Omega. 2024 Aug 3;9(32):34530-34543. doi: 10.1021/acsomega.4c02596. eCollection 2024 Aug 13.
The automotive sector is actively pursuing a lightweighting strategy as a means to urgently decrease greenhouse gas emissions, which are a significant driver of climate change. The development of lightweight composite structures has been identified as crucial for enhancing part performance while mitigating negative environmental impacts and adopting energy-efficient manufacturing methods. This comprehensive study aimed to decrease the main reinforcement content of talc in commercial compounds while integrating graphene derived from waste polypropylene (PP) grown on talc and graphene nanoplatelet obtained from waste tires by upcycling processes into the PP compound. The entire value chain of interior automotive part production, from compound development and scaling up with a high-shear mixer, to injection molding of the part and performance tests, was investigated with a focus on sustainability considerations. The successful integration of 4 wt % micron talc, together with 1 wt % graphene nanoparticles and 1 wt % hybrid additive into the blended HomoPP/CopoPP matrix resulted in a 10% weight reduction compared to the conventional part. Moreover, significant improvements in flexural and tensile strength were observed, with enhancements of 52 and 38%, respectively. The uniform dispersion of additives and improved interfacial adhesion between the PP matrix and additives facilitated efficient stress transfer, contributing to enhanced mechanical properties. Furthermore, a systematic life cycle assessment study demonstrated the positive impact of waste PP incorporation on CO reduction, achieving a remarkable 95% reduction compared to virgin PP. The developed compound also demonstrated favorable processability and flow properties, supporting its potential for mass production. Overall, this study presents a sustainable and effective approach for lightweight automotive interior part production using a synergistically designed PP compound meeting the requirements of the automotive industry.
汽车行业正在积极推行轻量化战略，以此作为紧急减少温室气体排放的手段，因为温室气体排放是气候变化的一个重要驱动因素。轻质复合结构的开发已被视为提高部件性能、减轻负面环境影响以及采用节能制造方法的关键。这项全面研究旨在减少商用复合材料中滑石粉的主要增强剂含量，同时将源自滑石粉上生长的废弃聚丙烯（PP）的石墨烯以及通过升级再造工艺从废轮胎中获得的石墨烯纳米片整合到PP复合材料中。对汽车内饰部件生产的整个价值链进行了研究，从使用高剪切混合器进行复合材料开发和扩大规模，到部件的注塑成型和性能测试，重点关注可持续性考量。在共混的均聚PP/共聚PP基体中成功整合4 wt%的微米级滑石粉、1 wt%的石墨烯纳米颗粒和1 wt%的混合添加剂，与传统部件相比，重量减轻了10%。此外，弯曲强度和拉伸强度有显著提高，分别提高了52%和38%。添加剂的均匀分散以及PP基体与添加剂之间改善的界面附着力促进了有效的应力传递，有助于提高机械性能。此外，一项系统的生命周期评估研究表明，掺入废弃PP对减少碳排放有积极影响，与原生PP相比，实现了高达95%的显著减排。所开发的复合材料还表现出良好的加工性能和流动性能，支持其大规模生产的潜力。总体而言，本研究提出了一种可持续且有效的方法，用于生产符合汽车行业要求的、通过协同设计的PP复合材料制造的轻质汽车内饰部件。
