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Journal of Polymer & Composites Original Research Special issue

Polymer Matrix-Based High-Performance Thermoplastic Composites for Automotive Applications: Design, Characterization, and Interface Behavior

  1. G. Nagaraj Department of Mechanical Engineering, Sethu Institute of Technology
  2. Ganesh M. Agnihotri Department of Physics, jalna education society’s R. G. Bagdia Arts, S. B. Lakhotia Commerce, R. Bezonji Science College, Jalna
  3. Deepika Singh Singraur Department of Mechanical Engineering, SGT University, Gurgaon
  4. Sandeep Bansal Department of Mechanical Engineering, SGT University, Gurgaon
  5. Varinder Singh Department of Applied Science, Chandigarh College of Engineering, Chandigarh Group of Colleges, Jhanjeri
  6. A. Anandhan Department of Chemistry, Dhaanish Ahmed Institute of Technology, Coimbatore

Abstract

The study emphasizes the role of high-performance thermoplastic polymer matrices such as PEEK, PPS, and PA6, selected for their superior thermal stability, mechanical strength, and recyclability in automotive environments. The expanded usage of electric vehicles (EVs) and self-driving transportation creates a demand for advanced materials which are weight-conscious yet high in strength relative to their weight, impact-resistant yet still being environmentally friendly. This study aims to create and define fiber-reinforced thermoplastic composites (FRTPs) for next-generation automobile use in mechanical performance, thermal stability, and durability. The study investigates the potential of Interfacial bonding between fiber reinforcements and polymer matrices was optimized using surface treatment techniques, significantly enhancing load transfer efficiency and composite toughness. HPTCs were manufactured using compression molding, injection molding, and additive manufacturing (3D printing). Mechanical properties were examined using tensile, flexural, and impact strength testing. Thermal stability was determined by Differential Scanning Calorimetry (DSC) and Thermal Gravimetric Analysis (TGA). Environmental stability was tested in accelerated aging conditions to determine long-term performance. The findings indicate that carbon fiber-reinforced thermoplastics (CFRTPs) have greater mechanical strength and thermal stability than conventional composites and are most suitable for structural car parts. Thermal analysis revealed matrix-dependent behavior in terms of melting point, crystallinity, and decomposition onset, confirming the polymer-specific thermal stability of the composites. Therefore, this research provides the possibility of employing light, long-lasting, and recyclable thermoplastic composites in future car manufacturing.

Keywords

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