Ultrasonic injection molding of glass fiber reinforced polypropylene parts using tungsten carbide-cobalt mold core

[Display omitted] •Glass fiber reinforced polypropylene composite microstructured parts were fabricated by ultrasonic injection molding.•The replication rate is used to characterize the molding quality of microstructure part.•Hydrophobic surfaces are fabricated in a short time without additional heating devices.•The influence of ultrasonic on mechanical properties and fiber orientation of samples is analyzed. A hybrid process combining ultrasonic injection molding and electrical discharge machining was proposed to realize the economic, high-precision, and environmental-friendliness production of glass fiber reinforced polypropylene microstructured parts. First, the prism array microstructures were processed on tungsten carbide-cobalt (WC-8 wt% Co) substrate by low-speed wire electrical discharge machining and used as the mold core. Then, the glass fiber reinforced polypropylene composite (GF/PP) was melted under ultrasonic vibration, and the surface microstructure of the mold core was replicated. The experimental results show that this method can efficiently and accurately manufacture microstructured parts, and the microstructure has a high replication rate up to 95.5%. By replicating the microstructure, the surface contact angle of GF/PP parts increased from 57.1° to 134.9°, and the wettability changed from hydrophilicity to hydrophobicity. The mechanical properties test results show that the GF/PP parts fabricated by ultrasonic injection molding had excellent mechanical properties, and the 30% GF/PP parts show the highest tensile strength of 56.9 MPa. This work provides a new option for fabricating fiber reinforced composite parts.