Mechanical behavior analysis of polypropylene composites with waste PET felt fibers

The utilization of plastic waste is another way to protect the ecology and reduce plastic pollution, which researchers and industries have been effectively focusing on for the last decade. Polyethylene terephthalate felt (PETf) is a packaging material abundantly utilized in the automotive sector and is released as waste, and its popularity as an industrial waste necessitates attention to proper disposal. Therefore, the current study utilized waste PETf as a reinforcement (5–15 wt%) for a polypropylene (PP) matrix using various molding approaches, in light of the higher aspect ratio of the fibers. In the first approach, the fibers were extracted from PETf through a mechanical process, and various percentages of PET felt fibers (PETff) were extruded with PP pellets, followed by injection molding. Second, PETf was directly laid on a PP sheet and processed by compression molding. The tensile strength, tensile modulus, and morphological and spectral properties of the fabricated composites were evaluated. Morphological and spectral analyses explain the distribution and interaction of the fibers in the PP matrix. The 10%PETff enhanced the tensile strength and modulus of PP by 37.3% and 52.15%, respectively. Conversely, the 1.5% malic anhydride‐g‐PP (MAPP)‐PP/PETf composites showed similar tensile behavior, with values of approximately 41.53 MPa and 1.6 GPa. In addition, the tensile strength significantly increased by 35.75% with the addition of MAPP. Overall, the current study demonstrates a well‐structured research design that effectively employs waste PETf as reinforcement for PP composites. The mechanical strength of these composites makes them highly versatile and renders them suitable for a wide range of applications, from automotive packaging to the manufacturing of high‐performance automotive components. Highlights Utilized waste PET as reinforcement for manufacturing of PP composite. PET and PP interacted in a self‐reinforcing manner. Injection and compression molding techniques used for PET/PP composites. Repurposing waste PET by compression molding is eco‐friendly practices. PET fibers significantly improved mechanical properties of PP composites. Schematic representation of fabrication and tensile results of polypropylene (PP)/polyethylene terephthalate (PET) composites as well as their probable application in automotive sector.