Separation and reconsolidation of thermoplastic glass fiber composites by power ultrasonics

Recycling of scrap aerospace composites generated during manufacturing process or after its end-of-use has been the current trend followed by aircraft manufacturing industries. These recycled composites shows a reduced mechanical performance as it was already used and further degraded by the recycling processes. Hence, a circular-material strategy is crucial, to recirculate these scrap composites in high-performance applications particularly where high raw material costs, raw material scarcity and energy demands are involved. This work investigates the circularity option for glass-fiber reinforced thermoplastic composite by the application of power ultrasonics. The glass-fiber layers along with the polypropylene matrix were separated in layers and then reconsolidated by power ultrasonics. This novel separation and reconsolidation approach by power ultrasonics, can retain approximately 75% of its original mechanical properties without any alteration in the fiber-bundle arrangement. Microscopic investigations at the reconsolidated interfaces provided a direct correlation with the mechanical performance and selected ultrasonic reconsolidation parameters. •Circularity approach instead of recycling for end-of-use aerospace scrap composites by power ultrasonics.•Ultrasonic pre-cracking and reconsolidation cycle preserves the physical aspects of the composite laminate.•Retention up to 75% of the original mechanical performance.•Transferring this novel approach to EoU or scrap FRPs to reduce raw material cost and energy demands.