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Carbon fiber reinforced ABS (Acrylonitrile Butadiene Styrene) was produced via extrusion with varying fiber content and length. Samples were prepared from neat ABS and mixtures containing 5% and 16.7% of carbon fiber with two different initial lengths (3 mm and 6 mm). In this initial study, the challenges of processing the material were investigated along with the determination of rheological and thermal properties of the final composite. For material characterization and property evaluation, Fourier-Transform Infrared Spectroscopy (FTIR), Thermogravimetric Analysis (TGA) and capillary rheology were used. Matrix degradation was observed at low processing temperatures. Results showed correlation between process additives and composite properties, mainly in thermal stability and actual fiber content. Increasing fiber content showed positive effects on thermal stability. Process additives and longer fiber lengths resulted in higher actual fiber contents. Rheological properties seemed largely unaffected mostly due to poor fiber/matrix interfaces.

Development and characterization of carbon fiber reinforced thermoplastics – part a: processing, thermal and rheological properties