Development of lightweight thermoplastic composites based on polycarbonate/acrylonitrile–butadiene–styrene copolymer alloys and recycled carbon fiber: Preparation, morphology, and properties

Thermoplastic composites of polycarbonate (PC)/acrylonitrile–butadiene–styrene copolymer (ABS) alloys reinforced with recycled carbon fiber (RCF) were prepared by melt extrusion through a twin‐screw extruder. The RCF was first cleaned and activated with a concentrated solution of nitric acid and was then surface‐coated with diglycidyl ether of bisphenol A as a macromolecular coupling agent. Such an approach is effective to improve the interfacial bonding between the fibers and the PC/ABS matrix. As was expected, the reinforcing potential of the RCF was enhanced substantially, and furthermore, the mechanical properties, heat distortion temperature, and thermal stability of PC/ABS alloys were significantly improved by incorporating this surface‐treated RCF. The composites also obtained a reduction in electrical resistivity. The morphologies of impact fracture surfaces demonstrated that the RCF achieved a homogeneous dispersion in the PC/ABS matrix due to good interfacial adhesion between the fibers and the matrix. In addition, the introduction of RCF into PC/ABS alloys also resulted in an increase in the storage moduli of the composites but a decrease in the loss factors. It is prospective that, with such good performance in mechanical data, heat resistance, and electrostatic discharge, the RCF‐reinforced PC/ABS composites exhibit a potential application in industrial and civil fields as high‐performance and lightweight materials. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013