The objective of this study was to investigate the feasibility of combining discontinuous recycled carbon fibres with polypropylene, to produce a low-cost, high specific stiffness material for high-volume applications. The inherent low affinity of carbon fibre and polypropylene motivated a detailed study of the surface characteristics of carbon fibre and interfacial behaviour between the two materials, using the microbond test. The effects of removing the sizing from the fibres, as well as introducing a maleic anhydride-grafted polypropylene coupling agent, were extensively investigated. Polypropylene was found to degrade when prepared under atmospheric conditions; therefore, it was necessary to form droplets under nitrogen. Removal of the sizing from the fibre using pyrolysis and solvolysis techniques altered the surface morphology of the fibre and increased the interfacial shear strength (IFSS) by 4 and 33 %, respectively. A more significant improvement in the fibre-matrix adhesion was achieved by adding a maleic anhydride coupling agent at 2 wt%, which increased the IFSS by 320 %.

A processing route is presented to manufacture discontinuous carbon fibre reinforced polypropylene (CF.PP) composites, using much longer fibre lengths (25mm) and higher volume fractions (up to 45%) than previously reported in the literature. Carbon fibre tows are coated with different ratios of polypropylene, blended with a maleic anhydride coupling agent, to investigate the influence of the interfacial shear strength at the microscale on the macroscale composite properties. Improvements in the tensile performance at the macroscale (70% increase) are not as high as those reported for the interfacial shear strength at the microscale (300%), following the addition of the coupling agent.Consequently, the tensile strength of the CF.PP material is only 45% of values reported for carbon fibre/epoxy systems, however, the tensile stiffness is comparable. This demonstrates the potential for using CF.PP for structural applications, following further process optimisation to overcome the current high levels of porosity (3.3% at 0.45Vf) to improve the tensile strength.