Title: Effects of Fiber Length and Coating on Recycled Ultra-High Molecular Weight Polyethylene Nonwoven Composites

Authors: John Misasi, Akash Parmar, Paige Yount

DOI:

Abstract: Ultra-high molecular weight polyethylene (UHMW) fibers are high strength, abrasion and impact resistant, and low density, yet in industries such as industrial and marine ropes, they are discarded at their end-of-life to landfill. This study explored the incorporation of mechanically recycled UHMW fibers into nonwoven reinforcements for epoxy-matrix composites as a potential end-oflife strategy. UHMW fibers were recovered from industrial waste ropes and carded into unidirectional nonwoven mats using fiber lengths of 50, 75, 100, and 125 mm to study the impacts of fiber length on processing and mechanical properties. Similarly, nonwoven mats were prepared from both uncoated and polyurethane-coated fibers to understand the impacts of coating on composite processing and properties. The nonwoven mats were fabricated into composite panels using vacuum-assisted resin transfer molding technique (VARTM). Panels were then waterjet-cut into specimens for testing tensile, impact, short beam shear, and density properties to evaluate performance. Density characterization and microCT image analysis were used to evaluate void content to understand processability and the role of voids in the composites’ mechanical performance. Average density of each composite panel was correlated with void content. Fiber length and coating had little impact on the composites’ density. The thermoplastic-nature of the reinforcements generated unique tensile properties, where all samples showed a yield before failure. It was found that yield strength increased with fiber length up to 100 mm, after which it plateaued. Composite modulus showed an increase with fiber length, while yield strain decreased with fiber length. Uncoated fibers consistently outperformed the coated samples in tensile tests, suggesting that the polyurethane coating hinders the adhesion of UHMW fibers to the epoxy matrix. Notched Izod impact showed high values of impact strength compared to literature, suggesting the nonwoven UHMW reinforcements can enhance impact toughness of composites. Short beam shear testing indicated a weak correlation between both fiber length and coating condition, all showing relatively low, but typical, interlaminar shear strengths. This work shows a potential recycling pathway for high performance UHMW rope fibers and establishes basic properties for a novel nonwoven UHMW-epoxy composite. The advances described herein highlight the potential for high performance properties from recycled materials and will further advance multiple industries’ current and future material circularity goals.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 18

Pages: 14

Price: $28.00