Toward the production of bioblends for the automotive sector: Reuse of recycled polyamide 6,6 to prepare super‐tough biopolyethylene

Abstract Plastics reuse is essential for promoting a sustainable future, especially by mitigating environmental impacts. Recycled polyamide 66 (PA66r) was reused for the produce biopolyethylene (BioPE)‐based blends, aiming to obtain a super‐tough material. Initially, a premix of PA66r with maleic anhydride‐grafted ethylene–propylene–diene (EPDM‐MA) was obtained in an internal mixer. Subsequently, the BioPE/PA66r and BioPE/(PA66r/EPDM‐MA) blends were processed in a twin‐screw extruder and injection molded. The rheological, mechanical, thermal, thermomechanical, structural, and morphological properties were investigated. Torque rheometry indicated an increase in the viscosity of the BioPE/(PA66r/EPDM‐MA) blends compared to BioPE/PA66r, which was confirmed by a reduction in the melt flow index (MFI). EPDM‐MA promoted greater stability in BioPE/(PA66r/EPDM‐MA) blends during processing, reducing the degradation rate and molecular weight loss. The BioPE/(PA66r/EPDM‐MA) blend with the 70/(15/15)% composition exhibited super‐tough behavior, with 822.4 J/m impact strength and 233% elongation at break. Scanning electron microscopy indicated a fracture with high plastic deformation, elongated fibrils, and refined particles (0.64 μm), confirming the high toughness. Apparently, a core‐shell morphology was formed, which favored maintaining tensile strength, Shore D hardness, and heat deflection temperature comparable to pure BioPE. The results indicate potential for application in the automotive industry, contributing to reintroducing recycled material into the production chain.