Untapped Potential of Recycled Thermoplastic Blends in UD Composites via Finite Element Analysis

The increasing demand for fully recyclable composites has spurred extensive research on thermoplastics, valued for their recyclability and excellent mechanical properties. High-performance thermoplastics such as PEEK and PPS have been widely adopted in aerospace applications due to their outstanding load-bearing capabilities, which are well documented. Recently, thermoplastic polymer blends have gained attention for their enhanced recyclability and sustainability, as well as their ability to improve thermal stability, viscosity, and manufacturability. However, limited data are available on the mechanical characterization of composites that incorporate these blends, particularly when recycled thermoplastics are used. In this study, we first examine the stress-strain behavior of the following three polymer blends relevant for structural applications: PES/PEEK, PPS/PEEK, and HDPE/PP. We then perform a numerical analysis to predict the mechanical performance of unidirectional fiber-reinforced composites using each blend as the matrix. This involves a micromechanical Representative Volume Element (RVE) approach combined with an advanced polymer model previously validated against experimental data. The findings are discussed to critically assess the suitability of these blends for producing fully matrix-recycled composites.