Comprehensive characterisation of S2-glass/PAEK composites manufactured via aqueous powder impregnation

This study experimentally investigates the manufacture of high-performance S2-glass fibre/Polyarylether ketone (PAEK) thermoplastic prepreg materials using an in-house aqueous wet powder impregnation method, with a focus on physical and mechanical testing to evaluate the production efficiency and material quality. The thermoplastic composite laminates produced exhibit remarkable mechanical and physical properties, with a high fibre volume content of up to 72 % and minimal void content. Processing pressure and time are shown to significantly influence the composite quality, with an optimal combination of 10.5 bar pressure and 20 min pressing time effectively eliminating most air voids. Mechanical evaluations, including interlaminar shear strength and flexural strength, provide insights into the distinctive performance characteristics of different laminate configurations. Additionally, certain composite laminates demonstrate impressive mechanical stability at elevated temperatures, with only a 15.9 % reduction in tensile strength, from 1760 MPa at room temperature to 1480 MPa at 250 °C, highlighting the potential of this material across a range of applications. • High-performance S2-glass/PAEK prepregs made via wet powder impregnation. • Laminates achieved up to 72 % fibre volume with voids as low as 0.19 %. • Optimal consolidation at 10.5 bar pressure and 20 min pressing time. • Tensile strength retained 84.1 % at 250 °C, showing excellent thermal stability. • Mechanical properties align closely with predicted values across configurations.