This work presents the development of high-performance thermoplastic polyurethane (TPU) nanocomposites reinforced with low contents of multilayer graphene (mG), aiming to improve their tribological behavior. Using twin-screw extrusion followed by hot pressing, nanocomposites containing 0.1, 0.25, 0.5, 1, and 2% mG weight were fabricated and systematically evaluated. Nanocomposites with only 0.1–0.25 wt% mG achieved a 36% reduction in friction coefficient and 87.5% reduction in wear volume compared to neat TPU. Results are rarely reported at such low filler loadings. Scanning electron microscopy (SEM) analysis revealed uniform dispersion at these optimal concentrations, while higher mG contents led to agglomeration and performance loss. Rheological studies indicated improved flow behavior, and dynamic-mechanical analysis confirmed increased energy dissipation and thermal response. These results suggest that the concentrations of 0.1% and 0.25% of multilayer graphene used in the study are promising for improving the performance of TPU nanocomposites in applications requiring high wear resistance for advanced applications in automotive, biomedical, and high-load engineering components, where durability and low friction are essential.

To reduce fuel consumption and extend flight time, the aerospace industry has focused on lightweight design. Achieving this without compromising structural integrity has been challenging. However, innovative additive manufacturing offers new opportunities for practical solutions. This study presents two methods: multi-material additive manufacturing (MMAM) and variable infill density additive manufacturing (VIDAM), aimed at reducing structural weight while maintaining mechanical performance. These methods were applied to a wing spar, a test geometry based on stress distribution principles from laminated beam mechanics. The structures produced with these new approaches showed improved mechanical responses compared to those made with traditional additive manufacturing techniques. A maximum increase of 91% in load-carrying capacity and a 34.8% increase in specific energy absorption were observed. scanning electron microscopy analysis revealed that layer bonding and material diffusion greatly influenced the mechanical performance. Although the study was conducted on small-scale models, the design concepts can be adapted to large-scale industrial applications that benefit from lightweight structures, such as the aerospace and automotive.

The study investigates the use of repurposed milled carbon fibre (mCF) as reinforcement for polyamide 66 (PA66) in gear applications, addressing environmental and cost concerns of virgin carbon fibres. Neat PA66 and PA66 composites reinforced with mCF, glass fibres (GF), and carbon fibres (CF), with and without polytetrafluoroethylene (PTFE), were injection moulded and evaluated for microstructure (fibre length), thermal, mechanical, surface, and tribological properties, as well as gear performance under VDI 2736 guidelines. CF reinforced composites showed the highest modulus and tensile strength, followed by mCF and GF. PTFE reduced modulus and strength in binary composites. All reinforced composites significantly lowered the coefficient of friction (COF) and wear rate compared to neat PA66, with mCF showing the most notable improvements. PTFE slightly improved tribological performance only for GF (wear) and CF (COF) composites. In gear testing, binary composites outperformed neat PA66, with CF performing best, followed by mCF and GF. Ternary composites had slightly lower performance than their binary equivalents. Correlation analysis showed that gear performance is closely linked to structural integrity. Failure analysis revealed higher crack susceptibility in mCF reinforced gears due to shorter fibre length. The findings highlight mCF reinforced PA66 as a sustainable, cost-effective material for durable polymer gears.

As polyvinyl chloride (PVC) films are hard and brittle in a low-temperature environment, aliphatic dibasic acid ester plasticizers with different acid chain lengths were fabricated, i.e. di(2-ethylhexyl) adipate (DOA), di(2-ethylhexyl) sebacate (DOS) and dioctyl dodecanedioate (DOD), and their effects on the cold-resistant properties of PVC were investigated using experiments and molecular dynamics (MD) simulations. The brittleness temperature and tensile properties of plasticizers/PVC are negatively related to the acid chain length of the aliphatic dibasic acid esters. The brittleness temperatures of the three systems are all below –50 °C. In-situ low-temperature tensile tests and aging tests indicate that DOA/PVC exhibits the best cold resistance and stability. MD simulations further reveal that the best compatibility between DOA and PVC is attributed to its strong binding energy and weak hydrogen bonding interactions, while van der Waals forces are dominant in DOS/PVC and DOD/PVC. This study elucidates the structure-property relationship between aliphatic dibasic acid ester plasticizers and PVC from the perspective of molecular interactions, and provides insights into the design of cold-resistant PVC plasticizers.

Crude oil, a natural hydrocarbon mixture, is a key energy source and the petrochemical industry’s primary feedstock. Its large-scale processing produces heavy oil fly ash (HOFA), a solid waste that demands effective management. This study explores HOFA’s valorization as a low-cost, carbon-based filler in isotactic polypropylene (iPP) composites. Composites containing 1–20 wt% HOFA were prepared by extrusion and injection molding, then subjected to tensile, impact, and structural analyses (differential scanning calorimetry (DSC), wide angle X-ray scattering (WAXS), microscopy). Mechanical testing revealed that even small HOFA additions raised Young’s modulus proportionately to filler content, consistent with typical filled-polymer behavior. Impact strength increased by roughly 25% at both 1 and 20 wt% loadings, while tensile strength and elongation at break remained comparable to neat iPP. DSC and WAXS demonstrated that HOFA acts as a nucleating agent, promoting the β-crystalline phase, known to enhance toughness, without significantly altering the melting or crystallization temperatures.
These findings confirm that HOFA, a waste by-product, can be an effective filler for iPP, improving stiffness and impact resistance without compromising other key properties. Its use offers both economic advantages, through reduced material costs, and environmental benefits by diverting industrial waste from disposal. This approach holds promise for developing sustainable, high-performance polymer composites.