Mechanical, Thermal, and Flammability Properties of Eco-Friendly Nanocomposites from Recycled PET/PA-11 Blends Reinforced with Graphene Nanoplatelets

This study investigates the development of sustainable nanocomposites using recycled polyethylene terephthalate (RPET) and polyamide 11 (PA-11) blends reinforced with graphene nanoplatelets (GNPs). RPET/PA-11 blends were compatibilized with 2 phr Joncryl® and processed using melt blending followed by injection moulding. The effects of varying GNP contents (1–4 phr) on mechanical, thermal, and flame-retardant properties were analysed. The nanocomposite with 1 phr GNPs exhibited an optimal balance of mechanical, flame-retardant, and thermal properties, along with improved dispersion compared to higher GNP loadings. Higher GNP concentrations led to increased stiffness but also promoted agglomeration, which negatively impacted tensile and impact strength. Thermal analysis revealed that GNPs influenced the cold crystallization behaviour of RPET, while the TGA results indicated a moderate enhancement in thermal stability. The maximum degradation temperature (Tmax) increased from 410.38 °C to 430.06 °C with 1 phr GNPs but declined at higher loadings. Similarly, flammability tests showed an improvement in the limiting oxygen index (LOI) from 19 to 24. Morphological analysis confirmed that GNPs facilitated PA-11 dispersion within the RPET matrix, particularly at lower GNP concentrations (1 phr). These findings highlight the potential of RPET/PA-11/GNP nanocomposites for multifunctional applications, providing an optimal balance between mechanical performance, thermal stability, and flame resistance. This research highlights the synergistic effect of GNPs in achieving sustainable, high-performance materials, addressing the challenges of plastic waste management and the need for eco-friendly engineering solutions for industries such as automotive, packaging, and construction.