Improved fracture toughness of glass fibers reinforced polypropylene composites through hybridization with polyolefin elastomers and polymeric fibers for automotive applications

Abstract Polypropylene‐reinforced composites mostly exhibit a trade‐off between stiffness and toughness. In this study, the impact of incorporating polyolefin elastomer (POE) and Polyvinyl Alcohol (PVA) fibers as individual and hybrid reinforcement to glass fiber‐reinforced polypropylene composite in the presence of a compatibilizer was explored. The main focus was on achieving an optimal stiffness/toughness balance. Several ternary and quaternary hybrid composite systems were developed and analyzed. All components were melt‐blended using a twin‐screw extruder and then injection molded for subsequent mechanical and morphological analysis. A significant stiffness of approximately 2.4 GPa Young's modulus, and notched izod impact strength ranges between 250 and 400 J/m can be attained with the quaternary hybrid system, PP/GF/POE/PVA fibers. Its performance can be controlled by altering the POE/PVA fibers ratio to achieve the targeted stiffness/toughness balance. These values represent a remarkable increase, with Young's modulus being 120% higher and the izod impact strength surpassing that of the control sample by over 800%. The achieved results aligned with the requirements of the automotive industry, so the developed composites could have a high potential for automotive parts. Highlights Ternary and quaternary hybrid systems were fabricated by a twin‐screw extruder. An improvement of 120% in stiffness and 800% in toughness was observed. Distinct micromechanical deformation mechanisms were identified. Remarkable stiffness‐toughness balance was achieved. Reduction in weight makes the system suitable for automotive applications.