A Comprehensive Review of Ultra‐High Performance Thermoplastic Nano and Multiscale Composites for Structural, Aerospace and Nuclear Applications: Recent Developments, Current Challenges, and Future Trends

ABSTRACT Ultra‐high performance thermoplastic polymers (UHTP) are a category of materials with high thermal stability, mechanical strength, and resistance to corrosion and wear. The composites made from such polymers reflect their retention of high‐performance characteristics under extreme conditions, thus rendering their suitability for structural, aerospace, and nuclear applications. Unlike thermosetting polymer‐based composites, thermoplastic polymer‐based composites are recyclable, thus reducing the generation of waste. This paper reviews the recent developments, challenges, and future trends in the application of ultra‐high performance thermoplastic composites such as PEEK (Poly Ether Ether Ketone), PAEK (Poly Aryl Ether Ketone), PEI (Poly Ether Imide) and PEKK (Poly Ether Ketone Ketone) based composites that were fabricated by various processing techniques. There is an elucidation of the structure–property relationship of each of these composite materials, as well as their mechanical properties and the various processing techniques adopted in recent works involving these high‐performance thermoplastics. The challenges in fabrication, processing, and treatment procedures have also been highlighted. High performance thermoplastics are the future super materials that can go a long way toward revolutionizing material technology. Thus, an effort is made here to pave the way for future research and development in the field of lightweight high strength composites as a futuristic trend with the dissemination of data obtained from a review of the latest research work in the field of ultra‐high performance composites.