Carbon fiber (CF)-reinforced high-temperature thermoplastics such as poly(phenylene sulphide) (PPS) are widely used in structural composites for aerospace and automotive applications. The porosity of CF-reinforced polymers is a very important topic for practical applications since there is a direct correlation between void content and mechanical properties. In this study, inorganic fullerene-like tungsten disulphide (IF-WS₂) lubricant nanoparticles were used to manufacture PPS/IF-WS₂/CF laminates via melt-blending and hot-press processing, and the effect of IF-WS₂ loading on the quality, thermal and mechanical behaviour of the hybrid composites was investigated. The addition of IF-WS₂ improved fiber impregnation, resulting in lower degree of porosity and increased delamination resistance, compression and flexural properties; their reinforcement effect was greater at temperatures above the glass transition (Tg). IF-WS₂ contents higher than 0.5 wt % increased Tg and the heat deflection temperature while reduced the coefficient of thermal expansion. The multiscale laminates exhibited higher ignition point and notably reduced peak heat release rate compared to PPS/CF. The coexistence of micro- and nano-scale fillers resulted in synergistic effects that enhanced the stiffness, strength, thermal conductivity and flame retardancy of the matrix. The results presented herein demonstrate that the IF-WS₂ are very promising nanofillers to improve the thermomechanical properties of conventional thermoplastic/CF composites.
Keywords: IF-WS2 nanoparticles; hybrid composites; poly(phenylene sulphide); porosity thermomechanical properties; synergistic effects.