Production and characteristics study of polycarbonate/Kevlar fiber/boron carbide hybrid composite

Abstract

Polymer-based fiber-reinforced composites are widely used for lightweight automotive structural components due to their distinct functional properties compared to monolithic polymeric matrices. However, conventionally synthesized composites exhibit low fracture toughness and moderate thermal stability due to poor load transfer, limited energy dissipation at higher impact loads, and the susceptibility of natural fibers to degradation at elevated temperatures. The main objectives of the present research are to enrich the thermo-mechanical characteristics of polycarbonate (PC) based poly matrix composite embedded with short Kevlar fiber and 2–6 wt% of boron carbide nanoparticle (B ₄ C) via the injection mould technique. During the production, the hybrid nanocomposite contained 10 wt% Kevlar fiber/4 wt% of B ₄ C is facilitated a higher tensile stress of 108 MPa, improved fracture toughness of 4.2 MPa m ^0.5 , high hardness of 94 HRR, reduced thermal expansion of 42 × 10 ⁻⁶ per °C, significant enhancement in thermal stability, and provide better heat deflection behaviour, which is superior to monolithic PC poly matrix without Kevlar fiber and B ₄ C nanoparticles. An optimal combination of Kevlar fiber and B ₄ C nanoparticles in the PC matrix is a trade-off for lightweight automotive cabinet and seat frame applications.