Characterisation of the Mechanical Properties of Natural Fibre Polypropylene Composites Manufactured with Automated Tape Placement

The integration of natural fibre thermoplastic composites, particularly those combining flax fibres with polypropylene, offers a promising alternative to traditional synthetic composites, emphasising sustainability in composite materials. This study investigates the mechanical properties of flax/polypropylene composites manufactured using flashlamp automated tape placement and press consolidation, individually and in combination. Tensile, compression, three-point bending, and double cantilever beam tests are utilised for comparing these manufacturing processes and the mechanical performance of the resulting composites. The microstructure of the tapes is investigated using cross-sectional microscopy, and the thermophysical behaviour is analysed utilising thermogravimetric analysis and differential scanning calorimetry. The temperature during placement is monitored using an infrared camera, and the pressure is mapped with pressure-sensitive films. The natural fibre tapes show a good aptitude for being manufactured with automated tape placement. The tensile performance of tapes manufactured with automated tape placement is close to that of press consolidated samples. Compression, flexural properties, and the mode I fracture toughness critical energy release rate all benefit from a second consolidation step.