Forming performance and environmental impact of bamboo fiber reinforced polypropylene composites based on injection molding process for automobiles

To explore the potential application of plant fiber reinforced composites for automotive component applications, this study prepared bamboo fiber (BF)/nano-talc/polypropylene (PP) composites based on the injection molding process, comprehensively evaluated the effect of reinforcement materials on the forming properties of composites, including thermal performance, mechanical properties, water absorption, etc. Furthermore, taking a certain automotive injection molded interior part as the object, a life-cycle assessment from production to the gate was conducted based on the real energy and material consumption during the composite preparation process. The results indicate that adding BF and talc powder increased the thermal stability, density, hardness, viscosity, and crystallinity of the composites while reducing the water contact angle on the surface. Surface-modified BF and PP showed good compatibility. Talc powder exhibited good dispersibility in PP, and the synergistic effect of BF and talc powder effectively enhanced the composite performance. The tensile, flexural, and impact strength of the composites were improved by 40.64%, 51.48%, and 66.51%, respectively, compared with pure PP. The modulus of the composite increased nearly 2 times compared with pure PP. Additionally, the composite demonstrated good friction and wear properties. The environmental impact of the BF composite manufacturing process was significantly higher than that of pure PP. The substantial consumption of electricity, chemicals, and water resources in the extraction and modification processes of BF were the main factors. The findings of this study contribute to achieving green, high-performance BF composite manufacturing and the expansion of its applications.