Study on mechanical performance of carbon fiber reinforced polyetherketoneketone prepreg and its composites prepared by slurry method

Abstract The increasing demand for high‐performance materials in aerospace, automotive, and industrial applications has driven research into carbon fiber reinforced polyetherketoneketone (CF/PEKK) composites. This study introduces a novel slurry method for preparing CF/PEKK prepregs and investigates the impact of fiber surface treatments—desized and non‐desized carbon fibers—on the mechanical properties of the resulting composites. CF/PEKK prepregs were successfully prepared by dispersing PEKK powder in deionized water to create a slurry, which was used to impregnate carbon fibers. After hot‐pressing, mechanical testing revealed that composites with desized fibers outperformed those with non‐desized fibers in tensile strength (3.29%), flexural strength (22.12%), and interlaminar shear strength (18.29%). Furthermore, desized composites exhibited improved impact toughness (24.29%) and reduced fiber pull‐out during tensile testing. Scanning electron microscopy (SEM) analysis confirmed enhanced fiber‐matrix bonding in desized composites, with fewer voids and better fiber dispersion. These findings underscore the effectiveness of the slurry method and fiber desizing in improving the mechanical performance of CF/PEKK composites, offering potential for advanced applications in high‐performance sectors. Highlights Thermoplastic CF/PEKK prepregs successfully developed using slurry method. Novel slurry method enhances prepreg quality in CF/PEKK composites. Desized carbon fibers improve interfacial bonding and strength. Desized composites exhibit reduced fiber pull‐out during tensile testing.