Co‐reinforcing sustainable graphenes from thermoset/thermoplastic wastes for enhanced polypropylene matrix composites in automotive engineering

Abstract Talc is widely used in the automotive industry as a primary reinforcement in part manufacturing. However, its relatively high density, low impact strength, and difficulty in recycling pose challenges. The present study investigates the utilization of graphene grown on talc derived from waste polypropylene (PP) and graphene nanoplatelet obtained from waste tires by recycling and upcycling processes to be used as reinforcing agents in thermoplastic processing by keeping mechanical integrity and part performance properties the same compared to the part used in serial production. The whole value chain was examined by developing compound formulation, scaling up with a high shear mixer, and injection molding of the selected exterior part of the glass front grill with its part performance tests with the real‐case thermal and structural finite element analysis. Regarding the mechanical performance analysis, the developed compound formulation having 9 wt% micron scale talc with graphene nanoparticles and hybrid additive yielded substantial enhancements of 32% and 22% in flexural and tensile strength, respectively, in the homopolymer polypropylene (HomoPP) matrix by achieving 10% weight reduction. With a systematic life cycle assessment study, CO₂ reduction was provided by 55% for the selected part by replacing virgin HomoPP with mechanically recycled waste PP originally unknown.