Investigation of impact resistance performance of carbon fiber reinforced polypropylene composites with different lamination to applicate fender parts

Thermoplastic composites are rapidly emerging as alternative materials for auto parts owing to recyclability as well as excellent stiffness- and strength-to weight ratios. In this study, an optimal stacking sequence using twill-weave carbon fiber-reinforced polypropylene (CF/PP) prepregs and random fiber-reinforced polypropylene (RFP) sheets were investigated for the fabrication of an automobile fender. The lamination consisting of CF/PP only incurred imperfect resin impregnation. RFP insertion between CF/PP layers improved the resin impregnation. The hybrid stacking sequence not only reduced internal void contents but also increased the flexural and impact strength of the composite laminate. Using the optimal stacking sequence, a real-scale composite fender was fabricated and impact tests were performed. The test results were compared with the ones from an existing steel fender. In case of the steel fender, permanent deformation was observed even in one attempt, while no visible damage was found from the composite fender even after five consecutive impact tests.