Date of Award

6-2025

Degree Name

MS in Mechanical Engineering

Department/Program

Mechanical Engineering

College

College of Engineering

Advisor

Eltahry Elghandour

Advisor Department

Mechanical Engineering

Advisor College

College of Engineering

Abstract

Carbon fiber reinforced polymer (CFRP) is an engineering material renowned for its high-strength and low-density material properties. Such properties make CFRPs especially useful for applications across many industries, including aerospace, automotive, marine, sporting goods, oil and gas, and more. However, with such favorable material properties comes the cost of high energy usage required to produce raw carbon fiber. Recycled carbon fiber (rCF) has emerged as a promising alternative, offering a significant reduction in energy usage. This research explores the viability of applying recycled CFRPs to internal combustion engines to both reduce energy costs during manufacturing and while in use. Mechanical properties of two CFRP materials were characterized through tension and compression testing. Composite connecting rod samples were fabricated utilizing autoclave curing and precision CNC machining, then tested in representative load cases simulating engine operation. Finite Element Analysis (FEA) models were developed in Abaqus to simulate and predict the mechanical behavior of the connecting rods and validated against experimental results. Results of this study showed that CFRPs exhibit mechanical performance similar to aluminum. While woven prepreg CFRPs achieved the highest performance, rCF demonstrated sufficient structural qualities to be considered a viable, sustainable engineering material. This work highlights the potential of recycled composites to reduce manufacturing emissions and support sustainable engineering practices with composite materials.

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