Carbon nanotubes‐polymer nanocomposites for controlled heating materials

Nanocomposites of modified carbon nanotubes (CNT) and either polyurethane (PU), poly(vinyl acetate) (PVAc), or silicone materials were synthetized and characterized for thermal mat application. The obtained results revealed that the polymer used as a matrix had an impact on the electrical resistance of the mats. The lowest results of 32 Ω of resistance was registered with silicone‐based mats containing 5 wt % of CNT. For the same CNT content the mats based on PVAc and PU displayed values of 55 and 60 Ω, respectively. The low resistance properties of silicone‐based materials were due principally to the good compatibility of both polymer and functionalized CNT. Because of the low resistance values, this mat was subjected to thermovision analysis revealing that the samples reached temperature of about 60 °C in 9 min and 70 °C after 27 min of 27 V of applied potential. The results showed an almost uniform temperature distribution in the samples’ surface with some high and low temperature spots, which were attributed to nonuniform distribution of CNT in the polymer matrix. In summary, all the obtained results confirm that silicone‐CNT are very promising materials that can be used as low‐voltage heating mats. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 44194.     

Effect of incorporation of carbon fiber and silicon carbide powder into silicone rubber on the ablation and mechanical properties of the silicone rubber‐based ablation material

This study examined the effects of the incorporation of carbon fiber (CF) and silicon carbide powder (SCP) into a high temperature vulcanized (HTV) silicone rubber, poly(dimethylsiloxane) (PDMS) containing vinyl groups on the ablation properties using an oxy‐acetylene torch test. The ablation test results showed that CF enhanced the hardness of the char formed on the composite surface during the oxy‐acetylene torch test and was an important factor determining the ablation properties. SCP was also beneficial in enhancing the surface char hardness of the HTV/CF composite. A new method was devised to evaluate the ablation properties more objectively by measuring the time elapsed for a rectangular‐shaped silicone rubber composite with specimens loaded with a constant weight to burn and fail off during the oxy‐acetylene torch test. The mechanical properties of the silicone rubber composites were also examined as a function of the additive content using a universal test machine (UTM). © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Fabrication and characterization of TiO2/poly(dimethyl siloxane) composite fibers with thermal and mechanical stability

The mechanical stability of titania (TiO₂) nanofibers was improved by fabricating TiO₂/poly(dimethyl siloxane) (PDMS) composite fibers using a combination of hybrid electrospinning and sol‐gel methods, followed by heat treatment at 250°C for 3 h. The compositions (90/10, 80/20, and 70/30, w/w) of the TiO₂/PDMS composite fibers were varied by adjusting the flow rate of the PDMS sol with the flow rate of TiO₂ sol fixed. There was no significant change in morphology and average diameter of the as‐spun TiO₂/PDMS fibers after heat treatment. Both the tensile strength and modulus of the TiO₂/PDMS composite fibers increased gradually with increasing PDMS content up to 30 wt %. In addition, from the photo‐degradation reaction of methylene blue, the photocatalytic activity of TiO₂/PDMS composite fibers was strongly dependent on the TiO₂ content (%) in the composite fibers. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Electrospinning polymer blend of PLA and PBAT: Electrospinnability–solubility map and effect of polymer solution parameters toward application as antibiotic‐carrier mats

Electrospinning of a biodegradable polymer blend of poly(lactic acid) (PLA) and poly(butylene adipate‐co‐terephthalate) (PBAT) is reported for the first time. Effects of several solution parameters on electrospinning are explored, including types of single and binary solvents, binary solvent mixing ratio, polymer blend concentration, polymer blending ratio, and loading content of tetrabutyl titanate as a compatibilizer. An electrospinnability–solubility map of the PLA/PBAT blend is firstly developed for the facile selection of a suitable binary solvent system, thus simplifying the laborious, time‐consuming, trial‐and‐error process. A particular binary solvent system derived from good and non‐solvent serves as the most suitable medium for the successful preparation of homogeneous bead‐free electrospun PLA/PBAT nanofibers. It is revealed that the compatibilizer acts not only as a diameter size tuner for the PLA/PBAT fibers but also as a mechanical property enhancer for the immiscible PLA/PBAT electrospun mats. Moreover, the antibacterial activity of the drug‐loaded PLA/PBAT fibrous mats suggests their potential application as antibiotic‐carrier mats. Preparation of the composite mats comprising bead‐free fibers with an average size at sub‐micrometer scale is also demonstrated, additionally promoting the possibility of using the PLA/PBAT‐based electrospun mats as a matrix of various additives for a wide range of applications. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46486.     

Effects of poly(dimethyl siloxane) on the water absorption and natural degradation of poly(lactic acid)/oil‐palm empty‐fruit‐bunch fiber biocomposites

Composites were fabricated with poly(lactic acid) and oil‐palm empty‐fruit‐bunch (EFB) fibers with extrusion; this was followed by an injection‐molding technique. Before compounding, the surface of the fiber was modified through ultrasound and poly(dimethyl siloxane) (PDMS). The influences of the ultrasound and PDMS on the water absorption and biodegradability of the composites were investigated. Additionally, the composites were buried under soil for 6 months, and their biodegradability was assessed through different characterization techniques, such as tensile testing and weight loss and diffussability measurement. The changes on the surface of the fibers due to treatment were examined by scanning electron microscopy analysis, and the influences on the biodegradability of the composites were observed. Functional group analysis and possible changes before and after degradation were also examined by a Fourier transform infrared spectrophotometric technique. The results analyses revealed that the treatment of fibers improved the density of the fibers and reduced the water uptake of the composites. The overall weight loss due to soil burial testing was found to be maximum for the untreated‐fiber‐based composites (6.8%), whereas the ultrasound‐ and silane‐treated composites showed the minimum value of weight loss (3.7%). The deterioration of the tensile strength due to degradation was found to be at a maximum for the untreated‐fiber‐based composite (27%), whereas the ultrasound‐ and silane‐treated‐fiber‐based composites showed a minimum value of 8%. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42784.     

X‐ray diffraction and dynamic mechanical analyses of α‐chitin whisker‐reinforced poly(vinyl alcohol) nanocomposite nanofibers

Electrospinning is a facile method for preparing nanocomposite materials in fiber form. Nanomaterials that have been incorporated within such fibers are usually inorganic in nature. Recently, nanocomposite nanofibers based on poly(vinyl alcohol) (PVA) as the matrix and nanocrystals of α‐chitin (i.e. chitin whiskers; ca 31 nm in width and ca 549 nm in length on average) as the nanofiller have been successfully prepared. In the study reported here, the fibers were further investigated using X‐ray diffraction (XRD) and dynamic mechanical analyses in comparison with the corresponding solvent‐cast films. The average diameters of the PVA/chitin whiskers fibers ranged between 175 and 218 nm. Careful analysis of the wide‐angle XRD patterns of the fiber mats and the films showed that PVA was partially crystalline, and the incorporation of the whiskers within the fibers was confirmed by peaks characteristic to α‐chitin crystals. Dynamic mechanical analysis showed that the fiber mats were weaker than the films and that the relaxation temperatures associated with the glass transition (T_g) of the fiber mats were greater than those of the films. The addition and increasing the amount of the whiskers caused the crystallinity of PVA within the nanocomposite materials to decrease and T_g to increase. The present study shows that the geometry of nanocomposite materials plays a major role in determining their properties. Copyright © 2009 Society of Chemical Industry     

Improvement of carbon nanotube dispersion in electrospun polyacrylonitrile fiber through plasma surface modification

In this study, surfaces of multiwalled carbon nanotubes (CNTs) were functionalized with poly(hexafluorobutyl acrylate) (PHFBA) thin film using a rotating-bed plasma-enhanced chemical vapor deposition (PECVD) method without imparting any defects on their surfaces. Polyacrylonitrile (PAN) electrospun polymer fiber mats and composite fiber mats with CNTs and functionalized CNTs (f-CNTs) were prepared. The wettability and chemical and morphological properties of the synthesized fiber mats were investigated, and the dispersion of CNTs and f-CNTs in the polymer matrix was compared according to the contact angle results of electrospun polymer mats. According to the chemical and morphological characterization results, PHFBA-coated CNTs were dispersed more uniformly in the polymer matrix than the uncoated CNTs. The f-CNTs/PAN composite fiber mat exhibits a lower surface energy than the pristine CNTs/PAN fiber mat. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47768.     

Morphologies and electrical properties of electrospun poly[(R)‐3‐hydroxybutyrate‐co‐(R)‐3‐hydroxyvalerate]/ multiwalled carbon nanotubes fibers

Electrospinning process was used to fabricate fine fibers from poly[(R)‐3‐hydroxybutyrate‐co‐(R)‐3‐hydroxyvalerate] embedded with multiwalled carbon nanotubes (MWCNTs). Rotating disc collector was used to provide additional drawing force to stretch and align both the embedded MWCNTs and electrospun fibers themselves. Morphological observation revealed MWCNTs aligned to the fiber axis and protruding from the surface. To understand the electrical properties of the fiber, a single‐composite fiber has been deposited on a substrate, across multiple electrodes. Electrical conductivity of the single‐electrospun fiber with low MWCNT content of 0.2 wt % was calculated to be in a remarkable magnitude of about 2.07 Sm^?1. Electrical current flow spanning the fiber length of 1400 μm indicates that the presence of an interconnected network of MWCNTs exists within the fiber. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Aspects of alkali treatment of sponge gourd (Luffa cylindrica) fibers on the flexural properties of polyester matrix composites

Sponge gourd (Luffa cylindrica) forms a natural mat that deviates the crack path in brittle thermoset resin matrix composites, leading to a controlled fracture mode and increasing the toughness of the composite. The use of luffa as reinforcement is, however, restricted by a very weak fiber–matrix interface. In this work, luffa fibers were alkali‐treated at two temperatures, with varying alkali concentrations. Although the surface analysis shows that the treatments promote a clear removal of the outer surface layer of the fibers with the exposition of the inner fibrillar structure and the consequent increase of the fiber surface area, only a secondary increase on the mechanical properties was obtained. The slight increase observed was attributed only to mechanical interlock. Long pullout lengths and neat fiber beads were the main features observed at the fracture surface of the treated and untreated fiber composites. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 87: 1927–1932, 2003     

Sea‐island polyurethane/polycarbonate composite nanofiber fabricated through electrospinning

Sea‐island polyurethane (PU)/polycarbonate (PC) composite nanofibers were obtained through electrospinning of partially miscible PU and PC in 3 : 7 (v/v) N,N‐dimethylformamide (DMF) and tetrahydrofuran (THF) mixture solvent. Their structures, mechanical, and thermal properties were characterized by scanning electron microscopy (SEM), transmission electron microscopy (TEM), Fourier transform infrared (FTIR) spectroscopy, thermogravimetric (TG), and differential scanning calorimetry (DSC). The structures and morphologies of the nanofibers were influenced by composition ratio in the binary mixtures. The pure PC nanofiber was brittle and easy to break. With increasing the PU content in the PU/PC composite nanofibers, PU component not only facilitated the electrospinning of PC but improved the mechanical properties of PU/PC nanofibrous mats. In a series of nanofibrous mats with varied PU/PC composition ratios, PU/PC 70/30 showed excellent tensile strength of 9.60 Mpa and Young's modulus of 55 Mpa. After selective removal of PC component in PU/PC composite nanofibers by washing with acetone, the residual PU maintained fiber morphology. However, the residual PU nanofiber became irregular and contained elongated indents and ridges along the fiber surface. PU/PC composite fibers showed sea‐island nanofiber structure due to phase separation in the spinning solution and in the course of electrospinning. At PC content below 30%, the PC domains were small and evenly dispersed in the composite nanofibers. As PC content was over 50%, the PC phases became large elongated aggregates dispersed in the composite nanofibers. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Dynamic mechanical properties of oil palm microfibril‐reinforced natural rubber composites

The dynamic mechanical properties of macro and microfibers of oil palm‐reinforced natural rubber (NR) composites were investigated as a function of fiber content, temperature, treatment, and frequency. By the incorporation of macrofiber to NR, the storage modulus (E') value increases while the damping factor (tan δ) shifts toward higher temperature region. As the fiber content increases the damping nature of the composite decreases because of the increased stiffness imparted by the natural fibers. By using the steam explosion method, the microfibrils were separated from the oil palm fibers. These fibers were subjected to treatments such as mercerization, benzoylation, and silane treatment. Resorcinol‐hexamethylenetetramine‐hydrated silica was also used as bonding agent to increase the fiber/matrix adhesion. The storage modulus value of untreated and treated microfibril‐reinforced composites was higher than that of macrofiber‐reinforced composites. The T_g value obtained for this microfibril‐reinforced composites were slightly higher than that of macrofiber‐reinforced composites. The activation energy for the relaxation processes in different composites was also calculated. The morphological studies using scanning electron microscopy of tensile fracture surfaces of treated and untreated composites indicated better fiber/matrix adhesion in the case of treated microfibril‐reinforced composites. Finally, attempts were made to correlate the experimental dynamic properties with the theoretical predictions. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Sheet‐Molded Polyolefin Natural Fiber Composites for Automotive Applications

The use of natural fibers as reinforcing filler in thermoplastics is a relatively new application and has great potential in replacing glass fiber products in automotive industry. However, most of the research in this area has been focused primarily on flax fiber. In the first part of the work presented here, hemp fiber non‐woven mats are used exclusively in combination with a poly(propylene) matrix to study the mechanical properties of natural fiber mat thermoplastics (NMT) in the absence of binder. Film stacking was used as the method of preparation. The results show that hemp‐based NMT have comparable or even higher strength properties as compared with conventional flax‐based thermoplastics. A value of 63 MPa for the flexural strength is achieved at a fiber content of 64 wt.‐%. The influence of the compression ratio on the mechanical properties and density of NMT is also reported. A definite increase in strength is observed with increasing compression together with a much more uniform density profile. In the second part of this study, a unique combination of random hemp fibers, non‐woven mats and poly(propylene) films was employed in film stacking to evaluate strength properties and economic implications. The same fiber content (64 wt.‐%) was maintained in the final NMT by replacing 78 wt.‐% of the mats by random fibers. Preliminary tests reveal better mechanical properties especially in terms of impact energy, which is 50 to 100% higher, as compared with different mats‐only/poly(propylene) combinations. Further, a net saving of 40% in fiber cost is anticipated by replacing 78% non‐woven mats with an equivalent amount of random fibers. Overall results of this study indicate that hemp‐based NMT are promising candidates in automotive applications where high specific stiffness is required.

Tensile Strength of different NMTs and GMT.     

On the electrospinning of poly(vinyl alcohol) nanofiber mats: A revisit

Electrospinning was used to fabricate mats of poly(vinyl alcohol) (PVA; M_w = 72,000 Da, degree of hydrolysis ≈ 97.5–99.5) nanofibers from PVA solutions in reverse osmotic water. The effects of solution concentration, applied electrical potential, sonication, and collection distance on morphological appearance and diameters of the as‐spun fiber mats as well as those of the individual fibers were carefully investigated mainly by scanning electron microscopy. The effect of the distance from the center of the as‐spun fiber mat on morphological appearance and diameters of the as‐spun fibers was also investigated. The mechanical integrity of some as‐spun PVA fiber mats was also investigated. At all concentrations and applied electrical potentials investigated, the average diameters of the as‐spun PVA fibers ranged between 85 and 647 nm. The use of sonication to prepare a PVA solution caused the viscosity of the solution to decrease; hence, the observed decrease in the average diameters of the as‐spun fibers and the average diameters of the as‐spun fibers were practically the same throughout the as‐spun fiber mat. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Large strain and toughness enhancement of poly(dimethyl siloxane) composite films filled with electrospun polyacrylonitrile-graft-poly(dimethyl siloxane) fibres and multi-walled carbon nanotubes

Unfilled cross-linked poly(dimethyl siloxane) (PDMS) is a weak material and is generally filled with high levels of particulate fillers such as silica, calcium carbonate and carbon black to improve its mechanical properties. The use of fibrous fillers such as electrospun nanofibres and multi-walled carbon nanotubes as fillers for PDMS has not been widely studied. In this study anew copolymer, polyacrylonitrile-graft-poly(dimethyl siloxane) (PAN-g-PDMS), is used as fibrous filler for PDMS. The graft copolymer is electrospun to produce the fibre filler material. It is shown how the PDMS content of the graft copolymer provides increased compatibility with silicone matrices and excellent dispersion of the fibre fillers throughout a silicone matrix. It is also shown that it is possible to include multi-walled carbon nanotubes in the electrospun fibres which are subsequently dispersed in the PDMS matrix. Fibre mats were used in the non-woven and the aligned forms. The differently prepared fibre composites have significantly different mechanical properties. Conventional composites using fibrous fillers usually show increased strength and stiffness but usually with a resultant loss of strain. In the case of the composites produced in this study there is a dramatic improvement in the extensibility of the non-woven PAN-g-PDMS fibre mat filled silicone films of up to 470%.     

Melt spun microporous fibers using poly(lactic acid) and sulfonated copolyester blends for tissue engineering applications

Microporous fibers can potentially increase diffusional properties of three‐dimensional nonwoven scaffolds used for tissue engineering applications. We have investigated the use of a water‐dispersible copolyester, sulfonated copolyester (SP), to create micropores in composite fibers containing a blend of SP and poly(lactic acid) (PLA) at 1, 3, 5, and 10% SP content. PLA and SP were blended at 175°C in a microcompounder followed by extrusion of composite fibers and removal of SP from composite fibers by using hydrodispersion to form micropores in the composite fibers. Differential scanning calorimetric studies on unhydrolysed composite fibers showed that SP was partially miscible in PLA. Fourier transform infrared mapping of composite fiber cross sections revealed that SP was randomly dispersed throughout the cross section where the degree of dispersion depended on the SP content. As revealed by the scanning electron micrographs, the size of the micropores was dependent on the SP content. Micropores on fiber cross sections were observed in fibers above 3% SP indicating that at least 3% SP content is needed to produce droplet morphology of SP in these fibers. These results show that SP can be successfully used in a blend with PLA to produce microporous fibers to fabricate three‐dimensional nonwoven scaffolds for tissue engineering applications. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Fabrication of unidirectional continuous fiber-reinforced mullite matrix composite with excellent mechanical property

This article reports the fabrication of continuous fiber reinforced mullite matrix composite via layer-by-layer assembly method, involving the coating of mullite fiber with BN coating, followed by compositing the coated fibers with mullite matrix and hot pressing. The influences of the fiber coating, fiber content and sintering temperature on the microstructure and mechanical properties of the composite are investigated. By optimizing the sintering temperature and fiber content, the damage of fiber could be avoided and the microstructure and mechanical properties could be improved. The composite containing 30?vol% fibers coated by BN layer sintered at 1300?°C exhibits 90.9% theoretical density with flexural strength value of 203.2?MPa and fracture toughness value of 4.74?MPa?m^1/2. Fracture behavior is investigated to explain the toughening mechanisms. The layer-by-layer assembly method realizes the achievement of an individual architecture featuring fibers distribution and weak interfaces.     

Fiber length distribution and thermal,mechanical and morphological properties of thermally conductive polycarbonate/chopped carbon fiber composites

Chopped carbon fibers (CCFs) coated by poly(ethylene terephthalate) (PET) were treated using 3‐aminopropyltriethoxysilane (Si), and then used for fabricating thermally conductive polycarbonate/CCF (PC/(Si + PET)@CCFi) composites with various filler contents. Optical microscopy measurements indicated that CCF fillers in the composites had a wide length distribution and, with CCF content increasing, the mean fiber length and mean fiber aspect ratio steadily decreased. Compared to PC/(Si + PET)@CCF0, the molten flowability of composites declined. Thermogravimetric analysis and pyrolysis–gas chromatography–mass spectrometry characterizations showed that introducing CCFs could enhance the thermal stability of the composites and restrict the pyrolytic degradation of the polymer matrix. Moreover, both in‐plane and through‐thickness thermal conductivities increased with increasing CCF content. These conductivities at 50% CCF content reached 2.45 and 0.59 W m^?1 K^?1, and were improved by 11.25 and 1.95, respectively. Furthermore, the tensile and flexural properties of the composites continuously enhanced, accompanying decreased impact strength and elongation at break. Fractography revealed that fillers dispersed in matrix uniformly and a great many fiber cross‐sections and circular cavities coexisted in fracture surface, besides a clear interface and reduced long fibers. And the fracture behavior was mainly the breaking and peeling of fibers from matrix. © 2018 Society of Chemical Industry     

Microscopic surface and bulk morphology of semicrystalline poly(dimethylsiloxane)–polyester copolymers

In this study, two series of semicrystalline poly(dimethylsiloxane) (PDMS)–polyester segmented copolymers with various PDMS contents were synthesized. One series was based on polybutylene adipate (PBA) as the polyester segment and the other was based on a polybutylene cyclohexanedicarboxylate ester (PBCH) segment. The copolymers were characterized using ¹H‐nuclear magnetic resonance, size exclusion chromatography, dynamic mechanical analyses, differential scanning calorimetry (DSC), and wide‐angle X‐ray diffraction (WAXD). The microscopic surface morphology and the microscopic bulk morphology were investigated using atomic force microscopy (AFM) and transmission electron microscopy, respectively. The effects of the polyester type and the PDMS content on the crystallinity degree as well as the copolymer surface and bulk morphology at room temperature were investigated for each series. DSC and WAXD results showed the ability of the copolymers to crystallize, to various degrees, depending on the polyester type and the PDMS content. The results showed that the PDMS content had a greater influence on the crystallinity degree in the PDMS‐s‐PBCH (cycloaliphatic) copolymer series than in the PDMS‐s‐PBA (aliphatic) copolymer series. In the copolymers with a low PDMS content, the AFM images showed spherulitic crystal morphology and evidence of PDMS nanodomains in between the crystal lamellae of the ester phase on the copolymer surface. A heterogeneous distribution of the PDMS domains was also observed for these copolymers in the bulk morphology as a result of this segregation between the polyester lamellae. All the copolymers, in both series, showed microphase separation as a result of the incompatibility between the PDMS segment and the polyester segment. Three types of surfaces and bulk morphologies were observed: spherical microdomains of PDMS in a matrix of polyester, bicontinuous double‐diamond type morphology, and spherical microdomains of polyester in a matrix of PDMS as the PDMS content increases. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Enhanced mechanical properties of PDMS/PMMA composite membrane using MWCNTs and its application in phenol separation from saline wastewater

This work describes the enhanced mechanical properties of composite polydimethylsiloxane/poly(methyl methacrylate) (PDMS/PMMA)/multi-walled carbon nanotubes (MWCNTs) nanofiber membrane and its application in the phenol separation from saline wastewater. MWNCTs with varied content were immobilized in the membrane matrix using electric field of electrospinning. The neat PDMS/PMMA and composite PDMS/PMMA/MWCNTs membranes were characterized by scanning electron microscopy, universal testing machine, contact angle measurement, 3D automatic optical profiler, and pore size analyzer. Results indicated that tensile strength of composite PDMS/PMMA/MWNCTs membrane was drastically increased six times with a water contact angle (WCA) of 163.3° due to increased roughness parameters compared to neat membrane. However, porosity and fiber diameter of PDMS/PMMA/MWCTs membrane decreased with the increase of MWCNTs content. Moreover, phenol extraction efficiency of PDMS/PMMA/MWNCTs membrane was found to be 34.5% higher than neat one with similar salt rejection efficiency of 99.97%. The stability of MWCNTs in the membrane matrix was confirmed by the cross-sectional morphology, which indicated the robust and novel design of membrane. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47123.     

Mechanical properties of injection molded long fiber polypropylene composites,Part 2: Impact and fracture toughness

This study describes the effect of fiber length and compatibilizer content on notched izod impact and fracture toughness properties. Long fiber polypropylene (LFPP) pellets of different sizes were prepared by extrusion process using a new radial impregnation die, and subsequently, pellets were injection molded as described in previous publication 1 . The content of glass fiber reinforcement was maintained same for all compositions. Maleic‐anhydride grafted polypropylene (MA‐g‐PP) was chosen as a compatibilizer to increase the adhesion between glass fiber and PP matrix and its content was maintained at 2 wt%. Notched izod impact property was studied for LFPP composites prepared with and without compatibilizer for different pellet sizes. Failure mechanism due to sudden impact was analyzed with scanning electron micrographs and was correlated with impact property of LFPP composites. Fracture and failure behavior of injection molded LFPP composite were studied and relationship between fracture toughness and microstructure of LFPP composite was analyzed. The microstructure of the composites was characterized by the dimensionless reinforcing effectiveness parameter, which accounts for the influence of fiber layer structure, fiber alignment, fiber volume fraction, fiber length distribution, and aspect ratio. Matrix stress condition factor and energy absorption ratio were determined for LFPP composites prepared with and without compatibilizer. Failure mechanism of both the matrix and fiber, revealed with SEM images, were discussed. POLYM. COMPOS., 2008. © 2008 Society of Plastics Engineers