Oxidation Process and Morphological Degradation of Drilling Chips from Carbon Fiber-Reinforced Polymers

Carbon fiber (CF) and carbon fiber-reinforced polymers (CFRPs) are widely used in the aerospace, automotive, and energy sectors due to their high strength, stiffness, and low density. However, significant waste is generated during manufacturing and after the use of CFRPs. Traditional disposal methods like landfilling and incineration are unsustainable. CFRP machining processes, such as drilling and milling, produce fine chips and dust that are difficult to recycle due to their heterogeneity and contamination. This study investigates the oxidation behavior of CFRP drilling waste from two types of materials (tube and plate) under oxidative (non-inert) conditions. Thermogravimetric analysis (TGA) was performed from 200 °C to 800 °C to assess weight loss related to polymer degradation and carbon fiber integrity. Scanning electron microscopy (SEM) was used to analyze morphological changes and fiber damage. The optimal range for removing the polymer matrix without significant fiber degradation has been identified as 500–600 °C. At temperatures above 700 °C, notable surface and internal fiber damage occurred, along with nanostructure formation, which may pose health and environmental risks. The results show that partial fiber recovery is possible under ambient conditions, and this must be considered regarding the harmful risks to the human body if submicron particles are inhaled. This research supports sustainable CFRP recycling and fire hazard mitigation.