Fatigue resistance of carbon fiber/polyphenylene sulfide composites engineered for automotive use

Abstract This study comprehensively investigates a carbon fiber‐reinforced polyphenylene sulfide (CF/PPS) composite through tensile, fatigue, interlaminar shear strength (ILSS), dynamic mechanical tests (DMA), and also fractographic analysis. Prepared via hot compression molding, the CF/PPS composites exhibit a consistent quality. Tensile tests show an elastic modulus of 37.2 ± 0.2 GPa and an average tensile strength of 800 ± 73 MPa. Fatigue tests demonstrate infinite life at 1 million cycles, achieved at 80% of the maximum stress level. Fractographic analyses unveil directly attributable fiber failures (DAFFs), affirming a robust fiber/matrix interface. DMA shows a glass transition temperature of 86°C, showcasing the composite's structural integrity across varied temperatures. With an ILSS of 68.8 ± 3.5 MPa, the composite displays excellent fiber‐matrix adhesion. The results highlight the suitability of the CF/PPS composite for high‐strength and lightweight applications in the automotive sector, offering valuable insights for material selection, design, and production processes. Thus, contributing to the production of durable and efficient automotive components among the challenges of modern and safe transportation. Highlights Comprehensive study on CF/PPS composites. Varied mechanical assessments: tensile, fatigue, ILSS, DMA. Uniform preparation via hot compression molding. Detailed fractography reveals a strong fiber/matrix interface. Suitability for high‐strength and lightweight automotive applications.