Recycling carbon-fibre-reinforced plastic (CFRP) and recovering high-cost carbon fibre (CF) is a preoccupation of scientific and industrial committees due to the environmental and economic concerns. A commercialised nonwoven mat, made of recycled carbon fibre and manufactured using carding and needle-punching technology, can promote second-life opportunities for carbon fibre. This paper aims to evaluate the mechanical and preforming behaviour of this nonwoven material. We focus on the influence that the fibre orientation distribution in the nonwoven material has on its mechanical and preforming behaviour at the preform scale, as well as the tensile properties at composite scale. The anisotropy index induced by fibre orientation is evaluated by analysing SEM micrographs using the fast Fourier transform (FFT) method. Then, the anisotropy in the tensile, bending, and preforming behaviour of the preform is inspected, as well as in the tensile behaviour of the composite. Additionally, we evaluate the impact of the stacking order of multi-layers of the nonwoven material, associated with its preferred fibre orientation (nonwoven anisotropy), on its compaction behaviour. The nonwoven anisotropy, in terms of fibre orientation, induces a strong effect on the preform mechanical and preforming behaviour, as well as the tensile behaviour of the composite. The tensile behaviour of the nonwoven material is governed by the inter-fibre cohesion, which depends on the fibre orientation. The low inter-fibre cohesion, which characterises this nonwoven material, leads to poor resistance to tearing. This type of defect rapidly occurs during preforming, even at too-low membrane tension. Otherwise, the increase in nonwoven layer numbers leads to a decrease in the impact of the nonwoven anisotropy behaviour under compaction load.
Modelling the permeability of random discontinuous carbon fibre preforms