Evaluation of the potential of three non-woven flax fiber reinforcements: Spunlaced, needlepunched and paper process mats

•The properties of three flax non-woven reinforcements were studied.•Architecture of the non-wovens depends on the manufacturing technique.•Influence of the manufacturing process on fiber tensile properties is shown to be limited.•Tensile properties of composites depend on non-wovens architecture.

This paper presents results from an experimental study of three types of non-woven preforms (needlepunched, spunlaced and mat manufactured using a paper-making process) intended as composite reinforcement. These are potentially very attractive for transport applications. First, the influence of processing on elementary fiber tensile properties is shown to be limited. Then the preforms are evaluated in polypropylene matrix composites and mechanical properties are determined. The structure of non-woven reinforcements is strongly dependent on the manufacturing route. By varying the fiber content it is shown that the most efficient reinforcement for flax fibers is the mat produced by paper processing. The new spunlaced reinforced composites are shown to have slightly lower tensile properties (15% lower strength, and 25% lower stiffness) compared to mat composites at equivalent volume fraction, but further optimization is possible for these materials. Based on the measured constituent properties micromechanics models have been used to estimate composite stiffness. A good correlation is obtained between test results and model predictions.