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This study aims to investigate the mechanical properties of sustainable recycled polypropylene (rPP) composite materials integrated with spherical silicon carbide (SiC) particles.

A representative volume element (RVE) analysis is employed to predict the Young’s modulus of rPP filled with spherical-shaped SiC at varying volume percentages (i.e. 10, 20 and 30%).

The investigation reveals that the highest values of Young’s modulus, tensile strength, flexural strength and mode 1 frequency are observed for the 30% rPP/SiC samples, exhibiting increases of 115, 116, 62 and 15%, respectively, compared to pure rPP. Fractography analysis confirms the ductile nature of pure rPP and the brittle behavior of the 30% rPP/SiC composite. Moreover, the RVE method predicts Young’s modulus more accurate than micromechanical models, aligning closely with experimental results. Additionally, results from ANSYS simulation tests show tensile strength, flexural strength and frequency within a 10% error range when compared to experimental data.

This study contributes to the field by demonstrating the mechanical enhancements achievable through the incorporation of sustainable materials like rPP/SiC, thereby promoting environmentally friendly engineering solutions.