Carbon fibre-reinforced polymer (CFRP) composites represent promising lightweight materials for automotive powertrain systems, where increasing demands for weight reduction, energy efficiency, and emission reduction are driving the replacement of conventional metallic components. However, automotive powertrain environments expose CFRP materials to elevated temperatures, cyclic mechanical loading, chemical exposure, and tribological interactions, creating complex degradation conditions that significantly influence long-term durability and reliability. This review systematically analyzes CFRP composites for automotive powertrain applications, focusing on the relationship between operational requirements, material selection, reinforcement architecture, manufacturing technologies, and degradation mechanisms. High-performance thermoplastic systems such as CF/PEEK, CF/PPS, and CF/PEKK are critically compared with conventional thermoset composites. CF/PEEK systems demonstrate superior thermomechanical stability, maintaining significant mechanical performance at temperatures approaching 250 °C and tensile strengths of approximately 1400-1600 MPa, whereas CF/PPS composites provide a more economically efficient compromise between thermal resistance, chemical stability, manufacturability, and recyclability for medium-temperature applications. The review further analyzes dominant degradation mechanisms, including creep deformation, fatigue damage, delamination, fibre-matrix interface degradation, and tribological wear. CFRP degradation is shown to result from the interaction of multiple coupled mechanisms rather than from isolated material failure modes. Tribological wear rates typically range from 10-6 to 10-5 mm3/(N·m), while creep-fatigue interactions may reduce component lifetime by up to 40-60% under combined thermomechanical loading. Advanced design strategies, including fibre orientation optimization, laminate architecture tailoring, thickness gradation, and hybrid metal-composite structures, are evaluated together with major manufacturing technologies such as injection moulding, compression moulding, overmoulding, automated fibre placement, and additive manufacturing. The presented review establishes an integrated framework linking material systems, operating conditions, manufacturing processes, and durability requirements for automotive powertrain applications. The analysis demonstrates that no universal CFRP system exists for all powertrain components and that optimal material selection requires balancing thermal stability, fatigue resistance, tribological performance, manufacturability, recyclability, and economic constraints according to the specific operating conditions of each component category.
To evaluate the effects of an exercise program combined with ergonomics training on pain, functional capacity, sleep quality, and fatigue in automotive workers with low back pain. Fifty-six automotive workers with low back pain were randomly assigned to an intervention group (ergonomics training plus exercise) or a control group (ergonomics training only). Outcomes were assessed at baseline and after 12 weeks. Both groups improved significantly after treatment (p<0.05). The intervention group showed greater improvements in pain, functional capacity, and sleep quality than the control group (p<0.05), with no significant between-group difference in fatigue severity. Exercise combined with ergonomics training is more effective than ergonomics training alone for reducing pain and improving function and sleep quality in automotive workers with low back pain.
This prospective cohort study examined whether work-family balance and work engagement were associated with employer-verified turnover over a 6-month follow-up among newly hired blue-collar workers in the automotive supplier industry, within the framework of the Job Demands-Resources model. The study was conducted in an automotive supplier company in the Bandırma Organized Industrial Zone, Türkiye. A total of 334 blue-collar workers with a job tenure of 0-6 months were included. Data were collected using a sociodemographic questionnaire, a work-family balance scale, and the short form of the Utrecht Work Engagement Scale. Participants were followed for 6 months, and turnover status was verified using company records. Descriptive statistics, group comparisons, chi-square tests, Spearman correlation analyses, and parsimonious adjusted binary logistic regression were performed to examine the factors associated with turnover. The median age was 26.5 years, and 76.6% of participants were women. At the end of follow-up, 16.2% of workers had left their jobs. Workers who left had higher scores on the "negative impact of work on family life" dimension, whereas work engagement scores were higher among those who remained employed. Job choice motivation was also associated with turnover, with higher turnover observed among those who reported negative reasons for choosing the job. Work engagement was negatively correlated with work-family conflict dimensions and positively correlated with family-work harmony. In the parsimonious adjusted logistic regression model, work engagement was significantly associated with turnover status. Higher work engagement was associated with lower odds of turnover (OR = 0.948; 95% CI: 0.902-0.996), whereas the negative effect of work on family, negative job preference group, and baseline tenure were not statistically significant after adjustment. Higher work engagement was associated with lower early turnover among newly hired blue-collar workers in the automotive supplier industry. Although work-family balance dimensions were related to psychosocial functioning and showed univariate differences, they did not remain statistically significant in the adjusted parsimonious model. Workplace strategies that strengthen engagement and support work-family balance may contribute to improved workforce stability in manufacturing settings.
There is an increasing trend in the use of polymeric materials in vehicle interior compartments. While these materials offer advantages such as design flexibility, reduced weight, and improved aesthetics, a key challenge is the emission of volatile organic compounds (VOCs), particularly under elevated temperatures typical of vehicle cabin conditions. These emissions can adversely affect in‑vehicle air quality and may contribute to occupant exposure. However, limited information is available on VOC emissions from automotive interior materials, which are typically evaluated using whole‑vehicle chamber methods or component‑level bag methods. In this study, VOC emissions from a wide range of automotive interior materials-including plastics, textiles, foams, rubbers, and composites-were quantified using thermal desorption (TD) and headspace (HS) gas chromatography-mass spectrometry (GC-MS) techniques. Emission behaviour was evaluated as a function of material type, temperature (50-100 °C), and sample size. The materials investigated represent common categories of automotive interior components; however, they do not correspond to specific manufacturer formulations and are intended for comparative, material‑level emission screening. Composite and foam materials exhibited the highest total VOC (TVOC) emissions, reaching up to 3713.09 ng g⁻¹, with toluene identified as the dominant contributor across all materials. VOC emissions increased significantly with temperature, with up to a 2.7-7.3 fold between 50 and 100 °C depending on material, while sample size had a limited influence on mass‑normalized emission rates. A strong correlation (R² = 0.93) between TD and HS methods confirms their consistency for material screening applications. The findings highlight the critical role of material selection and thermal exposure in influencing VOC emissions. The results are particularly relevant for comparative evaluation of material categories during early design stages and support the use of rapid screening methods for comparative material evaluation in the context of in‑vehicle air quality.
Vehicles with automated driving systems may provide substantial benefits to individuals who travel while seated in wheelchairs. Despite the importance of posture data for developing occupant protection systems, limited research has analysed wheelchair user posture in the context of automotive safety. In this study, we obtained three-dimensional postural data of 75 people seated in their personal wheelchairs and generated individualised baseline avatars in automotive posture using HumanShape software. Generated avatars were manually adjusted to match the posture of the field scan, and anatomical landmark locations and segment orientations were analysed relative to wheelchair and participant characteristics. Observed differences in pelvis, abdomen, and knee angles compared to standard automotive posture indicate the prevalence of reclined posture among wheelchair users offset by a more forward neck angle. Significant postural differences were observed based on gender, BMI, and disability. These posture differences have implications for the design of occupant protection systems. This study examines differences in seated posture between wheelchair users and those seated in vehicle seats. By generating HumanShape avatars for 75 wheelchair users, we calculated key postural angles and observed significant differences in posture. Results have implications for design of occupant protection systems for wheelchair seating stations in vehicles.
Driven by the automotive industry's strategies for energy conservation, emission reduction, and lightweighting, magnesium alloy wheels have emerged as a key focus of research and industrialization efforts, owing to their high specific strength, excellent vibration-damping properties, and superior heat dissipation performance. This paper provides a systematic review of the performance advantages, material systems, forming processes, applications, and industrialization challenges of magnesium alloy automotive wheels. The core advantages of magnesium alloy wheels in terms of weight reduction, vibration damping, and thermal management are elaborated. The compositional characteristics, suitable processes, and performance differences between cast magnesium alloys (e.g., AZ91D, AM60B) and wrought magnesium alloys (e.g., AZ80, ZK61-Y) are outlined. The technical characteristics, microstructural and property evolution, and limitations of casting processes (gravity, high-pressure, low-pressure, and semi-solid casting), plastic forming processes (isothermal extrusion forging, backward extrusion forging, and spin forming), and hybrid processes are discussed. Combined with the case studies of magnesium alloy wheel applications in the automotive sector, this paper analyzes the core bottlenecks of magnesium alloy wheels in terms of corrosion resistance, production cost, and industrial consistency, and outlines future research directions. This paper aims to provide theoretical references and technical support for the design, manufacturing, and large-scale application of lightweight, high-performance magnesium alloy wheels.
The relationship between alcohol consumption and the incidence of myocardial infarction (MI), stroke and all-cause mortality exhibits significant regional variation. This prospective study aimed to investigate this association analyzing data from a cohort of Swedish men aged 45-50 years at baseline, evaluating subgroups over various time intervals, and compiling data on cardiovascular endpoints. The Coeur study, conducted between 1993 and 1995, included 973 middle-aged male employees out of a randomly selected sample of 1144 individuals from a Swedish automotive company. Participants were followed for 30 years using national health registers. The accumulated incidence of first-time stroke, first-time MI and all-cause mortality was calculated and adjusted for cardiovascular risk factors. Data analysis employed time-to-event methods (Kaplan-Meier's estimates and hazard ratios) and measures of association (odds ratios and correlation analysis). No statistically significant association was observed between alcohol consumption and stroke (p > 0.05). However, alcohol consumption was associated with lower odds of MI (OR = 0.57, 95% CI: 0.41-0.79) and a slight increase in survival time (HR = 0.997, 95% CI: 0.995-1.000). Alcohol consumers had a median survival advantage of 1.3 years compared to non-consumers. All beverage types showed a negative association with all-cause mortality (total alcohol: OR = 0.57; beer: OR = 0.68, 95% CI: 0.50-0.92; wine: OR = 0.55, 95% CI: 0.41-0.75). Conversely, beer consumption was linked to higher odds of MI (OR = 1.70, 95% CI: 1.05-2.75). While alcohol consumption in middle-aged men after 30 years follow-up is associated with increased survival time, beer correlates with a higher likelihood of MI.
The growing demand for sustainable materials has intensified research into natural fiber-reinforced polymer composites as alternatives to conventional fossil-based plastics. In this study, polycarbonate (PC) composites reinforced with Spartium junceum L. (SJL) fibers were developed and systematically characterized to evaluate their potential for automotive applications. Composites containing 5-20 wt % of randomly oriented short SJL fibers were prepared and analyzed in terms of thermal, mechanical, and morphological properties. Dynamic mechanical analysis revealed increased stiffness with rising fiber content, accompanied by a slight reduction in glass transition temperature. Tensile testing showed significant improvements in strength and Young's modulus, with optimal performance observed at 10-15 wt % fiber loading, attributed to improved fiber dispersion and interfacial adhesion. At higher fiber content (20 wt %), mechanical performance declined due to fiber agglomeration and reduced stress transfer efficiency. Thermal analysis indicated good compatibility between SJL fibers and the PC matrix, although a gradual decrease in thermal stability was observed with increasing fiber content. Scanning electron microscopy confirmed generally adequate fiber-matrix interaction, particularly at intermediate fiber loadings. Swelling tests demonstrated minimal water uptake, indicating preserved hydrophobicity of the composites. Overall, the results highlight the potential of SJL fibers as an effective, sustainable reinforcement for polycarbonate composites, offering improved mechanical performance while contributing to environmentally friendly material solutions for the automotive industry.
Contactless automotive tailgate activation relies on recognizing intentional lower-limb gestures near the rear bumper, yet these systems are developed and evaluated from sensor-specific recordings rather than from the underlying human movement, so quantitative, sensor-independent kinematic reference profiles for these gestures are lacking. This study establishes wearable inertial measurement unit (IMU)-derived reference profiles of two tailgate-activation gestures: a forward kick and a lateral wipe. Lower-body motion was recorded in 56 adult participants using a seven-sensor Xsens Awinda configuration under application-oriented conditions, yielding 6879 segmented movements. To the best of our knowledge, this is among the most extensive of such datasets, providing a sensor-independent, joint- and segment-level movement reference. Both gestures shared a common sagittal structure dominated by knee, ankle, and hip flexion/extension, with mean knee flexion/extension of 45.9∘ for kick and 42.3∘ for wipe movements. Wipe gestures differed through markedly larger non-sagittal components, with hip abduction/adduction of 17.2∘ versus 7.7∘ and ankle internal/external rotation of 16.6∘ versus 8.7∘, confirmed in every participant (p<0.001). Foot-segment kinematics showed the highest velocities, with a mean resultant foot velocity of approximately 1.8m/s. These profiles provide a quantitative biomechanical basis for benchmarking gesture-recognition sensor systems, informing detection-window and threshold selection, and enabling standardized, repeatable testing of contactless automotive HMI systems.
The intercooler is a critical heat-exchange component in an automobile's turbocharging system, essential for maintaining engine efficiency and maximizing power output. However, its performance is often compromised during the spring-to-summer season by widespread poplar catkins (PCs). In this study, the effects of physical blockage and chemical corrosion induced by poplar catkin pollution on the intercooler's performance were investigated, employing an integrated approach that combined field sampling, experimental simulation, and multi-technique characterization. The results demonstrate that poplar catkins are readily trapped by the intercooler and accumulate on the windward side, resulting in a significant increase in pressure drop. After 100 min of operation in an environment with a poplar catkin concentration of 800 μg/m3, the pressure drop rose from 83 to 268 Pa. Additionally, the hydrolysis products of poplar catkins contain corrosive substances such as acetic acid. Corrosion experiments reveal that localized perforations were observed on the fin surfaces after 3 days of exposure to acetic acid environment, and the number and area of the perforations increasing over time. Among the evaluated mitigation strategies, 20 Pores Per Inch (PPI) filter cotton exhibits the best comprehensive performance for the interception. This filter cotton exhibits a filtration efficiency of 96.9% for poplar catkins and effectively mitigates the increase in pressure drop caused by them.
Accurate junction temperature (Tj) sensing is essential for the reliability of silicon carbide (SiC) power modules in electric vehicles. Nonetheless, the physical separation and consequent thermal signal delay between sensing elements and chips pose significant challenges to precise junction temperature monitoring. To solve this issue, an embedded temperature sensing structure integrated into the designed double-sided cooling (DSC) SiC power module is proposed, which leverages 3D vertical interconnects to enhance temperature observability. The customized design of a copper spacer serves as the primary heat dissipation path and electrical connection between the upper and lower chips in the same location. A compact thermal resistance network and 3D finite-element simulations are developed to reveal the vertical thermal coupling between the spacers and the chips, enabling accurate junction temperature estimation from spacer temperature. The proposed concept is experimentally validated on a fabricated prototype using embedded K-type thermocouples and an IR camera under power cycling conditions. The measured temperature differences between the copper spacers and the junction temperature are maintained within approximately 0.5-2 °C under the tested operating range. This approach provides a potential application in real-time condition monitoring and thermal management in high-power-density electric drives.
Tax reforms in emerging economies are increasingly being conceptualized as a tool of behavioral governance as opposed to being a tool of fiscal restructuring. This empirical research undertakes the behavioral implications of the GST 2.0 slab rationalization on voluntary tax compliance among Micro, Small and Medium Enterprises (MSMEs) that are engaged in the automotive market of India. Drawing on an integrated theoretical construct incorporating the Theory of Planned Behavior (TPB Theory), Tax Morale Theory (TM Theory), and the Slippery Slope Framework (SSF), the current research incorporates a mechanism-based model that outlines the extent to which cognitive appraisals, intrinsic moral motivation, and institutional trust all have an impact on compliance behavior. The survey data collected among the key stakeholders of MSMEs located in the main automotive industrial belts of Tamil Nadu, and analyzed through Partial Least Squares Structural Equation Modeling (PLS-SEM) were used as empirical evidence. Findings suggest that positive attitudes and perceived social norms are not sufficient to reflect into voluntary compliance but instead, perceived behavioral control is the most salient antecedent, and Tax Morale is a pivotal mediating construct. Furthermore, Trust in tax authorities strengthens the relationship between subjective norms and tax morale, highlighting the importance of institutional credibility in shaping voluntary compliance behavior. Overall, the findings suggest that perceived capability, intrinsic moral motivation, and institutional trust jointly influence compliance behavior under GST 2.0. The study contributes to behavioral taxation literature by integrating cognitive, moral, and institutional perspectives within a unified framework and offers practical implications for designing trust-based tax reforms in emerging economies.
Soil contamination by potentially toxic elements (PTEs) can alter the structure and functioning of ecosystems and pose risks to public health. In this context, micro.watersheds are important units of analysis, as they integrate natural and anthropogenic processes that influence the distribution of these elements in the environment. In general, environmental agencies establish soil quality guidelines valid for large territorial areas, such as states or countries.However, studies at smaller scales are still limited, especially in micro-watersheds. Our objectives were to quantify the concentrations of arsenic, cadmium, cobalt, copper, chromium, lead, nickel, and zinc in the soils of the Guamium river watershed, located in a Brazilian region with metalwork, boiler making and foundry industries, steel mills, sugarcane and ethanol plants, and the automotive sector; to compare these concentrations with the guidelines established by the Environmental Company of the State of São Paulo; and to establish quality reference values for PTEs in the micro-watershed. Arsenic and cooper presented the highest concentrations, with values equal to or greater than the prevention value established by the environmental agency. The study contributes to the understanding of the natural and anthropogenic variability of PTEs in tropical soils and provides support for environmental monitoring, risk assessment, and the definition of more representative reference values on a regional scale.
The development of low-noise, high-sensitivity magnetic sensors is essential for applications such as automotive systems, biomedical imaging, and magnetic microscopy. However, sensor performance has long been impeded by a fundamental constraint that noise and sensitivity increase concomitantly, which imposes a performance limit. Here, we show that this limit can be overcome by engineering spin-texture dynamics. While maintaining high sensitivity, the sensor noise is demonstrated to decrease inversely with enhanced spin-texture dynamics. Leveraging this mechanism, using synthetic ferrimagnets with accelerated spin-texture dynamics, low-noise and high-sensitivity anomalous-Hall sensors are constructed. With an active sensing area of 20×20  μm^{2}, the device demonstrates a field detectability of 15.7  nT/√Hz at 1 Hz, nearly an order of magnitude improvement over existing sensors based on ferromagnetic materials. Our results establish active control of spin textures as a general pathway to ultrasensitive, low-noise magnetic sensing platforms.
The widely used head injury criterion (HIC) has improved human safety and vehicle design in automotive environments. Because of its application to civilians, tests that led to HIC were conducted without helmets. Studies focusing on military environments are sparse. Behind helmet blunt trauma (BHBT)-specific head injury criteria do not exist to the best knoweldge of the authors. The objective of this study is to present a focused literature review of military studies and a novel paradigm for developing enhanced BHBT medical injury criteria (EMIC) for assessing helmet performance and advancing combat and medical readiness of the Warfighter. The widely used PubMed database was accessed to identify articles for a systematic literature review ranging from its inception to August 30, 2025. The review focused on experimental head injury articles with a focus on tests pertinent to the replication of the injury and developing injury criteria. The review identified literature involving different surrogates: The PubMed database query identified 390,032 and 102,390 articles for the key words "impact system" and "injury criteria". Using the key words "injury risk curve" and "blunt impact," the database returned 11,517 and 5,619 articles. "Blunt impact" and "injury risk curve" identified 31 articles, while "blunt impact" and "injury criteria" had 313 articles. BHBT-specific articles with biological surrogates were limited and discussed in the body of the paper. A reanalysis of post-mortem human subject surrogate (PMHS) test data was done to develop force and deflection injury risk curves. One paper in the database used a live animal model; however, brain injury and skull fracture outcomes were not presented. The literature review identified limited studies for BHBT-specific scenarios. Available PMHS test data are inadequate to develop robust region-specific injury criteria for skull fractures. A novel hybrid paradigm combining cadaveric human and animal, and live animal experimentation, and computational modeling is needed to develop human BHBT injury risk curves from which injury criteria can be specified for EMIC for Warfighter protection from skull fractures and brain injuries. The academic consortium from the present study authors is pursuing studies along these lines.
Optical flow estimation is a low-level module in computer vision, widely used in tasks such as visual odometry, autonomous driving, high dynamic range (HDR) imaging, and action recognition. Existing event-based optical flow estimation approaches suffer from scarcity of dense real-world datasets, while some unsupervised frameworks have reduced reliance on large-scale datasets by forward-backward consistency loss, they primarily exploit a 1D temporal reversal, while largely ignoring the rotational and scaling motions ubiquitous in robotics and automotive scenes. This work introduces radial consistency, a self-supervised pre-training framework that maps the event stream to log-polar coordinates and tessellates the spatial domain into K radial rings and L angular sectors, a shared encoder-decoder to predict four complementary flow fields whose cyclic sum is driven to zero, yielding a closed-loop constraint that generalizes the classical forward-backward check to 360° within a sector. Our core contribution, the radial consistency loss, is completely label-free, together with auxiliary terms, enabling self-supervised pre-training on large-scale event data. We optionally apply supervised fine-tuning on small labeled sets to adapt to specific domains, achieving competitive accuracy with fully supervised methods. Validation experiments on Multi Vehicle Stereo Event Camera (MVSEC) dataset demonstrate strong performance: our method achieves 0.67 EPE averaged across all sequences, surpassing E-RAFT (0.89 EPE) and EV-FlowNet (1.10 EPE), without any additional data. On the rotation-heavy indoor_flying3 sequence specifically, we achieve 0.93 EPE (fine-tuned) and 1.49 EPE (self-supervised only) vs. E-RAFT 1.66. We also improve upon E-RAFT in computational efficiency [55 frames per second (FPS) and 26 giga floating-point operations (GFLOPs) vs. 42 FPS and 38 GFLOPs], while requiring only minimal supervised fine-tuning.
Rising ecological concerns over synthetic fibers and petrochemical polymers have accelerated the search for sustainable alternatives in composite development. This study investigates a novel hybrid vinyl ester (VIE) composite reinforced with Borassus flabellifer and Cocos nucifera fibers at varying loadings (10-30 wt%). The composites were fabricated and systematically characterized for their mechanical, thermal, and moisture resistance properties. Results revealed that the 30 wt% hybrid composite exhibited the highest property enhancements, with tensile strength improving from 6 MPa (neat VIE) to 24 MPa, flexural strength from 238 MPa to 566 MPa, impact resistance from 6 kJ/m² to 34 kJ/m², and hardness from 9 HRB to 67 HRB. Thermogravimetric analysis demonstrated enhanced thermal stability, indicating better resistance to thermal degradation. Water absorption studies confirmed reduced moisture uptake compared to neat VIE, highlighting the improved interfacial bonding between fibers and matrix. These findings demonstrate that Borassus flabellifer and Cocos nucifera fibers effectively enhance the physico-chemical performance of VIE, making the hybrid composites suitable for diverse structural and functional applications in aerospace, automotive, marine, and sports equipment industries.
Rotational energy harvesters are often constrained by narrow operating bandwidths and sensitivity to specific rotational regimes, limiting their effectiveness under variable-speed conditions. This work presents an orientation-adaptive dual-mode piezoelectric rotational energy harvester capable of broadband energy extraction across diverse rotational and vibration environments. The proposed design combines gravity-induced magnetic excitation at low rotational speeds with centripetal-force-induced nonlinear dynamics at higher rotational speeds, enabling passive transition between operating modes without active tuning. A coupled nonlinear electromechanical model is developed to investigate the interactions among gravitational forcing, magnetic coupling, centripetal loading and piezoelectric transduction. Numerical simulations reveal the transition from gravity-dominated mono-stable behaviour to broadband nonlinear operation as rotational speed increases. Experimental validation is conducted using representative vibration profiles from aerospace, automotive, civil infrastructure and industrial environments. The results demonstrate clear orientation-dependent performance, with the downward cantilever configuration achieving a maximum average power output of 57.8 μW under aerospace elevation excitation, whilst the upward configuration exhibits improved robustness under broadband random vibrations. The proposed orientation-adaptive framework provides a compact, stator-independent solution for broadband rotational energy harvesting under realistic operating conditions.
Driven by the growing demands for lightweight, high-strength, and energy-absorbing systems in aerospace, defense, automotive, and civil infrastructure, studies on the dynamic behavior of advanced materials and structures have become increasingly crucial [...].
This study examines the concentration-dependent thermo-oxidative behavior of polypropylene/ethylene-octene rubber (PP/EOR, 80/20) composites reinforced with talc, whisker, and hybrid talc/whisker fillers (5-15 phr) for automotive interior applications. Accelerated thermal aging was conducted at 140 °C for 300 h to evaluate mechanical retention, oxidation behavior, crystallinity evolution, and residual thermal stability. Low talc loadings (≤10 phr) provided the most favorable aging response: T5 and T10 exhibited impact retention values of 165.46% and 139.37%, respectively, together with crystallinity retention values of 142.86% and 124.49%. These improvements were associated with crystallinity enhancement, limited carbonyl formation, and the barrier-related effect of platelet-like talc fillers. In contrast, high-whisker-loading and hybrid systems showed severe deterioration after aging, with W15 and TW7.5 retaining only 33.56% and 25.50% of their initial impact strength, respectively. These samples also showed pronounced early stage thermal instability, as indicated by reductions in the 5% weight-loss temperature (T 5%) from 364.57 to 289.65 °C for W15 and from 374.78 to 305.32 °C for TW7.5. FT-IR, DSC, TGA/DTG, SEM, and ANOVA results indicate that excessive filler loading, particularly in whisker-rich and hybrid systems, promotes filler-matrix interfacial defects, stress concentration, oxidation, and impact embrittlement. These findings provide a quantitative structure-property-degradation framework linking filler morphology, crystallinity evolution, oxidation behavior, thermal stability, and long-term mechanical durability of PP/EOR composites under high-temperature aging conditions.