Critical factors on manufacturing processes of natural fibre composites

Elevated environmental awareness of the general public in reducing carbon footprints and the use non-naturally decomposed solid wastes has resulted in an increasing use of natural materials, biodegradable and recyclable polymers and their composites for a wide range of engineering applications. The properties of natural fibre reinforced polymer composites are generally governed by the pre-treated process of fibre and the manufacturing process of the composites. These properties can be tailored for various types of applications by properly selecting suitable fibres, matrices, additives and production methods. Besides, due to the complexity of fibre structures, different mechanical performances of the composites are obtained even with the use of the same fibre types with different matrices. Some critical issues like poor wettability, poor bonding and degradation at the fibre/matrix interface (a hydrophilic and hydrophobic effect) and damage of the fibre during the manufacturing process are the main causes of the reduction of the composites’ strength. In this paper, different manufacturing processes and their suitability for natural fibre composites, based on the materials, mechanical and thermal properties of the fibres and matrices are discussed in detail.     

A review on basalt fibre and its composites

In recent years, both industrial and academic world are focussing their attention toward the development of sustainable composites, reinforced with natural fibres. In particular, among the natural fibres (i.e. animal, vegetable or mineral) that can be used as reinforcement, the basalt ones represent the most interesting for their properties. The aim of this review is to illustrate the results of research on this topical subject. In the introduction, mechanical, thermal and chemical properties of basalt fibre have been reviewed. Moreover, its main manufacturing technologies have been described. Then, the effect of using this mineral fibre as reinforcement of different matrices as polymer (both thermoplastic and thermoset), metal and concrete has been presented. Furthermore, an overview on the application of this fibre in biodegradable matrix composites and in hybrid composites has been provided. Finally, the studies on the industrial applications of basalt fibre reinforced composites have been reviewed.     

Bamboo fibre reinforced biocomposites: A review

The reduction in harmful destruction of ecosystem and to produce low cost polymeric reinforced composites, the researchers are emerging with policies of manufacturing the composites using natural fibres which are entirely biodegradable. These policies had generated safe strategies to protect our environment. The utilization of bamboo fibres as reinforcement in composite materials has increased tremendously and has undergone high-tech revolution in recent years as a response to the increasing demand for developing biodegradable, sustainable, and recyclable materials. The amalgamation of matrix and natural fibres yield composite possessing best properties of each component. Various matrices used currently are soft and flexible in comparison to natural fibres their combination leads to composite formation with high strength-to-weight ratios. The rapid advancement of the technology for making industry products contributes consumer the ease of making a suitable choice and own desirable tastes. Researchers have expanded their expertise in the product design by applying the usage of raw materials like bamboo fibre which is stronger as well as can be utilized in generating high end quality sustainable industrial products. Thereby, this article gives critical review of the most recent developments of bamboo fibre based reinforced composites and the summary of main results presented in literature, focusing on the processing methodology and ultimate properties of bamboo fibres with polymeric matrices and applications in well designed economical products.     

Development of durable cementitious composites using sisal and flax fabrics for reinforcement of masonry structures

Natural fibres are one of the most studied materials. However, the use of these fibres as reinforcements in composite materials for structural applications, especially for existing or historical masonry structures, remains a challenge. In this study, efforts were made to develop sustainable composites using cementitious matrices reinforced with untreated bi-directional fabrics of natural fibres, namely, flax and sisal fibres. The fibres were mechanically characterised by tensile tests performed on both single yarns and fabric strips. Ageing effects due to fibre mineralisation in alkaline cement paste environments may cause a reduction in the tensile strength of natural fibres. The matrices used to study fibre durability were a natural hydraulic lime-based mortar (NLM) mix with a low content of water-soluble salts and a lime-based grouting (NLG) mix containing natural pozzolans and carbonated filler. Tensile tests on impregnated single yarns subjected to wetting and drying cycles by exposure to external weathering were conducted at different ages to quantify these problems. Composite specimens were manufactured by the hand lay-up moulding technique using untreated fibre strips and an NLG matrix. The mechanical response of natural fibre reinforced cementitious (NFRC) composites was measured under tension, and the effect of the matrix thickness was also addressed. Both sisal and flax fibres showed good adhesion with the NLG matrix, making them capable of producing composites with ductile behaviour and suitable mechanical performance for strengthening applications in masonry structures.     

Flax fibre and its composites – A review

In recent years, the use of flax fibres as reinforcement in composites has gained popularity due to an increasing requirement for developing sustainable materials. Flax fibres are cost-effective and offer specific mechanical properties comparable to those of glass fibres. Composites made of flax fibres with thermoplastic, thermoset, and biodegradable matrices have exhibited good mechanical properties. This review presents a summary of recent developments of flax fibre and its composites. Firstly, the fibre structure, mechanical properties, cost, the effect of various parameters (i.e. relative humidity, various physical/chemical treatments, gauge length, fibre diameter, fibre location in a stem, oleaginous, mechanical defects such as kink bands) on tensile properties of flax fibre have been reviewed. Secondly, the effect of fibre configuration (i.e. in forms of fabric, mat, yarn, roving and monofilament), manufacturing processes, fibre volume, and fibre/matrix interface parameters on the mechanical properties of flax fibre reinforced composites have been reviewed. Next, the studies of life cycle assessment and durability investigation of flax fibre reinforced composites have been reviewed.     

Plant-based natural fibre reinforced cement composites: A review

The quest for sustainability in construction material usage has made the use of more renewable resources in the construction industry a necessity. Plant-based natural fibres are low cost renewable materials which can be found in abundant supply in many countries. This paper presents a summary of research progress on plant-based natural fibre reinforced cement-based composites. Fibre types, fibre characteristics and their effects on the properties of cement-based materials are reviewed. Factors affecting the fresh and hardened properties of cement-based composites reinforced with plant-based natural fibre are discussed. Measures to enhance the durability properties of cement-based composites containing plant-based natural fibres are appraised. Significant part of the paper is then focused on future trends such as the use of plant-based natural fibres as internal curing agents and durability enhancement materials in cement-based composites. Finally, applications and recommendations for future work are presented.     

Acoustic emission for monitoring the mechanical behaviour of natural fibre composites: A literature review

In recent years, natural fibres are increasingly used as reinforcements for the production of low-cost and lightweight polymer composites: other advantages include non-abrasive nature, high specific properties, and biodegradability. However, their limitations, including moisture absorption, poor wettability and large scattering in mechanical properties, and the not sufficient understanding of mechanisms controlling their mechanical behaviour and failure modes, still confine the use of natural fibre reinforced composites in non-structural applications. Acoustic emission (AE) proved useful for its capability of real-time monitoring over the whole material volume and high sensitivity to any process generating stress waves.This paper presents a literature review of AE applications in studies on natural fibre composites. The following fields of application are covered: (1) interface studies in single fibre composite (SFC) tests, (2) damage evolution and failure mechanisms detection and (3) crack propagation, including also current limitations of existing literature and future work.     

Manufacturing sisal–polypropylene composites with minimum fibre degradation

Natural fibres, such as sisal, flax and jute, possess good reinforcing capability when properly compounded with polymers. These fibres are relatively inexpensive, originate from renewable resources and possess favourable values of specific strength and specific modulus. Thermoplastic polymers have a shorter cycle time as well as reprocessability despite problems with high viscosities and poor fibre wetting. The renewability of natural fibres and the recyclability of thermoplastic polymers provide an attractive eco-friendly quality to the resulting natural fibre-reinforced thermoplastic composite materials. Common methods for manufacturing natural fibre-reinforced thermoplastic composites, injection moulding and extrusion, tend to degrade the fibres during processing. Development of a simple manufacturing technique for sisal fibre-reinforced polypropylene composites, that minimises fibre degradation and can be used in developing countries, is the main objective of this study. Composite sheets with a fibre length greater than 10 mm and a fibre mass fraction in the range 15% to 35% exhibited good mechanical properties.     

Defects in natural fibres: their origin, characteristics and implications for natural fibre-reinforced composites

This article reviews defects in natural fibres and how, ultimately, they affect the properties of composite materials reinforced with such fibres. Under ideal circumstances, certain natural fibre like flax and hemp can display excellent tensile mechanical properties. However, the potential of the fibre is generally not realised in natural fibre-reinforced composites. Partly, this poor performance can be explained by the presence of defects in the fibres known variously as dislocations, kinks or microcompressions. After briefly considering the chemistry and structure of plant fibres, the properties of selected natural fibres are reviewed. The origin of defects and the impact that processing has on their presence is then considered. The effect that defects have on the mechanical properties of bast fibre and their susceptibility to chemical degradation is also reviewed. Finally, the effect that dislocations have on the properties of composites reinforced with natural fibres is discussed and areas of potential further research needed are highlighted.     

Potentiality of utilising natural textile materials for engineering composites applications

This paper gives an overview of utilising natural textile materials as reinforcements for engineering composites applications. The definition and types of textile materials are addressed to provide readers a thoughtful view on the role of these materials in a structural composite system. Available material properties of natural textile and their composites are critically reviewed here. In general, these materials are categorised into fibre, yarn and fabric forms. The load bearing capacity of natural textile fibre reinforced polymer composites is governed by the quantity, alignment and dispersion properties of fibres. It has been found that the natural fibre reinforced composites are limited to use in low to medium load bearing applications. However, a limited research work has been performed to date and there is a significant gap between the high performance textile fabric and their use as reinforcement in fibre reinforced composite materials.     

Mechanical Properties of Natural Fibre Mat Reinforced Thermoplastic

The use of natural fibres instead of man made fibres, as reinforcements in thermoplastics, gives interesting alternatives for production of low cost and ecologically friendly composites. In this work different commercially available semi-finished natural fibre mat reinforced thermoplastics (NMT) composites have been studied. Mechanical properties and microstructure of different NMT composites were investigated and compared to conventional GMT (glass fibre mat reinforced thermoplastic) composites and pure polypropylene (PP). The study included also NMT composites manufacturing processing parameters as processing temperatures and pressure during compression moulding. The results showed that NMT composites have a high stiffness compared to pure polymer and the NMT with a high fibre content (50% by weight) showed even better stiffness than the GMT. The GMT composites had superior strength and impact properties compared to the NMT which might be due to the relatively low strength of the natural fibres but also to poor adhesion to the PP matrix. The NMT materials showed a large dependence on direction and are therefore believed to have more fibres oriented in one direction. The stronger direction (0°) of the NMT was in some cases as much as 45% better than the 90° direction.     

Static and fatigue characterisation of new basalt fibre reinforced composites

Basalt reinforced composites are recently developed materials. These mineral amorphous fibres are a valid alternative to carbon fibres for their lower cost, and to glass fibres for their strength. In order to use basalt reinforced composites for structural applications, it is necessary to perform a mechanical characterisation. With this aim in the present work experimental results of several static and fatigue tests are described. Two polymeric matrices are taken into account, vinylester and epoxy, to assess their influence on the evaluated parameters. In parallel to these mechanical tests, also the thermal answer of the specimens to mechanical loads is evaluated by means of thermography. This experimental technique allows defining the composite local heating during the application of mechanical loads and its behaviour in details. Final discussion on obtained results is proposed focussing the attention on basalt fibre composite behaviour, and comparing mechanical properties of BFRP with other composite materials in glass and carbon fibres.     

Potential materials for food packaging from nanoclay/natural fibres filled hybrid composites

The increasing demand for new food packaging materials which satisfy people requirements provided thrust for advancement of nano-materials science. Inherent permeability of polymeric materials to gases and vapours; and poor barrier and mechanical properties of biopolymers have boosted interest in developing new strategies to improve these properties. Research and development in polymeric materials coupled with appropriate filler, matrix-filler interaction and new formulation strategies to develop composites have potential applications in food packaging. Advancement in food packaging materials expected to grow with the advent of cheap, renewable and sustainable materials with enhanced barrier and mechanical properties. Nanoparticles have proportionally larger surface area and significant aspect ratio than their micro-scale counterparts, which promotes the development of mechanical and barrier properties. Nanocomposites are attracting considerable interest in food packaging because of these fascinating features. On the other hand, natural fibres are susceptible to microorganisms and their biodegradability is one of the most promising aspects of their incorporation in polymeric materials. Present review article explain about different categories of nanoclay and natural fibre based composite with particular regard to its applications as packaging materials and also gives an overview of the most recent advances and emerging new aspects of nanotechnology for development of hybrid composites for environmentally compatible food packaging materials.     

In State of Art: Mechanical and tribological behaviour of polymeric composites based on natural fibres

In this article, a comprehensive literature review on the mechanical and tribological behaviour of polymeric composites based on natural fibres is introduced. The effects of volume fraction, orientations, treatments and physical characteristics of different types of natural fibres on the mechanical and tribological properties of several thermoset and thermoplastic polymers are addressed. The effects of the tribological operating parameters (applied load, sliding velocity and sliding distance) on the frictional and wear performance of natural fibre polymer composites are demonstrated. The collected date and analyses revealed that volume fraction, orientations, type of treatment and physical characteristics of the natural fibres significantly influence the mechanical and tribological behaviour of composites. The most influence key in designing natural fibre/polymer composite is the interfacial adhesion of the fibre with the matrix. NaOH chemical treatment found to be the most useful treatment method to enhance the interfacial adhesion of the natural fibres with the matrix, while other techniques exhibited either no effect or deterioration on the fibre strength. Frictional characteristics of the natural fibre composites are poor and solid lubricants are recommended to reduce the friction coefficient of the materials.     

A review of bast fibres and their composites. Part 2 – Composites

Bast fibres are defined as those obtained from the outer cell layers of the stems of various plants. The fibres find use in textile applications and are increasingly being considered as reinforcements for polymer matrix composites as they are perceived to be “sustainable”. The fibres are composed primarily of cellulose which potentially has a Young’s modulus of ～140 GPa (being a value comparable with man-made aramid [Kevlar/Twaron] fibres). The plants which are currently attracting most interest are flax and hemp (in temperate climates) or jute and kenaf (in tropical climates). Part 2 of this review will consider the prediction of the properties of natural fibre reinforced composites, manufacturing techniques and composite materials characterisation using microscopy, mechanical, chemical and thermal techniques. The review will close with a brief overview of the potential applications and the environmental considerations which might expedite or constrain the adoption of these composites.     

Chemical treatments on plant-based natural fibre reinforced polymer composites: An overview

This paper provides a comprehensive overview on different surface treatments applied to natural fibres for advanced composites applications. In practice, the major drawbacks of using natural fibres are their high degree of moisture absorption and poor dimensional stability. The primary objective of surface treatments on natural fibres is to maximize the bonding strength so as the stress transferability in the composites. The overall mechanical properties of natural fibre reinforced polymer composites are highly dependent on the morphology, aspect ratio, hydrophilic tendency and dimensional stability of the fibres used. The effects of different chemical treatments on cellulosic fibres that are used as reinforcements for thermoset and thermoplastics are studied. The chemical sources for the treatments include alkali, silane, acetylation, benzoylation, acrylation and acrylonitrile grafting, maleated coupling agents, permanganate, peroxide, isocyanate, stearic acid, sodium chlorite, triazine, fatty acid derivate (oleoyl chloride) and fungal. The significance of chemically-treated natural fibres is seen through the improvement of mechanical strength and dimensional stability of resultant composites as compared with a pristine sample.     

Natural fibre composites: Comprehensive Ashby-type materials selection charts

To aid design engineers in closing the existing gap between current scientific knowledge and actual market applications of plant fibre reinforced plastics (PFRPs), this article provides comprehensive Ashby-type materials selection charts for PFRPs to facilitate product design and development. General tensile mechanical property profiles are presented for a variety of PFRPs to enable the design for (i) optimal stiffness and strength, (ii) minimal weight (i.e. optimal specific properties), (iii) minimal cost, and (iv) minimal eco-impact. A large database is used to capture the range in properties of different (i) reinforcements forms (short fibres: pellets and nonwovens; long fibres: multiaxials and unidirectionals), (ii) polymer matrices (thermoplastic and thermosetting), and (iii) manufacturing techniques (injection moulding, compression moulding, hand lay-up, vacuum infusion, resin transfer moulding and prepregging). As PFRPs are often viewed as alternatives to glass fibre composites (GFRPs), for demonstrative purposes the tensile properties of the various PFRPs are compared with similar GFRPs. Moreover, highlighting that other mechanical parameters may be critical performance indices for specific products and applications, a materials property chart for a fatigue-limited design is also produced.     

The influence of fibre microstructure on fibre breakage and mechanical properties of natural fibre reinforced polypropylene

The aim of the study was to investigate the influence of fibre morphology of different natural fibres on the composites mechanical properties and on the fibre breakage due to extrusion process. The composite materials were manufactured using LTF (long fibre thermoplastic) extrusion and compression moulding and the used fibres were sisal, banana, jute and flax, and the matrix was a polypropylene. The results showed that sisal composites had the best impact properties and the longest fibres after the extrusion. Generally, the composites flexural stiffness was increased with increased fibre content for all fibres, being highest for flax composites. The flexural strength was not affected by the addition of fibres because of the low compatibility. The addition of 2 wt.% maleated polypropylene significantly improved the composites properties. Unlike the other three fibres, flax fibres were separated into individual elementary fibres during the process due to enzymatic retting and low lignin content.     

Jute/polypropylene composites I. Effect of matrix modification

Natural fibre-reinforced polymers can exhibit very different mechanical performances and environmental aging resistances depending on their interphase properties, but most studies have been focused on fibre surface treatment. Here, investigations of the effect of maleic anhydride grafted polypropylene (MAHgPP) coupling agents on the properties of jute fibre/polypropylene (PP) composites have been considered with two kinds of matrices (PP1 and PP2). Both mechanical behaviour of random short fibre composites and micro-mechanical properties of single fibre model composites were examined. Taking into account interfacial properties, a modified rule of mixture (ROM) theory is formulated which fits well to the experimental results. The addition of 2 wt% MAHgPP to polypropylene matrices can significantly improve the adhesion strength with jute fibres and in turn the mechanical properties of composites. We found that the intrinsic tensile properties of jute fibre are proportional to the fibre’s cross-sectional area, which is associated with its perfect circle shape, suggesting the jute fibre’s special statistical tensile properties. We also characterised the hydrophilic character of natural fibres and, moreover, humidity environmental aging effects. The theoretical results are found to coincide fairly well with the experimental data and the major reason of composite tensile strength increase in humidity aging conditions can be attributed to both improved polymer–matrix and interfacial adhesion strength.     

Short natural-fibre reinforced polyethylene and natural rubber composites: Effect of silane coupling agents and fibres loading

Composites materials based on cellulose fibres (raw or chemically modified) as reinforcing elements and thermoplastic matrices were prepared and characterized, in terms of mechanical performances, thermal properties and water absorbance behaviour. Four different cellulose fibres with different average lengths were used, namely avicel, technical, alfa pulps and pine fibres. Two thermoplastic polymers, i.e. low density polyethylene and natural rubber, were employed as matrices. Cellulose fibres were incorporated into the matrices, as such or after chemical surface modification involving three silane coupling agents, namely γ-methacryloxypropyltrimethoxy (MPS), γ-mercaptoproyltrimethoxy (MRPS) and hexadecyltrimethoxy-silanes (HDS). As expected, the mechanical properties of the composites increased with increasing the average fibre length and the composite materials prepared using both matrices and cellulose fibres treated with MPS and MRPS displayed good mechanical performances. On the other hand with HDS bearing merely aliphatic chain only a modest enhancement on composite properties is observed which was imputed to the incapacity of HDS to bring about covalent bonding with matrix.