Effect of coupling agent on natural fibre in natural fibre/polypropylene composites on mechanical and thermal behaviour

To enhance the adhesion between the natural fibre and the thermoplastic matrix, a coupling agent of maleic anhydride grafted polypropylene MAPP is applied. In literature, there are different guidelines of the optimum percentage required of MAPP. Therefore, a systematic work is carried out to optimise the MAPP percent with respect to the type of the natural fibre. Different parameters are investigated namely; Coupling agent ratio to the fibre (0%, 6.67%, 10%, 13.3%, 16.67%), coupling agent source, fibre type (flax, hemp, sisal), and fibre content (30%, 50%). Composite is produced using a kneader and the resulting material is assessed mechanically, thermally, microscopically and for water absorption. For different MAPP source and the natural fibre type, optimum MAPP to fibre ratio is found in average to range between 10% and 13.3% according to the investigated property (stiffness, strength and impact). Increase of MAPP is found to decrease the melting temperature. The thermal behaviour is also linked to the copolymer molecular weight.     

Fibre/matrix adhesion of cellulose fibres in PLA,PP and MAPP: A critical review of pull-out test,microbond test and single fibre fragmentation test results

The present work deals with the practical fibre/matrix adhesion of regenerated cellulose fibres (lyocell) and bast fibre bundles (flax, kenaf) in different matrices (polylactide-PLA, polypropylene-PP, maleic-anhydride-grafted polypropylene-MAPP). The influence of different testing procedures (pull-out test, microbond test, fragmentation test) on the fibre/matrix characteristics is discussed. The results of the different tests showed the same trends, but the absolute values differ. Clearly higher interfacial shear strength (IFSS) for cellulose fibres was found in PLA and MAPP in comparison to PP due to higher polarity. In addition, bast fibres displayed higher apparent IFSS values compared to lyocell because of their rougher surface and their chemical composition. The apparent IFSS of the pull-out test resulted in higher values compared to results obtained from the fragmentation test. This phenomenon is explained by different stress distributions due to variable specimen geometry, different behaviour of failure and the friction which occurs between fibre and matrix during fibre pull-out in the pull-out test.     

PHBV nanocomposites based on organomodified montmorillonite and halloysite: The effect of clay type on the morphology and thermal and mechanical properties

The aim of this study was to evaluate the effect of the addition of two types of nanoparticles, organomodified montmorillonite Cloisite® 30B (C-30B), and a tubular like clay, halloysite (HNT), on the morphology and thermal and mechanical properties of poly(hydroxybutyrate-co-hydroxyvalerate) – PHBV nanocomposites. TEM and WAXD results showed a combination of a few tactoids and a partially exfoliated structure for PHBV/C-30B nanocomposites and a good dispersion of HNT in the PHBV matrix. DSC analysis indicated a lower nucleation density with the addition of nanoparticles. Furthermore, the presence of C-30B led to the formation of double melting peaks, related to different crystalline phases. However, a higher melting temperature was obtained for PHBV/HNT nanocomposites. A general increase in the Young’s modulus was observed. However, for PHBV/C-30B nanocomposites, this enhancement was at the expense of the strain at break and impact strength, probably due to the degradation of the polymer during processing.     

Influence of refiner fibre quality and fibre modification treatments on properties of injection-moulded beech wood–plastic composites

Thermo-mechanical pulp (TMP) fibres made from beech wood were produced using increasing refiner gap widths and thus with increasing fibre length and coarseness. Fibres (60% by weight) were compounded in an internal kneading mixer using high-density polyethylene as the matrix and injection-moulded. Fibre lengths and length/width ratios were determined (a) before processing and (b) after injection-moulding and Soxhlet extraction using the optical FibreShape system. An increase in fibre length resulted in a decrease in water absorption and an improvement in flexural strength and modulus of elasticity of the wood–plastic composites (WPC). However, flexural strength of the WPC with TMP fibres was not improved compared to WPC with wood flour when maleic anhydride-grafted polyethylene (MAPE) was used as a coupling agent. After injection-moulding, differences in length of the various TMP fibre types were minor. Fibre geometry before processing strongly influences the water absorption and flexural properties of the composite. Fibre treatment with emulsified methylene diphenyl diisocyanate (EMDI) resin before compounding was shown to be equally efficient in reducing water absorption and improving flexural strength as the addition of MAPE during the compounding step.     

The effect of reprocessing on the mechanical properties of polypropylene reinforced with wood pulp,flax or glass fibre

Composites of polypropylene, substitutable for a given application and reinforced with: Medium Density Fibreboard fibre (MDF) (40 wt%); flax (30 wt%); and glass fibre (20 wt%), were evaluated after 6 injection moulding and extrusion reprocessing cycles. Of the range of tensile, flexural and impact properties examined, MDF composites showed the best mean property retention after reprocessing (87%) compared to flax (72%) and glass (59%). After 1 reprocessing cycle the glass composite had higher tensile strength (56.2 MPa) compared to the MDF composite (44.4) but after 6 cycles the MDF was stronger (35.0 compared to 29.6 MPa for the glass composite). Property reductions were attributed to reduced fibre length. MDF fibres showed the lowest reduction in fibre length between 1 and 6 cycles (39%), compared to glass (51%) and flax (62%). Flax fibres showed greater increases in damage (cell wall dislocations) with reprocessing than was shown by MDF fibres.     

Factorial study of material and process parameters on the mechanical properties of extruded kenaf fibre/polypropylene composite sheets

Thin kenaf/polypropylene (PP) composite sheets were manufactured via extrusion. The effects of kenaf and maleated PP (MAPP) proportions, fibre length, PP melt flow index (MFI) and die temperature on tensile, flexural, in-plane and out-of-plane shear properties were analysed by conducting experiments through ‘design of experiments’ methodology. Higher kenaf content and lower die/barrel temperatures resulted in composite sheets with higher average mechanical properties in various modes of testing. Matrix MFI appeared to significantly affect all mechanical properties. It is interesting to note that the properties of the very short-fibre composites produced are comparable to those reinforced with longer discontinuous fibres and long-fibre mats.     

Micromechanical deformations in PP/lignocellulosic filler composites: Effect of matrix properties

Polypropylene composites were prepared from three different PP matrices, a homopolymer, a random and a heterophase copolymer, and corn cob to study the effect of matrix characteristics on deformation and failure. The components were homogenized in an internal mixer and compression molded to 1 mm thick plates. Mechanical properties were characterized by tensile testing, while micromechanical deformations by acoustic emission measurements and fractography. The results proved that the dominating micromechanical deformation process may change with matrix properties. Yield stress determined from the stress vs. strain traces may cover widely differing processes. Debonding is the dominating process when the adhesion of the components is poor, while matrix yielding and/or filler fracture dominate when adhesion is improved by the introduction of a functionalized polymer. The dominating deformation mechanism is determined by component properties and adhesion. Interfacial adhesion, matrix yield stress and the inherent strength of the reinforcement can be limiting factors in the improvement of composite strength. The properties of polymer composites reinforced with lignocellulosic fillers are determined by micromechanical deformation processes, but they are independent of the mechanism of these processes.     

Mechanical performance optimization through interface strength gradation in PP/glass fibre reinforced composites

A new design for thermoplastic composites based on the gradation of the interlaminar interface strength (IGIS) has been developed with the aim of coupling high impact resistance with high static properties. IGIS laminates have been prepared by properly alternating layers of woven fabric with layers of compatibilized or not compatibilized polymeric films. To prove the new concept, polypropylene (PP) and glass fibres woven fabrics have been used to prepare composites by using the film stacking technique. Maleated PP, able to compatibilize polypropylene with glass fibres, has been used to manage the interface strength layer by layer.The flexural and low-velocity impact characterizations have shown that the presence of the coupling agent in conventional composite structures (prepared with fully compatibilized polymeric layers) improves the static flexural properties through the strengthening of the matrix/fibre interface but considerably lowers the low velocity impact resistance of the composite, in terms of maximum load before fibre breakage and recovered energy after impact. The use of the IGIS design, that grade the interface strength through the laminate thickness, allows to prepare composites with both high flexural properties and high impact resistance, without affecting the balance and type of the reinforcement configuration.     

Mechanical properties of flax fibre/polypropylene composites. Influence of fibre/matrix modification and glass fibre hybridization

The effect of fibre treatments and matrix modification on mechanical properties of flax fibre bundle/polypropylene composites was investigated. Treatments using chemicals such as maleic anhydride, vinyltrimethoxy silane, maleic anhydride-polypropylene copolymer and also fibre alkalization were carried out in order to modify the interfacial bonding between fibre bundles and polymeric matrix. Composites were produced by employing two compounding ways: internal mixing and extrusion. Mechanical behaviour of both flax fibre bundle and hybrid glass/flax fibre bundle composites was studied. Fracture surfaces were investigated by scanning electron microscopy. Results suggest that matrix modification led to better mechanical performance than fibre surface modification. A relevant fact is that silanes or MA grafted onto PP matrix lead to mechanical properties of composites even better than those for MAPP modification, and close to those for glass fibre/PP.     

Environmental advantage by choice: Ex-ante LCA for a new Kraft pulp fibre reinforced polypropylene composite in comparison to reference materials

This study analyses the circumstances of environmental advantage by benchmarking a novel Kraft pulp fibre reinforced polypropylene against its matrix material and two other composites with talcum and glass fibres. With one exception, all composites use less non-renewable energy (−1% to −29%), but only the Kraft pulp fibre reinforced polypropylene achieves a reduction in global warming potential (14% to 35%) considering different functional units compared to polypropylene. The comparisons on basis of function–strength and stiffness in this case study–show that the adequate application of specific material properties, are key to achieve environmental advantages.     

Renewable resource based biocomposites from natural fiber and polyhydroxybutyrate-co-valerate (PHBV) bioplastic

Renewable resource based green biocomposites were prepared using a bacterial polyester i.e., poly(hydroxybutyrate-co-valerate) (PHBV) and natural bamboo fiber. Fabrication of the biocomposites was carried out by injection molding following extrusion compounding of PHBV and bamboo fiber with 30 or 40 wt.% fiber. The mechanical, thermo-mechanical and morphological properties of the biocomposites were evaluated. Little variation in the thermo-mechanical and impact properties was observed when the fiber content was varied. The tensile modulus of biocomposites at 40 wt.% fiber improved by 175% as compared to that of neat PHBV. The theoretical tensile modulus of the biocomposites was calculated using Christensen’s equations and compared with the experimental results. It was found to be in near approximation to the experimental data. The storage modulus was affected slightly by the variation of fiber content from 30 to 40 wt.% in biocomposites. The heat deflection temperature of PHBV increased by 9 °C at 40 wt.% of fiber reinforcement. Morphological aspects and thermal stability were studied using scanning electron microscopy and thermo-gravimetric analysis, respectively. In addition, a comparative analysis of bamboo fiber–PHBV with wood fiber–PHBV biocomposites was performed. Statistical analysis of both biocomposites was carried out by performing a two-way ANOVA on their tensile and flexural moduli in order to evaluate the effect of fiber type and content in the PHBV matrix.     

The potential of harakeke fibre as reinforcement in polymer matrix composites including modelling of long harakeke fibre composite strength

Mechanical properties of aligned long harakeke fibre reinforced epoxy with different fibre contents were evaluated. Addition of fibre was found to enhance tensile properties of epoxy; tensile strength and Young’s modulus increased with increasing content of harakeke fibre up to 223 MPa at a fibre content of 55 wt% and 17 GPa at a fibre content of 63 wt%, respectively. The flexural strength and flexural modulus increased to a maximum of 223 MPa and 14 GPa, respectively, as the fibre content increased up to 49 wt% with no further increase with increased fibre content. The Rule of Mixtures based model for estimating tensile strength of aligned long fibre composites was also developed assuming composite failure occurred as a consequence of the fracture of the lowest failure strain fibres taking account porosity of composites. The model was shown to have good accuracy for predicting the strength of aligned long natural fibre composites.     

Enhanced properties of lignin-based biodegradable polymer composites using injection moulding process

Composites from polybutylene succinate (PBS) and lignin-based natural material were fabricated using a melt mixing process. The effects of lignin material and polymeric methylene diphenyl diisocyanate (PMDI) compatibilizer on the properties of composites were investigated. Incorporation of 65% lignin material into PBS was achieved with an improvement in the tensile and flexural properties of composites. Incorporation of 1% PMDI in 50% lignin filled composites enhanced the tensile, flexural and impact strength simultaneously. Heat deflection temperature (HDT) of the virgin plastic also increased with lignin and PMDI incorporation. Improved interfacial adhesion was observed from SEM micrographs of the compatibilized composites.     

Mechanical properties and flammability of sisal/PP composites: Effect of flame retardant type and content

In this research, magnesium hydroxide (Mg(OH)₂) and zinc borate, as flame retardants, were incorporated into sisal/PP composites. Maleic anhydride grafted polypropylene was also used as a compatibilizer. Adding flame retardants into sisal/PP composites reduced burning rate and increased thermal stability of the composites. No synergistic effect was observed when both magnesium hydroxide and zinc borate were incorporated in the sisal/PP composites. In addition, the sisal/PP composites exhibited insignificant difference of shear viscosity at high shear rate indicating that types of flame retardants used in this study had no impact on the processability of the composites. Good distribution of flame retardants and sisal fiber in PP matrix was also observed. All PP composites had lower impact strength than the neat PP. However, the sisal/PP composites with the addition of Mg(OH)₂ and zinc borate exhibited comparable tensile and flexural properties to the sisal/PP composites without adding those flame retardants. Therefore, the addition of Mg(OH)₂ and zinc borate enhanced flame retardancy of sisal/PP composites without sacrificing their mechanical properties.     

Influence of an Agatha flax fibre location in a stem on its mechanical,chemical and morphological properties

The mechanical properties of flax fibres are analysed as a function of their biochemical and morphological characteristics. The fibres, from the Agatha variety, have been selected from either the top, the middle or the bottom of the stems. The results of each analysis are discussed according to the position of the fibre in the stem and compared among themselves. Considering a flax fibre as a natural composite, this study underlines the complexity of its structure and shows that many parameters intervene in its deformation behaviour.     

Shear characterisation of uni-directional fibre reinforced thermoplastic melts by means of torsion

Intra-ply shear appears during the forming process of hot thermoplastic laminates with a uni-directional fibre reinforcement. This paper proposes a torsion bar test to characterise the longitudinal shear mechanism, which can be performed with a standard rheometer. Sensitivity analyses showed that most reliable shear property measurements can be obtained by using torsion bar specimens with a close to square cross section. The method is implemented in practise and critically evaluated. Storage and loss moduli were determined for carbon UD/PEEK specimens at high temperatures. Non-linear material behaviour was found for relatively small shear strains. The linear regime was focussed on subsequently, where the characteristics were found to be similar to that of a visco-elastic solid or weak gel, confirmed by a dominant storage modulus and a weak frequency dependency. Future work is recommended to be focussed on the large strain regime, for which this paper provides a found basis.     

The effect of pre-softened wood chips on wood fibre aspect ratio and mechanical properties of wood–polymer composites

The objective of this work was to study the effect of chemical pre-treatment and moisture content of wood chips on the wood particle aspect ratio after compounding in a twin-screw extruder and on the mechanical properties of wood–polymer composites (WPCs). Composites with 50 wt.% wood content were manufactured using pre-treated and untreated wood chips. The effect of wood moisture content on composite properties was studied by using dried and undried wood chips. The mechanical properties and fracture surfaces of the composites as well as the microstructure and aspect ratio of wood particles after compounding were studied. The highest wood particle aspect ratio after extrusion was achieved by using pre-treated, undried wood chips as raw material. The chemical pre-treatment was found to enhance the defibration of wood chips as well as the mechanical properties of the composites.     

Development of slate fiber reinforced high density polyethylene composites for injection molding

During the last decade the use of fiber reinforced composite materials has consolidated as an attracting alternative to traditional materials due to an excellent balance between mechanical properties and lightweight. One drawback related to the use of inorganic fibers such as those derived from siliceous materials is the relative low compatibility with conventional organic polymer matrices. Surface treatments with coupling agents and the use of copolymers allow increasing fiber–matrix interactions which has a positive effect on overall properties of composites. In this research work we report the use of slate fiber treated with different coupling agents as reinforcement for high density polyethylene from sugarcane. A silane (propyltrimethoxy silane; PTMS) and a graft copolymer (polyethylene-graft-maleic anhydride; PE-g-MA) were used to improve fiber–matrix interactions on HDPE-slate fiber. The effect of the different compatibilizing systems and slate fiber content were evaluated by scanning electron microscopy (SEM), dynamic thermomechanical analysis (DTMA) as well as mechanical properties (tensile, flexural and impact). The results show that the use of silane coupling agents leads to higher fiber–matrix interactions which has a positive effect on overall mechanical properties. Interesting results are obtained for composites containing 30 wt.% slate fiber previously treated with propyltrimethoxy silane (PTMS) with an increase in tensile and flexural strength of about 16% and 18% respectively.     

Die drawn wood polymer composites. I. Mechanical properties

Oriented wood polymer composites (WPC) have been prepared by the Leeds die drawing process. Softwood and hardwood powder were used at 40% weight concentration (32% volume concentration) and in both cases materials with significantly increased stiffness (from 1.9 to 8.2 GPa) and strength (from 13 to 127 MPa) were obtained. Although the moduli of the drawn filled composites were lower than the equivalent unfilled polypropylene, the specific moduli, which take into account the lower density of the die drawn materials due to void formation were very similar. The type of wood particles and the use of polypropylene grafted with maleic anhydride had only a marginal influence on the mechanical properties of the die drawn composites. The morphology of the wood composites was studied by electron microscopy.     

Processing parameters and characterisation of flax fibre reinforced engineering plastic composites with flame retardant fillers

This work studies the possibility of compounding natural fibres (flax) into engineering plastics (PA6 and PB6) and comparing the results with counterpart glass fibre composites. The problem in compounding is the difficulty to compound the fibres with such polymers of high melting temperatures without decomposing the natural fibre thermally. Preliminary experiments are tried to define the possible processing window using the kneader namely temperature, compounding time and shear rate. Fibre content is tried in range of 0–50 wt.% with 10% step. The mixing temperature covers the range around the melting temperature ‘Tm’ [Tm−20, Tm+20]°C. The use of pre-melting temperature in compounding would utilise the energy evolving by fibres mutual rubbing. Compounding time is optimised at the minimum level. Shearing rate is tried at 25, 50, 75 and 100 rpm. Optimum conditions are defined to be 210–230 °C and 200–210 °C for PBT and PA6 respectively. Shearing rate is also defined to lie within 25–50 rpm.Two different additives of non-organic mineral and organic phosphate flame retardants are tried with the prepared composites either alone or in combination with each other. The loading of flame retardants is limited to 20 wt.% in order to leave a space for natural fibres as well as the polymer and to keep in turn the overall composite mechanical properties. A mix of 1:1 ratio between the both types of retardants is needed to reach V0 flame retardation level. Mechanical properties are even improved 30% in E-modulus and 4% in strength with respect to composites without flame retardants. However, the injection moulding is reported to be difficult because of the high viscosity and the parameters should be optimised regarding the desired flame retardance level and the required mechanical properties as well as keeping the fibres not damaged.