Processing–formulation–performance relationships of polypropylene/short flax fiber composites

This work is a comprehensive study of the effect of extrusion process parameters and formulation on the properties of polypropylene (PP)/short flax fiber composites. The parameters that were varied during the twin‐screw extrusion process were screw configuration, revolutions per minute (rpm), extrusion temperature, and flow rate. The effect of the feeding zone location of cellulosic fiber was also considered. This study investigates the effect of the formulation, cellulosic fiber content, the presence of a coupling agent, and of a reactive additive on composite performance. The composites were characterized in terms of morphology and microstructure, fiber length, rheological, thermal, and mechanical properties. Sensibility to humidity and recyclability were also considered. When compared with as‐received PP, the tensile strength of injection‐molded parts increased with cellulosic content by up to 40 vol %, and the tensile modulus increased 3.5 times when a combination of coupling and reactive agents was used. Exposed to controlled humidity of 50% during 1 year, these composites exhibited a very low level of humidity uptake around 0.85 wt %. The processability of these materials using a cast film line and the mechanical properties of extruded sheets are also presented. Furthermore, these materials demonstrate a good recyclability using injection molding by keeping the integrality of their mechanical properties after five reprocessing cycles. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41528.     

Resistance of paper mill sludge/wood fiber/high‐density polyethylene composites to water immersion and thermotreatment

The disposal of paper mill sludge (PMS) is a difficult environmental problem. Thus, PMS has been used as a substitute for wood fiber (WF) to reinforce high‐density polyethylene (HDPE). In this study, we compared PMS–WF–HDPE composites with composites without PMS after water immersion and thermal treatment. Water immersion and thermal treatment were conducted at 25 and 70°C, respectively. The results show that the composites with PMS absorbed less water but lost more of their original flexural properties after immersion; thereby, their strength was compromised. These reduced mechanical properties could be partially restored after redrying. After the thermotreatment, the composites with added PMS lost their weight and flexural properties, whereas the composites without PMS gained flexural strength. The results show that the thermotreatment improved the impact strength of the composites when no more than one‐third of WF was replaced with PMS. Fourier transform infrared spectroscopy and energy‐dispersive X‐ray energy‐dispersive spectroscopy showed that the wood index of the PMS composite decreased more than the index of the non‐PMS composite, whereas the carbonyl index increased more. However, the PMS composite showed a lower increase in the total oxygen/carbon weight ratio. This study suggested that limited amounts of WF could be substituted with PMS to reinforce HDPE. However, WF–PMS–HDPE composites should not be used in hot, humid environments for long periods. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41655.     

Alfa fiber/polypropylene composites: Influence of fiber extraction method and chemical treatments

Alfa fiber/polypropylene composites were manufactured using twin-screw extrusion. Fibers were extracted using alkaline and steam explosion methods. Three chemical treatments were also applied to the alkaline-extracted fibers: stearic acid (SA), and potassium permanganate dissolved in water (KW) and in acetone (KA). Finally, thermal annealing was applied to the composites. The results indicate that composites with steam-exploded fibers had a significantly higher melt flow index than composites with alkaline-extracted fibers. Moreover, the incorporation of fibers into the matrix increased the Young's modulus, where the optimum results were obtained utilizing the alkaline-extracted fibers. Both extraction methods also significantly decreased the water uptake, especially the steam explosion. The three chemical treatments increased the melt flow index and conversely decreased the tensile strength and Young's modulus. In addition, KW treatment decreased the water uptake. Finally, thermal annealing increased the tensile strength and Young's modulus of composites with SA-treated fibers. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 47392.     

Creep and recovery behavior of kenaf/polypropylene nonwoven composites

This article reports an exploratory study on the creep and recovery behavior of kenaf/polypropylene nonwoven composites (KPNCs), serving as a bio‐based substitution for polypropylene (PP) plastics in the automotive industry due to the environmental concern. The creep and recovery behavior of KPNC and solid virgin PP were performed by dynamic mechanical analyzer (DMA) which allowed it to be studied extensively. The linear viscoelastic limit (LVL) was found at 1 MPa. Two popular creep models, the four‐element Burgers (FEB) model and the Findley power law (FPL) model, were used to model the creep behavior in this study. The FEB model was found only appropriate for characterizing short‐term creep behavior. In contrast, the FPL model was satisfactory for predicting the long‐term creep performance. The long‐term creep behavior of KPNC in comparison to virgin PP plastic was predicted using the time‐temperature superposition (TTS) principle. The 1‐year creep strains were estimated to be 0.32% for KPNC and 1.00% for virgin PP at 40°C. A three‐day creep test was conducted to validate the effectiveness of the TTS prediction. KPNC showed a better creep resistance and higher recoverability than the virgin PP, especially in a high‐temperature environment. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40726.     

Toward green three‐phase composites with enhanced dielectric permittivity

This work aims to investigate the dielectric potential of microcrystalline cellulose, a green biosourced material, as a third constituent in the three‐phase composites based on ethylene vinyl acetate‐vinyl ester of versatic acid (EVA‐VeoVa) terpolymer and BaTiO₃. For that, new green three‐phase composites were prepared using an economic and green process, with simple implementation at room temperature and using water as a solvent. Compared with the binary composite EVA‐VeoVa/BaTiO₃, the three‐phase composite EVA‐VeoVa/BaTiO₃/microcrystalline cellulose showed an improvement of the BaTiO₃ particles dispersion, enhanced relative permittivity, and reduced dielectric loss, which explains the significance of this study. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46147.     

Wood‐based composites with thermoplastic polyurethane as matrix polymer

This research reports the influence of the mechanical properties of thermoplastic polyurethane (TPU) as a function of wood filler percentage. Wood flour was mixed with two different chemically based TPUs. Also, moisture content during compounding process as well as the origin of moisture (wood or TPU) were studied. All experimental designs and statistical analysis were done with the software Design Expert Version 10. Composite preparation took place in a multi‐stage process. The results showed that 70% wood filler can be incorporated in the composite manufacture. The properties of the composite were mainly influenced by the proportion of wood and TPU. Wood flour increased the density, hardness, water absorption, and tensile modulus with a decrease in impact resistance and abrasion resistance of the composite. Tensile strength exhibited a decrease up to ～35% wood content, but an increase with further addition of wood. Moisture content had only a minor influence on the mechanical and water absorption properties despite the noted severe moisture sensitivity of TPU, which usually leads to decline in mechanical properties. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46344.     

Polypropylene‐based composites reinforced with textile wastes

The present work describes the preparation of polypropylene composites reinforced with cotton fibers, which were obtained from textile waste. The cellulosic fibers were bleached and then chemically modified on the surface using acetylation or silanization methods. Fourier transform infrared spectroscopy analysis and energy dispersive X‐ray spectroscopy confirmed the efficiency of both treatments. Results of thermal degradation by thermogravimetric analysis (TGA) of treated fibers indicated that the acetylated ones decreased thermal stability while the silanized fibers increased this property. The influence of the chemical modifications and fibers content in polypropylene‐based composites was studied by thermomechanical and mechanical properties (dynamic mechanical analysis and tensile tests) and thermal analyses (TGA and differential scanning calorimetry). The results showed that the addition of the obtained cellulose fibers in polypropylene caused increase of storage and Young's moduli, along with stress at break. Moreover, scanning electronic microscopy micrographs of cryofractured surfaces revealed stronger adhesion between fiber and matrix in the composites reinforced with the modified fibers. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45060.     

Polypropylene composites obtained from self‐reinforced hybrid fiber system

The purpose of the study was to obtain a composite material with the self‐reinforced structure, which processing provide increased mechanical properties. The composites used in presented work were prepared from the two types of fiber mixtures, both were based on polypropylene fibers, the difference was in used cellulose or wood flour filler. Composites were prepared using the hot compaction method. The presented research describes the effect of the composite composition and processing conditions. The results include the static tension measurements, tensile impact tests and thermal analysis, including: DSC and DMTA. The structure has been studies using the SEM observations. Results of presented studies confirm the self‐reinforcing effect in obtained hybrid composites. It provides in the comparison to the standard wood polymer composites to the higher level of material reinforcement with lower amount of natural filler. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43283.     

Recycling of lignocellulosics filled polypropylene composites. I. Analysis of thermal properties,morphology, and amount of free radicals

Composites of isotactic polypropylene filled with comminuted rapeseed straw are studied. Improvement in interfacial adhesion is achieved by chemical modification of the lignocellulose filler. Composites were subjected to recycling by extrusion. The effect of multiple recycling of the composites on the process of nucleation and crystallization of polypropylene matrix, surface topography, and free radical generation was checked. On the basis of differential scanning calorimetry data, a significant influence of the recycling on nucleation activity of the lignocellulose filler was evidenced. A relation between the filler particle size and multiple recycling was established by observations under a polarization microscope, while scanning electron microscope analyses confirmed the positive effect of chemical modification of rapeseed straw on the interfacial adhesion. The composite structure changes forced by multiple recycling are discussed in the context of free radical generation. Concentration of free radicals in the rapeseed straw samples and composites was measured by the electron paramagnetic resonance spectroscopy to show that it was higher in the systems subjected to multiple recycling. Interestingly, the composites after multiple recycling showing elevated concentration of free radicals are also characterized by higher nucleation activity. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41693.     

Fire retardancy of polypropylene composites reinforced with rice husks: From oxygen index measurements and cone calorimetry to large‐scale single‐burning‐item tests

Rice husks containing 12 wt % inorganic silica were incorporated together with halogen‐free fire retardants in a polypropylene matrix and extruded into facade profiles. An increase in the amount of rice husks resulted in an increase in the oxygen index. The cone calorimetry measurements showed that all of the fire retardants tested significantly reduced the peak heat‐release rate (pHRR) and maximum average rate of heat emission (MARHE) of the formulations and moderately reduced total heat release. The best results in terms of MARHE were achieved for the formulation including 24% melamine‐coated ammonium polyphosphate. pHRR and MARHE were reduced with increasing amount of rice husks. Single‐burning‐item (SBI) tests were performed for the extruded profiles based on rice husks and, for comparison, wood flour. In the best case, a B‐s2, d0 classification was obtained. The results obtained from cone calorimetry and SBI tests were in agreement. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46654.     

Preparation,structure, and property of wood flour incorporated polypropylene composites prepared by a solid‐state mechanochemical method

In this article, a solid‐state mechanochemical method based on a pan‐mill equipment was used to prepare 60 wt % loading of wood flour (WF) incorporated polypropylene (PP) wood–plastic composite (WPC) with good comprehensive performance. The particle size distribution, crystallization, microstructure, and properties of the prepared WPC were accordingly investigated. The results show that under co‐effects of the strong shear force field of pan milling and the compatibilization of PP grafted maleic anhydride (PP‐g‐MAH), the mixture of PP and WF is effectively pulverized and homogeneously mixed. Meanwhile, the WF particles are adequately activated by exposure of their characteristic functional groups, which is beneficial to the interfacial mechanochemical reaction. PP‐g‐MAH and PP prove to be in situ grafted onto WF particles surface during pan milling, thus resulting in the substantial enhancement in both the dispersion of the added WF fillers in PP matrix and the interfacial bonding. The mechanochemical effects of pan milling could also remarkably promote the heterogeneous nucleation effect of WF particles on PP crystallization and influence the dynamic mechanical behavior of composite. Compared with the unmilled and uncompatibilized composite, the milled and compatibilized WPC material possesses greatly enhanced mechanical performance and shows good application prospects. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43108.     

Surface treatment of eucalyptus wood for improved HDPE composites properties

In this study, the effect of Eucalyptus globulus wood (UE) used as a filler (5–20% w/w) on the physical and thermal properties of high-density polyethylene (HDPE) composites was evaluated. To improve the compatibility with HDPE, the wood was modified (TE) using crude glycerol derived from biodiesel production. The addition of 20% (w/w) of UE or TE led to more rigid and durable composite materials compared to neat HDPE (about 50 or 100% increase in tensile strength, respectively). Composites also revealed 55–75°C higher temperatures at maximal degradation rates. The advantageous behavior of TE over UE in composites was attributed to the improvement of surface morphology of modified wood and it is better compatibility with the HDPE as revealed by surface energy analysis. The changes in wetting behavior of HDPE and ensuing HDPE-TE composites (contact angles of ca 72 and 80°, respectively) explain the matrix-filler interactions. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020 , 137, 48619.     

Mechanical performance and moisture absorption of various natural fiber reinforced thermoplastic composites

Natural fibers are seeing increased use in composite applications due to their reduced cost, low density, and environmental benefits (more sustainable and lower carbon footprint). Although many natural fiber systems have been examined over the last decade, there have been relatively few studies which have compared a variety of fiber types and processing methods directly in the same experimental set. In this study, natural fiber composites made from low density polyethylene (LDPE) and a variety of Canadian based fiber feedstocks were examined including hemp bast, flax bast, chemically pulped wood, wood chips, wheat straw, and mechanically pulped triticale. The effect of fiber type, fiber fraction and maleic anhydride polyethylene (MAPE) coupling agent on the mechanical properties and long‐term moisture absorption behavior was quantified. In general, addition of natural fiber to LDPE results in an increase in modulus (stiffness) with a corresponding loss of material elongation and impact toughness. Of the fiber types tested, composites made from chemically pulped wood had the best mechanical properties and the least moisture absorption. However, the use of MAPE coupling agent was found to significantly increase the mechanical performance and reduce moisture absorption for all other natural fiber types. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 130: 969‐980, 2013     

Effect of dimethyl sulfoxide on synthesis of thermoplastic cellulose‐Graft‐poly(l‐lactide) copolymer using ionic liquid as reaction media

In this study, ring‐opening graft polymerization of l ‐lactide onto cellulose was carried out homogeneously in ionic liquid (IL)/dimethyl sulfoxide (DMSO) co‐solvent as a reaction media. Through the effective control of high viscosity and steric hindrance caused by the interaction between the IL and the hydroxyl group of cellulose by adding DMSO as a co‐solvent, cellulose‐graft‐poly(l ‐lactide) (Cell‐g‐PLLA) copolymer with higher substitution efficiency was successfully prepared, at relatively low concentration of l ‐lactide. The maximum values of molar substitution, degree of lactyl substitution, and degree of polymerization of poly(l ‐lactide) in the copolymer were 3.76, 1.74, and 2.16, respectively, determined by ¹H‐NMR. The prepared cell‐g‐PLLA copolymers showed thermal plasticization with a glass transition temperature of 155°C. In addition, the thermal processibility could be improved as the amount of grafted PLLA in the copolymer increased. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 41331.     

Nonlinear tensile behavior of cotton fabric reinforced polypropylene composites

From the perspectives of elastoplasticity (nontime-dependent) and viscoelasticity (time-dependent), the Ramberg–Osgood relation and time-varying viscosity Maxwell (TVM) models were used to model and analyze the stress–strain behavior of cotton fabric-reinforced polypropylene composites (CFRLs), respectively. The Ramberg–Osgood relation could well describe the tensile behavior of CFRLs as an elastoplastic behavior, while the tensile behavior could also be described as a nonlinear viscoelasticity behavior by Maxwell model. The fitting results showed that the Maxwell model accurately described the tensile behavior of different CFRLs samples under low strain, but there was a considerable gap between the test data and model values when the strain was greater than 5%. Therefore, a time-varying viscosity fluid damper was used instead of a Newtonian fluid damper to modify the Maxwell model, namely the TVM model. The TVM model closely described the stress–strain behavior during the entire tensile process.     

Algae fiber polypropylene composites: Modeling of the degradation by solid state kinetics

Knowledge of the mechanisms of degradation in natural fiber composites (NFCs) has great importance for the life cycle assessment of the automotive components based on NFCs. The purpose of this study was to evaluate the solid state kinetic models available to describe the degradation process of algae fiber/grafted polypropylene (AFPPg) composites processed by extrusion compression molding (ECM). Samples of the 0.14 volume fraction (υ_f ) AFPPg composite, algae fiber, and grafted PP were evaluated before and after 576 hours of accelerated UV light weatherization. The weight loss of the specimens was determined by thermogravimetric analysis (TGA) at six isothermal temperatures, and weight loss data were transformed into the conversion fraction α . Curves of the factor α and time were linearized using MATLAB software to find the parameters of the degradation. The best statistical fit to model the degradation was given by the Avrami–Erofe'ev model. The kinetic parameters of PP grafted after UV exposure were frequency factor (A ) of 6.26 min^?1 and activation energy E ₀ of 24 kJ/mol. The effect of degradation was characterized by Fourier transformed infrared spectroscopy (FTIR). The characteristic bands of the main products of degradation in the composite were identified as pentane and propane. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 44622.     

Thermoplastic composites of polyamide‐12 reinforced by cellulose nanofibers with cationic surface modification

Cellulose nanofibers (CNFs) have many useful properties, including high strength and low thermal expansion, and are also environmentally friendly, readily renewable, safe, and biodegradable. The focus of this study was the development of lightweight thermoplastic polymer composites with good mechanical properties based on the incorporation of CNFs that have undergone surface pretreatment with a cationic reagent. The polyamide (PA12) was mixed with surface‐treated CNFs using a twin screw extruder and the resulting pellets were injection molded. The Izod impact strength without notch of CNF‐based composites exceeded that of composites incorporating organophilic montmorillonite (OMMT), a representative nanocomposite material. When the Izod impact test without notch, the impact hammer was stopped by the specimen with incorporation of surface treated CNF. Furthermore, the bending modulus and strength were equal to or greater than that of OMMT composites. The heat distortion temperature was improved as 33°C from neat PA12, and moreover improved as 29°C from OMMT composites. Cationic pretreatment of the CNF surfaces was found to increase the dispersion of the fibers and also to greatly improve the mechanical and thermal properties of the composites. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40920.     

Syndiotactic polypropylene/microfibrous cellulose composites: Effect of filler size on tensile properties

Syndiotactic polypropylene (SPP)/ethanol swelled microfibrous cellulose (MFC) composite was prepared by a melting mixer, and its morphology and tensile properties were studied. The scanning electron microscope microphotograph did not show the aggregated MFC part up to the 40 wt % MFC loading content, and the Young's modulus was exponentially increasing with the increase of the MFC loading content. These results suggested that the MFC was well‐dispersed in the SPP matrix by an ethanol surfactant work. The Young's modulus was much higher than that of the composite with commonly used fibrous cellulose and moreover, exceeded the theoretical one obtained from the Halpin‐Tsai equation. The differential scanning calorimetry and wide‐angle X‐ray diffraction measurements showed that the MFC acted as a good α‐nucleation agent for SPP. It was found that the excessive Young's modulus of the MFC composite was originated from an increase of that of the SPP matrix induced by the α‐nucleation effect. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Effect of acetylation on the properties of microfibrillated cellulose‐LDPE composites

Solvent‐free acetylation of microfibrillated cellulose was carried out in order to improve their hydrophobicity. All the samples were filled with low‐density polyethylene. The morphology, mechanical properties, and water uptake of the ensuing composites were investigated. An excessive reaction time leads to degradation of the fibers, which was observed by scanning electron microscopy and fiber quality analysis. The acetylation treatment did not improve the mechanical properties of composites but extensively decreased the moisture absorption of the composites. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 44933.     

Bio‐composites for structural applications: Poly‐l‐lactide reinforced with long sisal fiber bundles

Fully bio‐based and biodegradable composites were compression molded from unidirectionally aligned sisal fiber bundles and a polylactide polymer matrix (PLLA). Caustic soda treatment was employed to modify the strength of sisal fibers and to improve fiber to matrix adhesion. Mechanical properties of PLLA/sisal fiber composites improved with caustic soda treatment: the mean flexural strength and modulus increased from 279 MPa and 19.4 GPa respectively to 286 MPa and 22 GPa at a fiber volume fraction of V_f = 0.6. The glass transition temperature decreased with increasing fiber content in composites reinforced with untreated sisal fibers due to interfacial friction. The damping at the caustic soda‐treated fibers‐PLLA interface was reduced due to the presence of transcrystalline morphology at the fiber to matrix interface. It was demonstrated that high strength, high modulus sisal‐PLLA composites can be produced with effective stress transfer at well‐bonded fiber to matrix interfaces. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40999.