Development and erosion wear analysis of polypropylene/Linz‐Donawitz sludge composites

Abstract

AbstractIn the present investigation, a steel industry waste Linz–Donawitz (LD) sludge was added in different proportions with a polypropylene (PP) matrix and composite specimens were manufactured using the hand layup method. Experiments were performed to study the physical, mechanical, and erosion wear properties of the PP–LD sludge composites. This investigation also includes scanning electron microscopy (SEM), and x‐ray diffraction analysis of filler and composites. The erosion wear tests were carried out by Taguchi's experimental array design, where the effect of five control factors (impingement angle, filler content, erodent size, impact velocity, and erodent temperature) on erosion rate was analyzed. It was observed that filler content is the most influencing factor affecting were rate of the composites. At the maximum filler content of 20 wt%, the compressive strength and hardness increased to 85.71 MPa and 0.643 GPa, respectively. The tensile strength of the composites marginally decreased by 12.97% with the addition of 20 wt% filler. It was further observed that the flexural strength of the neat polymer decreased from 29.23 to 22.98 MPa with the addition of 20 wt% LD sludge. The SEM pictures of the eroded surface exhibited that the material removal is due to micro cracking and crack propagation.Highlights In this study, an industrial waste (LD sludge) is successfully used as a potential filler material in the PP matrix. Physical and mechanical properties of the PP‐LD sludge composites are analyzed. Effects of different parameters like filler content, impact velocity, impingement angle, erodent size and erodent temperature on the wear behavior are studied. Scanning electron microscopy is carried out so that a micro‐examination of the surfaces can be performed, as well as an assessment of the wear derbies.