Hybrid Composite Materials Research Articles

Investigation on novel ultralight weight thermally insulated fireproof composite

Abstract This study highlights the performance of ultra-lightweight fireproof composite. Polyacrylonitrile based carbon fiber (CF) has been reinforced in Polyetherimide (PEI) polymer to develop the composite. The Surfac2e of CF and PEI film was modified by low-pressure plasma to improve the bonding strength between matrix and reinforcement. The polymeric composite was fabricated by compression molding with a pressure of 2 bar, temperature of 380 °C and holding time of 30 min. CF/PEI composite was used to make a hybrid composite by layering of silicone foam in between the layers. The hybrid composite was exposed to a Bunsen burner under sustained flame for a duration of 10 min. The composite panel’s flame-facing side reached 676.2 °C after 10 min of fire exposure, while the temperature on the other side only reached 58.2 °C. The fabricated hybrid composite was exposed to very low temperature in order to test its ability of thermal insulation under extreme cold temperature. Over the specific period of testing, the temperature of the dry ice decreased from 25 °C to −3.1 °C. After exposure to fire, only minimal loss of material was observed. The hybrid composite of carbon fiber and PEK film, sandwiched between silicone foam, exhibits excellent fire resistance due to its high limiting oxygen index. This composite is considered to be among the best thermally insulating and fire-resistant materials. Thermogravimetric analysis of carbon fiber and PEI-Carbon fiber composite was performed to determine the optimal processing temperature of compression molding for the composite, upon heating, it showed a modest weight decrease of 6.053%. The composite shows a significant improvement of impact resistance, compressive strength and thermal stability. A simulation model was developed under Ansys fluent software for both heating and cooling. The analysis of developed model also shows similar results.

Exploring the synergistic effects of graphene on the mechanical and vibrational response of kenaf/pineapple fiber‐reinforced hybrid composites

AbstractThe automotive, aerospace, and sports industries are increasingly utilizing hybrid composites made from natural fiber reinforcements. This study evaluated the performance of a composite made from kenaf and pineapple fibers, manufactured using the compression molding process, with graphene nanoparticles added at varying weight concentrations of 0.5, 1.0, 1.5, and 2.0 wt%. Results showed that adding 0.5 wt% graphene increased the tensile, flexural, and impact strength of hybrid composite by 133.75%, 90.24%, and 25.67%, respectively. Microstructural analysis revealed that graphene integration has enhanced the interfacial bond between the fiber and the matrix, creating resin‐rich areas. Furthermore, the free vibrational analysis indicated that graphene‐infused composites exhibited higher natural frequencies, improving their energy‐absorbing capabilities. Water absorption tests demonstrated that the inclusion of graphene reduced water penetration by improving interfacial bonding, minimizing voids, and decreasing surface energy, which limited water pathways in the composite. Furthermore, the composites with 0.5 wt% graphene showed a contact angle of 80.8°, indicating lower hydrophilicity compared to neat composites, which had a contact angle of 70.7°. This research emphasizes the advantages of hybrid composite materials derived from kenaf and pineapple fibers, specifically for applications in vehicle interiors and construction, including wall panels and separators.Highlights Hybrid composite was prepared using the compression molding process. Adding 0.5 wt% graphene improved the mechanical properties of composites. Hybrid composites with lower wt% graphene had higher natural frequencies. The composites with 0.5 wt% graphene had better water absorption properties.

Progress in MXenes and Their Composites as Electrode Materials for Electrochemical Sensing and Dye-Sensitized Solar Cells

In the present mini-review article, we have compiled the previously reported literature on the fabrication of MXenes and their hybrid composite materials based electrochemical sensors for the determination of phenolic compounds and counter electrodes for platinum (Pt)-free dye-sensitized solar cells (DSSCs). MXenes are two-dimensional (2D) materials with excellent optoelectronic and physicochemical properties. MXenes and their composite materials have been extensively used in the construction of electrochemical sensors and solar cell applications. In this paper, we have reviewed and compiled the progress in the construction of phenolic sensors based on MXenes and their composite materials. In addition, co1.unter electrodes based on MXenes and their composites have been reviewed for the development of Pt-free DSSCs. We believe that the present review article will be beneficial for the researchers working towards the development of phenolic sensors and DSSCs using MXenes and their composites as electrode materials.

Dry sliding wear behaviour of AA6082/BN/Mos2 hybrid metal matrix composites synthesized using stir casting process

This study examines the wear behaviour of AA6082/x Boron Nitride (BN) (x = 1, 2, 3 wt.%)/1 wt.% of Molybdenum Disulphide (MoS2), a novel hybrid metal matrix composite (MMC), under dry sliding conditions. The composite was fabricated through liquid-state processing, i.e., stir casting. A pin-on-disk tribometer was used to estimate the coefficient of friction (COF) and wear rate by varying tribological process parameters under dry sliding conditions. The results show that at the maximum load of 40 N, the wear rate of the unreinforced alloy is observed 4.077 × 10−2 mm3/m, while at the AA6082/3 wt. of %, BN/1 wt. % of the MoS2 composite's wear rate is reduced to 2.162 × 10−2 mm3/m. Further, the wear rate increases as the sliding distance increases from 500 m to 2000 m. Moreover, the friction coefficient of the unreinforced alloy is observed 0.37, whereas the AA6082/3 wt.% of BN/1 wt.% of MoS2 composites is observed 0.31 under reduced loads. It might be due to the presence of hard ceramic BN and MoS2 reinforcements enhancing the developed composite's resistance to wear by forming a mechanically mixed layer (Fe2O3) on the sliding contact surface. Moreover, the novel hybrid composite materials exhibit a lower coefficient of friction at higher sliding velocities, sliding distances, and applied loads. However, minimal fine grooves with limited abrasion are observed on the worn surface, which was examined through a scanning electron microscope.

Response Surface Methodology for Optimisation of Parameter on Water Absorption of Natural Fibre Hybrid Composite in Boat Construction

Today, the utilisation of natural or green fibre has supplanted engineered fibre as fibreglass has become a pattern in composite boat producing and other gears because of its lightweight, excellent relative mechanical properties, and more significant elements. For example, it is eco-accommodating, has manageable materials, and has lower costs compared to fibreglass. The utilisation of fibreglass is costly and has a high effect on the natural biological system. It also gets over the area of ecological contamination, word-related well-being, and security concerns. This study used the Woven Kenaf/fibreglass as reinforcement and polyester as matric to fabricate hybrid composite coupons. Response Surface Methodology (RSM) of Box-Behnken Design (BBD) was applied to optimise fibre contents (35 to 75 wt%) and water absorption performance for the development of Woven Kenaf/fibreglass to polyester hybrid composite material based on the parameters. The BBD revealed that 45% Woven Kenaf/fibreglass to polyester performed the optimum fibre content and water absorption. Analyses of variance (ANOVA) showed that the model satisfactorily correlated the parameters. After immersion, 45% Woven Kenaf/fibreglass to polyester composite also gained 9.48% weight.

Flexural Strength of Modern CAD/CAM Restoratives After Artificial Aging.

Before clinical trials are initiated, studying the mechanical performance of modern CAD/CAM restorative materials exposed to aging conditions would provide insights on their performance in service. This study evaluated the impact of thermomechanical aging on various resin composite, ceramic, hybrid, and nano-filled resin composite materials after two polymerization modes. Specimens (3 × 4 × 14 mm3) were fabricated using (n = 12 per group) a universal composite (Filtek Supreme XTE photo-polymerized for either 40 s or 120 s per layer), hybrid ceramics (BRILLIANT Crios, GC Cerasmart, Lava Ultimate, VITA ENAMIC), glass ceramics (IPS e.max CAD, VITA Suprinity PC, Straumann n!ce), or feldspar ceramics (VITABLOCS Mark II, GC Initial LRF). In each group, half of the specimens underwent thermomechanical aging. A three-point bending test was applied to all specimens and the results were statistically analyzed (α = 0.05). Glass ceramics and hybrid ceramics presented higher flexural strength values than feldspar ceramics and the universal composite before and after aging (p < 0.05). Thermomechanical cycling affected the flexural strength of all materials (p < 0.05) except Lava Ultimate, Straumann n!ce, and GC Initial (p > 0.05). The highest decrease in flexural strength after aging was found in the universal composite (40 s polymerization) (p < 0.001) and Vita Enamic (p < 0.001), while the lowest decrease was in the hybrid ceramics, Cerasmart and Lava Ultimate (p < 0.05). Extending polymerization duration reduced the aging effect on the universal composite tested. Thermomechanical aging affected the flexural strength of most materials tested. Universal composites and feldspar ceramics presented similar flexural strength values.

Comparison of mechanical and flammability properties of thermoplastic and thermoset matrix glass fibre woven fabric composites

This study aims to examine the mechanical and burning properties of composites made from twill (0°/0° and 0°/90° orientations) and plain fabrics using hybrid yarns produced by combining glass and polypropylene yarns with interwoven and intermingled methods. The properties of interwoven and intermingled hybrid fabric composites were compared with thermoset composites. Each composite (56% glass fibre content) plate is produced by combining eight fabrics with the same parameters using the press moulding technique. The effects of yarn and fabric weaving types on the results were examined in detail. When the results are examined, the breakage of glass fibres in intermingled hybrid yarns negatively affects the strength results. Therefore, composites made with intermingled hybrid yarn types and plain weave types of fabric had the lowest tensile strength value (132 MPa). The composite of twill woven fabrics produced with interwoven yarns arranged in 0°/0° orientation had the highest tensile strength of 315 MPa, and these results were very close to those of thermoset composites. Although the 0°/90° oriented twill composite showed a 2.3 times lower tensile strength value than the 0°/0° oriented twill composite, it had a 7.7 times higher value when bending strength values were taken into account. The main reason for this is that glass fibres contribute to the warp and weft directions. It has been observed that the composite consisting of plain fabrics woven with commingled hybrid yarns had the highest impact resistance. Additionally, when the combustion results were examined, it was concluded that the type of yarn and fabric weaving affected the burning rate. The slower combustion of hybrid commingled yarn composites resulted from fibreglass breakage during yarn production. These findings provide valuable insights into optimizing composite materials for specific applications, considering factors such as weaving pattern, fibre orientation, and mechanical performance.

Sustainable pseudocapacitance potential of a hybrid triad involving activated carbon derived from polyester wastes

This study introduces an innovative approach to fabricate high-efficiency supercapacitor electrodes by utilizing waste polyester (PES), a common fabric waste, as a precursor for producing activated carbon. This approach not only addresses waste disposal issues but also provides a valuable resource for various environmental and industrial applications. Through a series of chemical and thermal treatments, PES waste is transformed into a porous carbon structure, which is then functionalized with PPy and V2O5 to enhance its electrical conductivity and electrochemical performance. The synthesized composite is characterized by several analytical and spectral techniques to elucidate the morphological, structural and surface properties. The specific surface area of the hybrid composite material is 50.4 m2g−1. Cyclic voltammetry, galvanostatic charge-discharge and impedance spectroscopy are employed to evaluate the performance of the composites as supercapacitor electrodes. From the CV curves, the electrochemically active surface area was calculated to be 0.085 m2g-1. The composite exhibits a remarkable specific capacitance of 535 Fg-1 and energy as well as power density values of 171 W h Kg−1 and 2877 W Kg−1 respectively at a current density of 2 Ag−1. The material was fabricated into device and was observed to show excellent cycling satbility for up to 10,000 cycles.

Jute-reinforced hybrid biocomposite incorporated with low thermal conductive silica aerogel for improved resistance to conductive and radiative heat

This study aims to develop jute-reinforced polypropylene composites by incorporating low-heat conductive silica aerogel for enhanced thermal performance, envisioning their utilization as heat-insulating panels in buildings. The fabrication of hybrid composites using a heat press molding technique showed a significant improvement in thermal properties due to incorporating aerogel into the material. The lowest obtained thermal conductivity of hybrid composite was 0.0986 W/m·K, which was almost halved (0.1704 W/m·K) to the material without aerogel. The radiative heat resistance of hybrid composites was also improved with the aerogel in the material. Additionally, composites with higher amounts of aerogel showed superior flame resistance and thermal stability at high temperatures. The hybrid composites, however, demonstrated a decrease in tensile strength due to the presence of aerogel particles at the interface of composites. The composite without aerogel displayed the highest tensile strength of 64.67 MPa, which was the lowest (47.87 MPa) for the material with the maximum amount of aerogel. The fractographic investigation also revealed the existence of aerogel particles and their random distribution at the interface of the material. The low water absorption owing to reduced interfacial vacuities and the existence of super-hydrophobic aerogel in the interior of composites indicated their durability in humid conditions without deteriorating the dimensional stability. The outcomes of the study revealed a considerable effect of aerogel on the thermal performance of composites and ascertained their excellence as a prospective heat-insulating material for conserving thermal energy by minimizing heat transfer from inside to outside of the building and vice versa.

Development of a Novel Wear Equation by Comparing the Wear Behaviour of Hard (AA7075) and Soft (AA6063) Hybrid Composite Materials

Development of a Novel Wear Equation by Comparing the Wear Behaviour of Hard (AA7075) and Soft (AA6063) Hybrid Composite Materials

Multi-objective Process Optimization of Micro-drilling Parameters on Carbon and Carbon–Aramid (Hybrid) Fabric Composites

Multi-objective Process Optimization of Micro-drilling Parameters on Carbon and Carbon–Aramid (Hybrid) Fabric Composites

Flexural properties and optimisation of hybrid composites reinforced by carbon, glass and flax fibres

This paper presents a study on the flexural properties of hybrid composites (HC) reinforced by carbon, glass, and flax fibres, utilising Finite Element Analysis (FEA). Possible optimal layups are identified through the application of design rules, and regression-based models are developed to predict flexural strength. With the developed models, multi-objective optimisation is done to minimise the cost and weight subjected to a given minimum required flexural strength. By integrating numerical simulation, regression analysis, and optimisation techniques, this research offers a practical approach to the design and fabrication of HC with enhanced mechanical performance and cost-efficiency.

Synthesis and Utilization of MXene/MOF Hybrid Composite Materials

Synthesis and Utilization of MXene/MOF Hybrid Composite Materials

Processing and characterization of waste dolomite dust filled hemp‐epoxy composites

AbstractThe necessity to adapt sustainable development, green chemistry and industrial ecology leads to the creation of newer materials and the utilization of waste. In this context, this work aims at exploring the feasibility of the fabrication of hybrid composites comprised of a polymeric resin reinforced with a natural fiber (hemp) and an industry waste filler (dolomite dust). While the hemp fiber content is kept constant, epoxy‐based hybrid composites are fabricated with different weight percentages of dolomite dust using the conventional hand lay‐up route. The microstructural features of the constituent materials are studied using stereo and scanning electron microscopes which show the shape and size of dolomite particles and the arrangement of fibers. An x‐ray diffraction analysis revealed the presence of hematite, graphite, lime and manganite. The presence of functional groups like hydroxyl, carboxyl and azide is ascertained from the transmittance spectra of Fourier transform infrared spectroscopy. The density and void fractions are increasing with the amount of filler particles in the composite. It is observed that the tensile and flexural strengths of the composites marginally drop with increase in dolomite dust content, but there is a reasonable improvement in their inter‐laminar shear strength, micro‐hardness and impact strength values.

Synthesis and Characterization of Shungite Modified Poly-N-Ninylpyrrolidone-Agarose Composites for Medical Application.

A systematic investigation was conducted to synthesize hybrid composite materials that use synthetic poly-N-vinylpyrrolidone and natural (agar-agar) macromolecules with plasticizers (PEG-400) and mineral filler shungite by means of electron irradiation. The XRD and SEM data showed that the structure of the resulting hybrid composites is an interpenetrating network with distributed particles of mineral component. It has been established that the mechanical properties of hybrid composites are determined mainly by the structural organization of the interpenetrating polymer network formed under electron irradiation of the initial synthetic and natural polymer mixture in the presence of plasticizers, as well as by the conditions for intercalation of polymer segments into the mineral matrix and vice versa. It has been revealed that the degree of swelling of hybrid composites strongly depends on the concentration of a low-molecular plasticizer in the polymeric interpenetrating network, which easily impregnates into the matrix of shungite. Successfully obtained [PVP-AA-PEG] hydrogels with shungite can be applied in regenerative medicine as wound healing dressings.

Wear behaviour of titanium diboride and zirconium carbide reinforced LM13 hybrid composite for automotive applications

Abstract This study investigates the wear behaviour of a hybrid composite material reinforced with titanium diboride and zirconium carbide in LM13. The ASTM standard is followed for conducting wear tests, utilizing a pin-on-disc setup to assess the wear rate. An empirical relationship is established to predict the wear rate using statistical tool analysis of variance, and the model’s adequacy is checked. Low wear is observed at a sliding distance of 110 mm, sliding speed of 2.5 m s−1, and sliding load of 12.5 N. The observed low wear is attributed to the optimal level of reinforcement provided by titanium diboride and zirconium carbide. From the analysis of variance, sliding speed is identified as the major contributing factor to wear rate, followed by sliding distance and load. The reinforcement materials enhance the wear resistance of the hybrid composite and their effectiveness is particularly evident under the specified sliding conditions.

Organic Heterophase Composites Induced Sulfur Vacancies and Internal Electric Field Enhancement for Advanced Magnesium Storage of Copper Sulfide Cathodes

AbstractRechargeable magnesium‐ion batteries (MIBs) hold significant promise for safe and efficient large‐scale energy storage, but the lack of high‐performance cathodes hinders their development for practical applications. In this work, a series of nanocomposites consisting of π‐conjugated perylene‐3,4,9,10‐tetracarboxylic dianhydride annealed at 450 °C and copper sulfide (CuSP) are synthesized solvothermally to explore their utility as a host for Mg2+ storage in MIBs. The carbonyl organics in the hybrid materials modify the predominant CuS phase, expanding interlayer spacing and enriching sulfur vacancies through modifications of the internal electric field. This synergistic interaction enhances magnesium storage performance and accelerates reaction kinetics. Using chlorine‐free Mg[B(hfip)4]2/DME electrolytes, the CuSP91 cathode containing an appropriate organic content displays a remarkably high reversible capacity of 285 mAh g−1 at 50 mA g−1, and demonstrates a stable capacity of 220 mAh g−1 at 100 mA g−1, surpassing pure CuS cathode in terms of shorter activation time. The CuSP91 cathode maintains a discharge capacity of 55 mAh g−1 over 1000 cycles at 500 mA g−1. A co‐redox mechanism is revealed through in/ex situ investigations and analyses. Overall, this research contributes valuable insights targeting the development of advanced organic–inorganic hybrid composite cathode materials in next‐generation energy storage systems.

High-performance novel ZIF-67 and ZIF-67@MWNTs composite adsorbents for efficient removal of pharmaceutical contaminant from water: Exceptional capacity and excellent reusability

The removal of pharmaceutical waste products like ibuprofen (IBP) from water is very important for the environment and the health of human and aquatic organisms. In the present work, the adsorption of IBP from aqueous solution was investigated by synthesizing novel ZIF-67 and ZIF-67@MWNTs hybrid composite material by incorporating ZIF-67 particles with carboxyl functionalized multiwalled carbon nanotubes (COOH-MWNT). The synthesized ZIF-67 and ZIF-67@MWNTs adsorbents were characterized by the XPS, XRD, SEM, TEM, BET, FTIR, and TGA analysis to examine their physio-chemical properties. The synthesized novel ZIF-67 has a 1743 m2/g BET surface and 0.692 cm3/g total pore volume. The IBP adsorption process including isotherm and kinetic studies as well as the effect of different parameters i.e. pH, initial concentration, time, adsorbents, and their dosage were examined. Among all the synthesized composite materials, the ZIF-67@MWNT-50 mg material showed the highest IBP adsorption capacity of 841 ± 5 mg/g, about 467 ± 5 mg/g more than the ZIF-67 following the Langmuir and pseudo-second-order model. The enhancement in the IBP adsorption is because of the incorporation of COOH-MWNT and the presence of a large number of active binding sites which showed the van der Waal interactions, host–guest interactions, π- π interactions, and H-bonding between the adsorbate and adsorbent. For the detailed study of the IBP adsorption mechanism of ZIF-67, molecular dynamic (MD) simulations were performed. Additionally, the reusability of ZIF-67@MWNT-50 mg material via a simple regeneration method up to five cycles while maintaining about 96 % adsorption capacity of the pristine non-used ZIF-67@MWNT-50 mg material revealed its importance as an effective adsorbent for the adsorptive elimination of different pharmaceutical hazardous materials from water.

Societal impact of recycling waste into composite materials

Demands for consumer goods and synthetic materials have increased significantly due to rapid population growth. As a result, environmental pollution, natural disasters and catastrophes, and controlling and recycling waste have become crucial issues for global sustainability and developing a circular economy. Besides the various sources, solid waste is generated from medical fields, ready-made garment (RMG) industries, and human hair during their service time and life. Human hair, face masks, and RMG waste are disposed of in landfills, buried, and incinerated without recycling. It creates dust and microparticles and develops CO2, methane, and harmful gases before fully decomposing in landfills, promoting environmental hazards and degrading air quality and social attributes. In addition, it causes the infiltration of microplastics and other micro/nano-particles into aquatic life, birds, and animals, and ultimately into human organs through food chains. It can be controlled by reducing, reusing, and recycling waste into useful materials and resources. Therefore, scientists seek to replace synthetic materials by developing bio-composites through recycling waste. This study explores the social impact of recycling human hair, waste face masks, and RMG waste into composite fields, which will help to reduce environmental pollution and global warming, achieve sustainability, develop a circular economy, and deter climate change. In contrast to societal impacts, the scalability, cost-effectiveness, and long-term durability of composites will not be an issue since the cost of waste is tiny, composite's strengths are higher than some natural fiber-reinforced composites, and those wastes can also be used to fabricate hybrid composites as cheap constituents.

Enhanced mechanical, tribological and corrosion properties of graphite and carbon nanotube-reinforced copper-based hybrid composites

Copper (Cu)-based hybrid composites were fabricated by powder metallurgy, incorporating Graphite (Gr) and Carbon nanotube (CNT) reinforcements at various fractions. The composites were formed using a cold pressing technique and subsequently sintered at various temperatures. The structural properties of the hybrid composites were evaluated using Scanning Electron Microscopy (SEM), Energy Dispersion Spectrum (EDX) and X-ray diffraction (XRD). Hardness, compression, wear and corrosion tests were performed to show the effect of the reinforcements. It was shown that the hardness of Gr and CNT reinforcements have significantly improved the properties of pure Cu. The Cu-Gr-2CNT hybrid composite, which was subjected to sintering at a temperature of 850°C, exhibited the highest level of hardness, showing a significant increase of 51.4% in comparison to the pure Cu sample. While the compressive stresses increased in the Cu matrix with the addition of Cu-Gr, it increased to 350 MPa with the addition of 2 wt% CNT. The hardness value exhibited a similar increase and was measured to be 122 HV in Cu-Gr-2CNT. During the wear tests, the coefficient of friction values fell by 9.2% for Cu-2CNT, by 3.88% for Cu-CNT, by 3.92% for Cu-Gr-2CNT, and by 5.27% for Cu-Gr-CNT, as compared to pure Cu. The comprehensive findings demonstrated that the tests and analyses yielded consistent results, and the utilization of various combinations of Gr and CNT reinforcements enhanced the mechanical, tribological, and corrosion resistance properties of the fabricated hybrid composites. Nevertheless, the combination of Cu-Gr-2CNT yielded the most advantageous outcomes.