Polypropylene Hybrid Composites Research Articles

The investigation of the mechanical thermal and physical properties of using waste toner/MCC/old newspaper fiber in polypropylene hybrid composites

AbstractIn this study, the effects of polypropylene (PP) composites produced by adding 10% old newspaper fibers (ONP), 5% microcrystalline cellulose (MCC), 3% polypropylene carbonate (PPC), and waste toner from 1% to 4% on the mechanical properties, physical properties, morphological, and thermal properties were investigated. According to the FTIR‐ATR and SEM‐EDS analysis results, it was determined that a significant part of the waste toner used in the study consisted of polystyrene co‐acrylate, and the remaining part consisted of carbon black and trace amounts of silicate. In the research, it was determined that the flexural and tensile strengths of MCC/ONP/PP composites containing 1% waste toner and 3% PPC increased by 13% and 46%, respectively, compared to the control sample. Additionally, the samples with the lowest water absorption values were measured in composites containing 1% waste toner and 3% PPC. The highest crystallinity value (50.75%) was obtained with the use of 1% waste toner and 3% PPC in MCC/ONP/PP composites. However, with waste toner usage above 1%, the mechanical, thermal properties, and water absorption rate have slightly decreased. As a result of the study, it was concluded that up to 1% waste toner with 3% PPC can be used successfully in MCC/ONP/PP composites.

Multi‐objective optimization of hybrid polypropylene composites for enhanced mechanical, thermal, and flame‐retardant properties

Multi‐objective optimization of hybrid polypropylene composites for enhanced mechanical, thermal, and flame‐retardant properties

Mechanical Characterization, Water Absorption, and Thickness Swelling of Lightweight Pineapple Leaf/Ramie Fabric-Reinforced Polypropylene Hybrid Composites.

Fiber-reinforced composites are among the recognized competing materials in various engineering applications. Ramie and pineapple leaf fibers are fascinating natural fibers due to their remarkable material properties. This research study aims to unveil the viability of hybridizing two kinds of lignocellulosic plant fiber fabrics in polymer composites. In this work, the hybrid composites were prepared with the aid of the hot compression technique. The mechanical, water-absorbing, and thickness swelling properties of ramie and pineapple leaf fiber fabric-reinforced polypropylene hybrid composites were identified. A comparison was made between non-hybrid and hybrid composites to demonstrate the hybridization effect. According to the findings, hybrid composites, particularly those containing ramie fiber as a skin layer, showed a prominent increase in mechanical strength. In comparison with non-hybrid pineapple leaf fabric-reinforced composites, the tensile, flexural, and Charpy impact strengths were enhanced by 52.10%, 18.78%, and 166.60%, respectively, when the outermost pineapple leaf fiber layers were superseded with ramie fabric. However, increasing the pineapple leaf fiber content reduced the water absorption and thickness swelling of the hybrid composites. Undeniably, these findings highlight the potential of hybrid composites to reach a balance in mechanical properties and water absorption while possessing eco-friendly characteristics.

Mechanical and thermal characterization of elastomer modified polypropylene hybrid composites reinforced with hazelnut shell and wollastonite fillers

AbstractThe demand for sustainable and recyclable materials in industrial applications has led to a surge in interest in green composites, particularly those incorporating natural fillers derived from agro‐food industry waste. This study investigates the mechanical and thermal properties of polypropylene (PP) hybrid composites filled with hazelnut shell and wollastonite, along with the effect of styrene‐ethylene/butylene‐styrene (SEBS) and SEBS‐g‐maleic anhydride (SEBS‐g‐MA) compatibilizers. Various characterization techniques, including tensile, flexural, and impact tests, as well as differential scanning calorimetry (DSC), thermogravimetry (TGA), and scanning electron microscopy (SEM) analyses, were employed to evaluate the composites. Results demonstrate that the addition of wollastonite significantly improves mechanical properties, while hazelnut shell filler affects thermal behavior and stability. SEBS and SEBS‐g‐MA compatibilizers enhance impact resistance; however, they lead to a decrease in other mechanical properties. DSC and TGA analyses demonstrate changes in crystallization behavior and thermal stability due to filler and compatibilizer incorporation. SEM microstructure images show the distribution of SEBS and SEBS‐g‐MA within the composite structure, affecting mechanical and thermal properties. Overall, this study highlights the importance of filler selection, compatibilizer addition, and their distribution in attaining desired properties for industrial applications. Future research should focus on optimizing formulations for specific uses and assessing long‐term performance under real‐world conditions.

Thermal, Mechanical Properties and Finite Element Analysis of Polypropylene Hybrid Composites from Nonmetallic Fractions of Waste Printed Circuit Boards (WPCBs) and Shellfish Waste

Thermal, Mechanical Properties and Finite Element Analysis of Polypropylene Hybrid Composites from Nonmetallic Fractions of Waste Printed Circuit Boards (WPCBs) and Shellfish Waste

Thermo-Mechanical, Structural, and Biodegradability Properties of Water Hyacinth and Sheep Wool Fiber Reinforced Hybrid Polypropylene Composites

Hybrid fiber reinforcements can incorporate a wider array of qualities than single fiber reinforcement. Instead of synthetic fibers, applying plant and animal-based organic materials as reinforcement in polymer matrix offers certain benefits, such as low price, greater availability, and better biodegradability. In the present study, water hyacinth fiber and sheep wool fiber reinforced polypropylene hybrid composites were fabricated at three different (5, 10, and 15 wt.%) fiber loading. The effect of fiber loading on thermo-mechanical, structural, and biodegradability properties was subsequently investigated. The manufacturing process of the composite material was carried out with utmost consideration for biodegradability, since polypropylene, the primary constituent, is not inherently biodegradable. The insertion of fibers into the polypropylene matrix showed variance in properties of different aspects. The tensile strength of the composites displayed a downward trajectory (from 25 to 10 MPa) with a 15% increase in fiber loading due to voids, and fiber dispersion, while impact strength exhibited an opposite trend (from 25 to 32 J/m). Except for hardness, all the mechanical properties degraded slightly after the employment of the reinforcement. Fourier transform infrared spectroscopic analysis revealed the movement of typical peaks and the appearance of new peaks demonstrating the bonding between the fiber and the matrix. Thermogravimetric analysis showed that the thermal degradation temperature of the composites improved at maximum fiber loading. On the other hand, the goal of achieving biodegradability has been succeeded by the implementation of a combination of plant and animal-based fibers as biodegradability of the manufactured composites thrives with increasing fiber content for the presence of cellulosic bonds, as evident from the FTIR spectrum. Even though some properties of the hybrid composite declined slightly with increasing fiber loading, the other characteristics, including service temperature and biodegradability experienced a prospective advancement. Hence, the 15% fiber-loaded composite was found to be a potential candidate in terms of slightly high temperature and environment-friendly applications.

Long coir and glass fiber reinforced polypropylene hybrid composites prepared via wet-laid technique

Natural fiber composites offer an advantage in terms of weight saving for many automotive applications; however, many natural fiber composites lack properties to justify substitution for synthetic composites. Hybridizing the natural fiber composites by adding a fraction of synthetic fibers is an innovative approach to provide a balance between composite's performance and weight savings. In this study, coir fiber (40 wt%)-reinforced polypropylene (PP) composites were hybridized by substituting a fraction of coir fiber with glass fiber (0–30 wt%). The composites were prepared using a novel wet-laid technique followed by compression molding, where the fiber length is preserved. The composites prepared by hybridizing PP/coir fibers with glass fibers were light in weight (6–20% lighter compared to 40 wt% glass fiber reinforced PP) with significantly enhanced tensile (strength – 49–182%, modulus – 54–130%), flexural (strength – 41–104%, modulus – 64–193%), and impact properties (157 - 474%) compared to 40 wt% coir fiber reinforced PP composites. Furthermore, the addition of glass fiber (10–30 wt%) to coir fiber reduced the water-absorbing tendency (by 18–74%) of PP/coir fiber composites. All in all, this work has potential applications in automotive, mass transit, and truck applications where natural fiber composites are being investigated as alternatives to metal and/or fully synthetic composites.

Mechanical behavior of carbon/glass polypropylene hybrid composites

AbstractThis research investigates the influence of graphene and some additives on the mechanical behavior of polypropylene (PP). Anhydride maleic coupling agent (MAPP), graphene nanoplatelets (GNPs), and glass fiber (GF) were incorporated into the polymer matrix. The incorporation of MAPP and/or GNP significantly improved the affinity between the PP matrix and fibers while altering the surface morphology. More than 60% of the fibers showed a dimension lower than 0.5 mm. The tensile strength increased from 27.45 to 41 MPa for the neat PP compared to one of the composites. The strength modulus varied from 0.5 to 0.9 GPa. Mechanical tests showed that the addition of MAPP improved the tensile toughness (from 27.45 to 41 N mm mm−2) by 49%, while the GF increased tensile strength, albeit reducing elongation at break. The dynamic mechanical thermal analysis uncovered distinct behavioral variations among fiber‐reinforced samples, particularly in modulus peak differences. In rheological assessment, the presence of GF notably increased viscosity within certain shear rate ranges (at 100 [1/s], the viscosity goes from 200 to 300 Pa s to neat PP for some composites). This research highlights how chosen additives can influence a PP homopolymer's properties, offering useful insights for practical material processing and design.Highlights MAPP and GNP can increase PP and glass fiber interfacial bonding. Glass fiber raises tensile strength and decreases elongation. Sample with just GNP has a rougher surface, implying better energy dissipation. Glass fiber raises viscosity in the observed shear rate ranges. DMA demonstrates that MAPP and GNP have an influence on energy dissipation.

Synergistic reinforcing effect of fly ash and powdered wood chips on the properties of polypropylene hybrid composites

Synergistic reinforcing effect of fly ash and powdered wood chips on the properties of polypropylene hybrid composites

Synthesis, characterization, thermal and mechanical behavior of polypropylene hybrid composites embedded with CaCO<sub>3</sub> and graphene nano-platelets (GNPs) for structural applications

<abstract> <p>In this study, ultra-fine graphene nanoplatelets (GNPs) were employed as nanofillers to reinforce a polypropylene (PP) matrix. This was done in conjunction with a polypropylene grafted maleic anhydride (PP-MAH) compatibilizer and calcium carbonate (CaCO<sub>3</sub>), with the aim of improving the mechanical and thermal properties of the resulting hybrid composites. Formulations for the hybrid composites were fabricated by compounding the PP matrix with varying weight percentages of GNPs (x = 0.5, 1.0, 1.5, 2.0), 2 wt.% CaCO<sub>3</sub>, and 5 wt.% PP-MAH using a twin-screw extruder followed by injection molding. This research thoroughly investigates the mechanical and thermal characteristics. X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), and Fourier-transform infrared spectroscopy (FTIR) results confirm the successful development of hybrid composites. The thermal stability, crystallization temperature, melting temperature, tensile strength, flexural strength, and impact resistance were evaluated using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), universal testing machine, and low-velocity impact tester, respectively. The results indicated a significant improvement in the tensile strength of the PP matrix with the addition of GNPs, with the highest enhancement observed at 1.5 wt.% GNP loading, where the tensile strength reached a maximum of 40.54 MPa. This improvement was attributed to the proper interconnection, bonding, and compounding of PP with GNPs, thus leading to an increase in the load transfer efficiency.</p> </abstract>

Effect of waste toner powder on the performance of microcrystalline cellulose‐talc reinforced polypropylene hybrid composites

AbstractThis study examines reducing the environmental hazards of toner waste and producing low‐cost: high‐performance value‐added hybrid polypropylene‐PP‐composites. The incorporation of microcrystalline cellulose (MCC) and inorganic filler(s) into a polymer matrix leads to superior performance and environmental advantage compared to inorganic‐filled polymer composites. Waste toner (WT) was used up to 2% by weight with increments of 0.5 and the other fillers: MCC/talc/polypropylene carbonate loading ratios were kept constant as 5/10/3 wt% in this study. The production process of hybrid PP composites was carried out with single‐screw extrusion and molding. Chemical and thermal characterization of the filler and the hybrid PP composites were performed by FTIR and it was revealed that the main resin of WT consists of polystyrene co‐acrylate. In DSC analysis, the highest crystallinity value was calculated as 52.36% in the composite containing 1.5% waste toner. SEM micrographs proved the PPC prompts the dispersion quality of MCC and talc in the PP matrix. Mechanical, water absorption and surface properties of the hybrid composites were enhanced by adding WT at 1 and 1.5 wt%. Above this ratio, all properties of the hybrid composites moderately decreased. In light of the results, the WT could be utilized as a filler up to 1.5% in the PP‐matrix.Highlights TS of the composites increased by increasing the waste toner content to 1.5%. PP‐based hybrid composites had higher flexural properties than unfilled PP. The crystallinity increased up to the addition of 1.5% wt. PPC‐coupling agent promoted the interaction between talc/MCC and PP matrix.

Effect of fibre ratio and chemical treatment on thermo-mechanical and water absorption properties of bagasse and chicken feather reinforced hybrid polypropylene composites

ABSTRACT Employing plant and animal-based biodegradable resources as reinforcement in polymeric composites has undeniable advantages on synthetic fibres, including low cost, renewability, biodegradability, low energy consumption, and easy and safe handling. Bagasse is agricultural waste, while chicken feathers can also be collected from poultry industry waste – both hold the potential to be used as fibre reinforcement in polymer matrix composite. The incorporation of both hybrid fibres together might have a synergistic effect on several properties. In the present research, composites at 5% fibre weight were prepared using a hot-press machine, altering the contribution of individual fibre, keeping bagasse and chicken feather at the ratio of 1:1, 3:1 and 1:3. Subsequently, tensile, flexural, impact, hardness and water absorption tests and thermo-gravimetric analysis were executed. Composite materials with a greater portion of chicken feathers (bagasse:chicken = 1:3) demonstrated superior mechanical properties, as well as better water absorption, thermal stability as compared to composite materials with a more significant proportion of bagasse fibre. To ensure excellent adhesion between polymer matrix and fibre, a significant factor for excellent reinforcement, chemical treatment with 5% NaOH was conducted on both fibres. Five per cent NaOH-treated hybrid fibre-reinforced composite outperformed untreated composite in impact strength, hardness, and water absorption.

Tensile behavior of high-performance interlayer hybrid composites of polypropylene and glass fiber for civil engineering

Traditional interlayer fiber reinforced polymer (FRP) composites utilized in civil engineering are deficient in either the sufficient stiffness or ductility. For this, a study was conducted on the tensile behavior of interlayer hybrid FRP composites, which were composed of polypropylene (PP) and glass fabrics with an epoxy resin as the matrix and a central layer of glass fabric. This paper presents the design concept, failure mode, and constitutive model for glass/PP FRP composites. The experimental results indicate that the glass/PP FRP composites exhibit higher stiffness and ductile compared to traditional FRP composites, thereby demonstrating superior mechanical properties. Moreover, the finite element (FE) method was employed to identify all potential failure modes of glass/PP FRP composites, and it was concluded that only delamination failure mode is applicable in civil engineering. Based on the FE results, a failure mode map was generated for glass/PP FRP composites, which can facilitate rapid identification of its failure modes. To quantify the tensile behavior of these composites, a two-limit tensile constitutive model was developed. Considering that composites are typically designed for tension, the research presented in this paper can offer theoretical support for the implementation of glass/PP composites in civil engineering applications.

Comparative effects of different coastal weathering on the thermal, physical, and mechanical properties of rubberwood–latex sludge flour reinforced with polypropylene hybrid composites

The influence of coastal weathering in tropical countries is a concern in terms of applications of wood-plastic composites (WPCs). Therefore, developing the WPCs into hybrid composites for increasing the resistance to the coastal climate needs further investigation. The current work studies the effects of different coastal climates (Gulf of Thailand and Andaman Sea), exposure times, and latex sludge contents on the properties of rubberwood-latex sludge flour reinforced with polypropylene hybrid composites. The hybrid composites were manufactured with a twin-screw extruder for mixing and a compression molding machine for forming. The results revealed that the hybrid composites weathered for 12 months significantly (α = 0.05) decreased the modulus of rupture, modulus of elasticity, screw withdrawal strength, and hardness with a maximum reduction of 218.6%, 207.4%, 84.2%, and 11.4%, respectively. However, adding the latex sludge flour of about 25 wt% increased crystallinity degree and thermal stability as compared with the WPCs filling 50 wt% rubberwood flour. The hybrid composites weathered under the Andaman Sea exhibited less loss of all the mechanical properties than that weathered under the Gulf of Thailand. It is therefore suggested that the hybrid composites added to the latex sludge waste have the potential to be used to produce the engineering products that were applied under the coastal climates.

Investigation of Nano SiO2 Filler Loading on Mechanical and Flammability Properties of Jute-Based Hybrid Polypropylene Composites

Investigation of Nano SiO2 Filler Loading on Mechanical and Flammability Properties of Jute-Based Hybrid Polypropylene Composites

Influence of reprocessing cycles on the morphological, thermal and mechanical properties of flax/basalt hybrid polypropylene composites

Vegetable fibers hybridization with basalt ones is a suitable way to exploit the environmental advantages of vegetable fibers while preserving composites mechanical properties. Nevertheless, there are no studies available on the mechanical recycling of short fiber hybrid reinforced polymer composites. In light of this, the present work addressed the mechanical recycling of flax/basalt hybrid polypropylene composites up to seven reprocessing cycles, evaluating the effect on microstructure, thermal and mechanical behavior and providing a direct comparison with flax composites. The results proved that the interaction of flax and basalt fibers promotes a faster degradation of flax fibers length inducing a significant decrease in hybrid mechanical properties already at the second reprocessing cycle. Despite this, hybrids are able to ensure a higher flexural stiffness and flexural strength by 5.2% and 7.7%, respectively, and an impact strength by 29.8%, 24.0% and 16.6% higher than flax at −50 °C, room temperature and + 50 °C after the second reprocessing cycle, respectively. Considering the easier processability of hybrid composites thanks to a higher Melt Volume Flow Rate (MVR), they can be conveniently repurposed and mechanically recycled to produce components traditionally manufactured with flax fibers.

Fabrication and characterization of woven and comingled nonwoven sheet polypropylene hybrid composite by recycling and alkali-treated jute waste fibers

Natural fiber reinforced hybrid composite materials, with their enhanced characteristics, represent the future of our advanced material search. Natural fibers are the substitute for synthetics because their less manufacturing cost, bio-degradable, easy availability, durability, resistance to environmental degradation, etc., makes them popular nowadays. This paper presents how jute fibers are recycled from various jute waste sources. After recycling, jute fibers are used to fabricate the hybrid composites. Two forms of recycled jute sheets are used to fabricate the composites that is, woven sheets and nonwoven comingled (jute and polypropylene) sheets. The NaOH treatment was performed on recycled jute sheets with different concentrations (0%, 2%, 4%, 6%, and 8%). The hybrid composites are made using three distinct fiber-polypropylene weight fraction ratios (50/50, 40/60, and 30/70), as well as five different stacking sequences. Mechanical parameters such as tensile strength, elongation (%), flexural strength, impact strength, and water absorption were evaluated. Among the five fabricated combinations, it is found that the combination of (40/60), (JJJ), with 2% NaOH treated fibers composite gives the maximum tensile and flexural strength, and the combination of (30/70) (CCC) with 2% NaOH treated fiber composites exhibits the maximum Impact strength. The combination of (50/50), and (CCC) with 2% NaOH treated fiber composite gives the maximum Elongation %, and the combination of (50/50), (JJJ), and 0% NaOH treatment yields the maximum water absorption. A relationship between fabric loading, tensile modulus, and flexural modulus and other relationship between chemical treatment and water absorption% has been established for JJJ laminated sheet which shows almost best properties among them. These assessments make them most valuable for a variety of sectors, including car, aircraft, marine, and building construction.

Thermal Adsorption and Mechanical Behaviour of Polypropylene Hybrid Composite Synthesized by Glass/Hemp Fibre via an Injection Moulding Process

Thermoplastic-based polymers are gathering importance in several engineering fields like electrical, electronic, automotive, aerospace, and structural. The additions of secondary phase reinforcements such as natural and synthetic fibre improve thermoplastic-based polymer’s properties. The thermoplastic and natural fibre combinations are found to have low mechanical strength and incompatibility and need special treatment for synthesizing the natural fibre. The present experimental investigation deals with the enhancement of polypropylene hybrid composite by using the combinations of glass (synthetic)/hemp (natural) fibre for the ratio of 0 : 35, 5 : 30, 10 : 25, and 15 : 20 reinforced with 5 wt% compatibilizer through injection moulding. The revealed test results of polypropylene hybrid composite showed improved mechanical impact and flexural and tensile strength of 37.5%, 14.2%, and 21.1%, respectively. The thermal adsorption characteristics were evaluated by thermogravimetric analysis apparatus. It showed the decomposition of composite limited by hemp fibre at 27°C to 700°C.

Characterisation of Nanoclay and Spelt Husk Microfiller-Modified Polypropylene Composites.

Current research is devoted to the investigation of spelt husk (SH) and nanoclay-modified compatibilised polypropylene (PP) binary and ternary composites for injection-moulding applications. PP composites were obtained using twin-screw extrusion. The content of mechanically milled SH microfiller with aspect ratio within 2 and 6 was fixed at 40 wt.%, whereas the amount of nanoclay functional filler in the polypropylene matrix was changed in the range from 0.5 to 5 wt.%. Nanoclay filler was introduced in the polypropylene matrix either in the form of nanoclay powder (C) or as a masterbatch (M). Regular distribution of the clay nanofiller within the polymer matrix has been observed, disregarding its form and concentration. The effects of the individual or combined addition of SH microreinforcement and nanoclay fillers on the rheological, mechanical, calorimetric, and thermal properties of the developed PP composites were investigated. It is revealed that the addition of the nanoclay fillers insignificantly influences the viscosity of both PP nanocomposites and hybrid composites with SH. Additionally, for PP nanocomposites, remarkable increases in tensile and flexural modules and strength are observed by maintaining considerable ultimate deformations, mainly in the case of M-containing systems. Concomitantly, because of the addition of the nanoclay filler, the improvement in thermal stability of PP nanocomposites and PP hybrid composites with SH is observed. As a result of SH addition, considerable increases in tensile and flexural modules are also observed. Results of the research demonstrate the potential of the use of natural materials (agricultural residues and clay minerals) for the development of PP composites with increased stiffness and thermal properties.

Modeling the mechanical properties of polypropylene/lignin/flax hybrid composites

Flax and lignin were used to prepare hybrid polypropylene composites. The lignin contents were varied between 0 and 50 vol%, while the amounts of flax used were 0, 10, 20, and 30 vol%. The components were homogenized in a twin-screw compounder and then injection molded into tensile bars. Tensile and impact tests were used to characterize the mechanical properties, and the structures were studied by scanning electron microscopy. The simultaneous effects of reinforcement on composite properties were analyzed quantitatively with models to establish synergies or a coupling effect of lignin. The agreement between measured results and predicted values proved to be excellent. The models were also successfully applied to data published in the literature. Lignin increased the strength from 10 to 20 MPa, and a smaller amount of added flax increased the strength up to 30 MPa. Modeling also established the stronger reinforcing effect of flax; the corresponding B parameters for lignin and flax were 3.7 and 5.9 for strength and 1.0 and 5.2 for impact resistance, respectively. The two reinforcements acted independently; their effects were additive, and synergism could not be detected. Only quantitative analysis and modeling offer reliable information about the effect of components in hybrid materials.