Manufacture Of Composite Materials Research Articles

Surface Wettability of Lignin Materials from Supercritical Water Hydrolysis of Wood

To meet the demands of the evolving circular economy, there is a growing need for renewable resources as base materials for innovative, easily recyclable products. Lignin, the second most abundant biopolymer, has emerged as a promising source of aromatics and reinforcing agent in polymer composites. For the successful manufacturing of homogeneous composite materials, good bonding between the coexisting phases is essential to prevent the formation of voids and agglomerates. Therefore, understanding the surface properties of these materials is crucial for designing optimal composite compounds. In this study, the wettability of lignin-cellulose composites and lignin samples obtained through supercritical water hydrolysis (SCWH) of birch wood is investigated. The contact angle (CA) technique, specifically the sessile drop method, was employed to assess and compare the wettability of SCWH lignin with commercially available lignin and raw birch wood. The results provide insights into their surface energy, adhesion, and hydrophilic or hydrophobic characteristics under processing conditions. All samples exhibited hydrophilicity, with an initial CA approximately 40 °, except for raw birch wood, which had a higher initial CA of ~ 64°. Notably, when lignin is accompanied by significant amounts of cellulose, different trends in CA changes over time were observed. The influence of pressure on the CA between water and these polymers was also analyzed, but no significant impact was detected. This research advances the development of lignin-based materials with tailored surface properties for various industrial applications.

Current status and challenges of lightweight design and manufacturing technology for aerospace structures

Lightweight technology refers to the technology of reducing the structural mass by optimizing materials, structures and manufacturing processes while meeting the requirements of structural performance. It has become one of the key technologies for the development of the new generation of aerospace equipment. This paper first analyzes the development history of lightweight technology. Secondly, from the perspectives of design principles, composition methods and optimization methods, three types of lightweight design methods are introduced: bionic structure design, cellular structure design and efficient topology optimization design. Then, from the perspective of lightweight manufacturing processes and modes, the application of additive manufacturing, collaborative manufacturing and composite material manufacturing in lightweight manufacturing of aerospace structures is explained. Finally, the challenges and future development of lightweight technology are discussed.

Subtractive manufacturing of composite materials with robotic manipulators: a comprehensive review

AbstractRobotic manipulators play an innovative role as a new method for high-precision, large-scale manufacturing of composite components. However, machining composite materials with these systems presents unique challenges. Unlike traditional monolithic materials, composites exhibit complex behaviour and inconsistent results during machining. Additionally, robotic manipulator as a machine tool often associates with stiffness and vibration issues which adds another layer of complexity to this approach. By employing a comprehensive analysis and a combination of quantitative and qualitative review methodology, this review paper aims to survey diverse properties of composite materials by different categories and their interaction with machining processes. Subsequently, a survey of manufacturing techniques for composite machining following with a review in various modeling practices to capture material machining behaviour under a systematic framework is presented. Thereafter, the reviewed literature examines the errors inherent in robotic systems, alongside ongoing research efforts in modeling to characterise robot behaviour and enhance its performance. Afterward, the paper explores the application of data-driven modelling methods, with a primary focus on digital twins, in enabling real-time monitoring and process optimisation. Finally, this paper aims to identify the gap in this field and suggests the potential routes for future research and application as well as their challenges.

Manufacturing of Sustainable Composite Materials: The Challenge of Flax Fiber and Polypropylene.

The widespread use of synthetic composite materials has raised environmental concerns due to their non-biodegradability and energy-intensive production. This paper explores the potential of natural composites, specifically flax-polypropylene, as a sustainable alternative to traditional composites for semi-structural applications. In fact, the mechanical properties of flax-polypropylene composites are similar to synthetic ones (such as those made with E-glass fibers). However, processing challenges related to fiber-matrix interaction and material degradation necessitate suited process parameters for this sustainable type of material. For this reason, this review highlights the importance of optimizing existing manufacturing processes, such as hot press molding, to better accommodate the specific characteristics of polypropylene-flax composites. By refining the parameters and techniques involved in hot press molding, researchers should overcome current limitations and fully capitalize on its potential to produce composite materials of optimal quality. Therefore, a comprehensive literature assessment was conducted to analyze the properties and processing challenges of flax-polypropylene composites. Key process parameters affecting the material's performance are identified and discussed. By optimizing process parameters for flax-polypropylene composites, it is possible to develop a sustainable and high-performance material with a reduced environmental footprint. Further research is needed to scale up production and explore different applications for this sustainable composite material.

Study of technological aspects of manufacture of polymer composite material by centrifugal fiber forming method

The object of the study is the technological aspects of manufacturing the hesperidin polymer composite material by the method of centrifugal fiber formation. This method is considered the basis of a relatively new and cost-effective way of producing solid dispersion systems. Using the centrifugal molding method, it is possible to obtain highly soluble forms of active pharmaceutical ingredients in the form of fibers of various sizes using a wide range of polymeric materials with high speed and low cost due to simple equipment. Due to the innovative design of the centrifugal fiber formation method, it was chosen for the development of solid dispersion systems of the bioflavonoid hesperidin, which has a wide range of different pharmacological properties, but low bioavailability. Solid dispersed systems of hesperidin by the method of centrifugal fiber formation were produced on the basis of a pharmaceutically acceptable polymeric carrier of polyvinylpyrrolidone and mannitol. For the obtained solid dispersed systems, such basic pharmaco-technological characteristics as loss in mass during drying, bulk volume, bulk volume after shrinkage, bulk density, bulk density after shrinkage, compressibility index, Gaussner coefficient were determined. Comprehensive tests of the stability of the studied samples of the solid dispersion system of hesperidin were carried out under the conditions of accelerated tests for 6 months. According to the obtained results, it was established that the developed polymer composite material is stable in the studied conditions, and its conditional shelf life is 2 years. A technological scheme for the production of the hesperidin polymer composite material in the form of solid dispersed systems by the method of centrifugal fiber formation has been developed. In particular, the technological process is described step by step and the critical indicators of quality control of the obtained composite material are determined. The proposed technology can be implemented in modern chemical and pharmaceutical industries. This will contribute to the expansion of the market of highly effective socially oriented medicines.

Additive Manufacturing of Composite Materials and Functionally Graded Structures Using Archerfish Hunting Technique

ABSTRACTThis paper proposes an optimisation method for fabricating composite materials and functionally graded structures. Using the proposed method, 3D printing of copper (Cu)–polyethylene (PE) composite, Al2O3–ZrO2 ceramic composite and functionally graded CuO foams are utilised. This work aims to advance the capabilities of additive manufacturing by leveraging nature‐inspired approaches to create complex, tailored structures with enhanced performance across various industries. The major objective of the proposed method is to reduce the feed rate and increase the airflow rate and airflow temperature for the heat transfer process. Using the proposed technique in the advanced preparation conditions, Cu–PE composites with unreliable Cu substances are fabricated. The PE binder particle is melting as well as forming thick composites by means of soft surfaces. Using the proposed AHO approach, functionally graded materials with common distributions can be efficiently optimised. By then, the proposed model is implemented on the MATLAB platform, and its execution is calculated using the current procedures. The proposed technique displays superior outcomes in all existing methods like wild horse optimiser, particle swarm optimisation and heap‐based optimiser. The proposed method shows a throughput of 57 mm3. The existing method shows the throughput of 32, 27 and 45 mm3. The results show that the proposed method has higher throughput compared with existing methods.

Innovative polymer‐based composite materials in additive manufacturing: A review of methods, materials, and applications

AbstractThis review paper delves into the manufacturing methods, material properties, and applications of polymer‐based composites in the field of advanced manufacturing, offering a detailed explanation of their production through various additive manufacturing (AM) techniques and their diverse applications across multiple industries. Polymer‐based composite materials have emerged as crucial elements in AM due to their enhanced properties and design versatility, enabling the creation of components with unprecedented performance characteristics. The paper comprehensively covers the major AM methods employed for composite materials, including fused filament fabrication, Digital Light Processing/Stereolithography, Direct Ink Writing, and Selective Laser Sintering. Each of these methods is explored in terms of its mechanism, suitability for different composite materials, and the resulting material properties. The review also provides an insightful analysis of how these AM techniques are revolutionizing industries such as soft robotics, mechanical, electrical, and biomedical fields. The paper concludes by discussing the current challenges in this domain and projecting future trends in the development and application of composite materials in advanced manufacturing. This review aims to offer a comprehensive resource for researchers and practitioners in the field, highlighting the transformative impact of polymer‐based composites in AM and their growing significance across various sectors.Highlights Comprehensive review and classification of novelties in printing method for polymer based composite material manufacturing. Introduces innovative techniques to create and enhance material properties of composites. Explores interdisciplinary applications in biomedical, electronics, and sensors, demonstrating material versatility. Provides a systematic correlation between manufacturing method, material properties, and applications of novel polymer‐based composites.

Development of PLA-Waste Paper Biocomposites with High Cellulose Content.

In this study, the integration of paper industry waste with high cellulose content into biocomposites of polylactic acid (PLA), a widely used biobased polymer material, was investigated. The PLA/waste biocomposite samples (0-25 wt.%) were manufactured using the extrusion and injection moulding techniques. The mechanical test results showed improvements in terms of tensile properties and a decrease in impact strength as the percentage of residue increased. The melting temperature decreased, and the crystallinity increased in all biocomposites according to the Differential Scanning Calorimetry (DSC) analysis. Water absorption increased proportionally with the percentage of residue, attributed to the higher cellulose content in the biocomposites, determined by Fourier transform infrared spectroscopy (FT-IR) and X-ray diffraction (XRD) techniques. The scanning electron microscopy (SEM) fracture analysis demonstrated effective reinforcement-matrix cohesion, supporting the previously observed behaviour of the analysed materials. This work highlights the potential of using waste from the paper industry as reinforcement in PLA matrices, opening new perspectives for sustainable applications in the framework of the manufacture of composite materials.

Chemical Modification of Nanocrystalline Cellulose for Manufacturing of Osteoconductive Composite Materials.

Cellulose is one of the main renewable polymers whose properties are very attractive in many fields, including biomedical applications. The modification of nanocrystalline cellulose (NCC) opens up the possibility of creating nanomaterials with properties of interest as well as combining them with other biomedical polymers. In this work, we proposed the covalent modification of NCC with amphiphilic polyanions such as modified heparin (Hep) and poly(αL-glutamic acid) (PGlu). The modification of NCC should overcome two drawbacks in the production of composite materials based on poly(ε-caprolactone) (PCL), namely, (1) to improve the distribution of modified NCC in the PCL matrix, and (2) to provide the composite material with osteoconductive properties. The obtained specimens of modified NCC were characterized by Fourier-transform infrared spectroscopy and solid-state 13C nuclear magnetic resonance spectroscopy, dynamic and electrophoretic light scattering, as well as thermogravimetric analysis. The morphology of PCL-based composites containing neat or modified NCC as filler was studied by optical and scanning electron microscopy. The mechanical properties of the obtained composites were examined in tensile tests. The homogeneity of filler distribution as well as the mechanical properties of the composites depended on the method of NCC modification and the amount of attached polyanion. In vitro biological evaluation showed improved adhesion of human fetal mesenchymal stem cells (FetMSCs) and human osteoblast-like cells (MG-63 osteosarcoma cell line) to PCL-based composites filled with NCC bearing Hep or PGlu derivatives compared to pure PCL. Furthermore, these composites demonstrated the osteoconductive properties in the experiment on the osteogenic differentiation of FetMSCs.

Sustainable All-Cellulose Biocomposites from Renewable Biomass Resources Fabricated in a Water-Based Processing System by the Vacuum-Filtration-Assisted Impregnation Method.

The increasing awareness of global ecological concerns and the rising sustainability consciousness associated with the manufacturing of non-renewable and non-biodegradable composite materials have led to extensive research on product and process developments of more sustainable, environmentally friendly, and fully biodegradable biocomposites for higher-value end-use applications. All-cellulose composites (ACCs) are an emerging class of biocomposites, which are produced utilizing solely cellulose as a raw material that is derived from various renewable biomass resources, such as trees and plants, and are assessed as fully biodegradable. In this study, sustainable ACCs were fabricated for the first time based on the full dissolution of commercially available sulfite dissolving (D) pulps as a matrix with concentrations of 1.5 wt.% and 2.0 wt.% in an aqueous NaOH-urea solvent, and they were then impregnated on/into the pre-fabricated birch (B), abaca (A), and northern softwood (N) fiber sheets as reinforcements by the vacuum-filtration-assisted impregnation approach. This research aimed to investigate the effects of the impregnated cellulose matrix concentrations and types of the utilized cellulose fiber reinforcements (B, A, N) on the morphological, crystalline, structural, and physio-mechanical properties of the ACCs. The highest degrees of improvements were achieved for tensile strength (+532%, i.e., from 9.24 MPa to 58.04 MPa) and strain at break of the B fiber-reinforced ACC B1.5 (+446%, i.e., from 1.36% to 4.62%) fabricated with vacuum impregnation of the 1.5 wt.% cellulose matrix. Noticeably, the greatest improvements were attained in strain at break of the A and N fiber-reinforced ACCs A2.0 (+218%, i.e., from 4.44 % to 14.11%) and N2.0 (+466%, i.e., 2.59% to 14.65%), respectively, produced with vacuum impregnation of the 2.0 wt.% cellulose matrix. The study highlights the diverse properties of the all-cellulose biocomposite materials that could, expectedly, lead to further development and research for upscaled production of the ACCs.

Cold Spray Technology and Its Application in the Manufacturing of Metal Matrix Composite Materials with Carbon-Based Reinforcements

Cold spray technology, as an emerging surface engineering technique, effectively prepares hard coatings by high-speed projection of powder materials onto substrates at relatively low temperatures. The principal advantage of this technology lies in its ability to rapidly deposit coatings without significantly altering the properties of the substrate or powder materials. Carbon-based materials, especially carbides and diamond, etc., are renowned for their exceptional hardness and thermal stability, which make them indispensable in industrial applications requiring materials with high wear resistance and durability at elevated temperatures. This review elucidates the fundamental principles of cold spray technology, the key components of the equipment, and the properties and applications of hard coatings. The equipment involved primarily includes spray guns, powder feeders, and gas heaters, while the properties of the coatings, such as mechanical strength, corrosion resistance, and tribological performance, are discussed in detail. Moreover, the application of this technology in preparing metal matrix composite (MMC) materials with carbon-based reinforcements, including tungsten carbide, boron carbide, titanium carbide, and diamond, are particularly emphasized, showcasing its potential to enhance the performance of tools and components. Finally, this article outlines the challenges and prospects faced by cold spray technology, highlighting the importance of material innovation and process optimization. This review provides researchers in the fields of materials science and engineering with a comprehensive perspective on the application of cold spray technology in MMC materials with carbon-based reinforcements to drive significant improvements in coating performance and broaden the scope of its industrial applications.

Functional and structural modification of polyvinyl alcohol/carbon nanotubes composite fibers

This research was based on the synthesis of new materials with capacitive properties and low cost, seeking efficient energy storage, through the manufacture and characterization of composite materials of polyvinyl alcohol (PVA)/multiwalled carbon nanotubes with carboxyl group (MWCNTs-COOH) (1 %) for electrodes. Forcespinning and electrospinning techniques were used to develop composite fiber films and compare the physical structure of the fibers and its influence on their capacitive properties. These samples were characterized by SEM, FESEM, FT-IR, XRD, TGA, Raman spectroscopy and electrochemical techniques. The characterization of the composites makes evident the structural modification that the material underwent after the treatments. The electrochemical parameters were measured by electrochemical impedance spectroscopy (EIS), with the samples immersed in H2SO4 1 M as electrolyte. The PVA/MWCNTs-COOH composites with thermal treatment (340 °C) showed a considerable decrease in total impedance of up to 6 orders of magnitude (124 Ω) with respect to the blank sample (2.3 × 108 Ω), as a function of the immersion time in the acid solution. As well as, an increase in the specific capacitance of up to 8 orders of magnitude (1.01×10−2 F cm−2) with respect to the blank sample (5.07 × 10−10 F cm−2) for the composite manufactured by the electrospinning technique. The obtaining of fibers with directionality as a result of the forcespinning technique, the highly crossed network observed by electrospinning and the electrochemical properties shown by the structural modification of PVA/MWCNTs-COOH composite, make it, a material with potential technological applications such as electrode in electrochemical capacitors.

Optimization of the VARTM Process for Prototyping a Bumper Using Hybrid Composite Materials

To provide an alternative for manufacturing auto parts using composite materials, the Vacuum Assisted Resin Transfer Molding (VARTM) process was utilized to prototype the bumper for the Chevrolet Aveo vehicle. This technique emerges as an alternative for composite material manufacturing, allowing for rapid and high-quality production of advanced composites. In this study, a hybrid composite material reinforced with fiberglass, cabuya fiber, IN2 epoxy resin, an infusion mesh, peel ply, and a vacuum bag was employed. To optimize the VARTM process in bumper prototyping, several simulations of resin flow were conducted with different locations of resin injection and vacuum entry points. Autodesk Moldflow Insight software facilitated the modification and addition of resin injection points to observe the flow evolution, thus determining the filling time for each proposed design. Six different designs were applied for the bumper mold filling. The proposed linear flow design reduced the total filling time of the bumper mold by 81.56% compared to the other five designs analyzed. The result of the numerical simulation was validated through the experimental process, where a high degree of concordance in the mold filling time was achieved between both methods.

An adhesion promoter layer for high-frequency printed circuit boards (PCBs) via initiated chemical vapor deposition

Establishing robust bonding between dissimilar materials, particularly metal and polymer composites is a significant challenge in electronics. This study focuses on enhancing the interfacial adhesion strength between super flat copper foil and ultra-low-loss dielectric material, crucial for optimizing the performance of high-frequency printed circuit boards (PCBs). Despite the common practice of mechanically treating the copper surface, which increases the surface roughness and significantly deteriorates signal transmission for high-frequency applications, herein, we present a novel approach involving a thin adhesion promoter layer coating onto an ultra-low-profile copper foil using the one-step, solventless technique of initiated vapor deposition (iCVD). Poly(glycidyl methacrylate) (pGMA) is utilized as the adhesion promoter and deposited on a super-flat profile copper surface via iCVD. The results demonstrate that the straightforward iCVD pGMA deposition significantly improves adhesion performance to 0.68 N/mm between the copper foil and prepreg, representing a 70 % improvement compared to 0.4 N/mm for the untreated copper surface. This research introduces a promising, scalable, and environmentally friendly adhesion promoter layer for copper-clad laminates (CCLs), particularly in the manufacturing of high-performance composite materials for the electronics industry.

Interfacing the IoT in composite manufacturing: An overview

Abstract It is a well-known fact that many sophisticated works consume a lot of human resources, leading to the need to find effective alternative. The manufacturing industry demands a lot of human resources, with around half of the global working population participating in this sector. Challenges such as sudden conflicts in the data, disasters, and loss of productivity are encountered by the manufacturing industries and can be overcome by monitoring machine performance data and automatically configuring the machines according to changing needs. This emphasizes the importance of the Internet of Things (IoT) in addressing niche areas of manufacturing. IoT is a buzzword heard everywhere around the globe. Implementing this technology makes most of the work more accessible than other conventional methods. This has created a lot of research interest on this topic. Among many manufacturing sectors, polymer composite material manufacturing is one of the most demanding. This review article purely focuses on polymer composite manufacturing and its allied processes. The consolidation of data is based on the influence of IoT on the extraction of fibers and manufacturing of polymer composite material using novel techniques, quality assessment of manufactured polymer composite material, challenges faced in exploring the use of IoT, and future scope. It can be stated from the survey that various researchers have minimally explored the incorporation of IoT, but its future looks very promising in terms of producing high-quality products at less time and lower cost by integrating this technique with conventional methods.

Bamboo as a natural optimized fiber reinforced composite: interfacial mechanical properties and failure mechanisms

Bamboo is a typical natural fiber-reinforced composite with an optimized distribution of vascular bundles as reinforcement and parenchyma tissues as bio-matrix. The interfacial bonding performance between vascular bundles and parenchyma tissue is critical for the mechanical properties and failure mechanisms of bamboo. This study employed pull-out tests to determine the interfacial shear strength (IFSS) between bamboo vascular bundles and parenchyma tissue and evaluate the critical embedded lengths () of vascular bundles. The effects of embedded vascular bundle lengths on interfacial strength and failure behaviors were also investigated. The results revealed a value of 2.51 mm, lower than the majority of plant fiber-reinforced composite materials, with an IFSS of around 20 MPa, surpassing most artificial bamboo fiber composites. The pull-out process of the vascular bundles involved elasticity, debonding, and sliding friction stage, where debonding energy absorption (DEA) outweighed frictional energy absorption (FEA) and increasing with embedded length. The primary failure features include interfacial debonding, parenchyma tissue ripping, delamination of fiber thin layers, and fiber breakage. Moreover, the parenchyma cells between the two fiber sheaths and at the top of the bamboo block readily detached. The interfacial failure mechanisms of bamboo included debonding, reinforcement, and matrix failure, with the proportions varying as the embedded length increased. Quantitative analysis of the interfaces structure and mechanical properties between vascular bundles and parenchyma tissues could provide a reference for the biomimicry of bamboo structures and the manufacturing of natural fiber-reinforced composite materials.

Influence of variable viscosity on existing sheet thickness in the calendering of non-isothermal viscoelastic materials

Abstract The calendering process is pivotal in enhancing various materials’ surface properties and characteristics, making them indispensable for achieving desired product quality and performance. Also, this process holds significant relevance in various industrial applications, such as polymer processing, food production, and the manufacturing of composite materials. So, the aim of this study is to theoretically examine the calendering process applied to third-grade materials. It specifically explores how temperature variations impact material behavior during passage through two counter-rotating heated rolls. Particular consideration is given to the influence of temperature-dependent viscosity via Reynold’s model. The complexities of mass, momentum, and energy balance equations are reduced through the application of the Lubrication approximation theory. Solutions to these equations for variables such as velocity, flow rate, and temperature fields are accomplished by combining perturbation and numerical techniques. In relation to the calendering process, the thickness of the exiting sheet is specifically explored. Furthermore, this study quantifies substantial engineering parameters such as roll-separating force, pressure distribution, and power transferal from the rolls to the fluid. The governing equations belong to three key dimensionless parameters, namely, the Brinkman number, which is a product of Eckert number and Prandtl number, the temperature-dependent consistency index μ \mu , and a parameter η \eta correlating to non-Newtonian behavior. The outcomes of this study are presented both graphically and in tabular form. It has been observed that a rise in the third-grade parameter decreases detachment point and sheet thickness due to increased material rigidity. Furthermore, established results in the literature regarding the calendering of Newtonian fluids are validated.

Utilization of Silica Filler as Reinforcement Material of Polylactic Acid (PLA) in 3D Printing Applications: Thermal, Rheological, and Mechanical Performance.

Glass was introduced as an additive to filaments used for the manufacturing of composite materials, employed by Additive Manufacturing applications. Glass accounts for a large waste electric and electronic equipment (WEEE) percentage, and its recovery and recycling can lead to the production of sustainable composite materials. In this work, poly(lactic acid) (PLA)/commercially available silicon oxide composite filaments were manufactured and their structural, thermal, rheological, and mechanical properties were assessed. Scanning Electron Microscopy confirmed the 1:2 ratio of silicon: oxygen, along with the relatively low adhesion between the filler and the matrix. Differential Scanning Calorimetry presented steady glass transition and melting temperatures of composites, whereas a crystallization temperature of 10% wt. and a crystallinity of 15% wt. composite slightly increased. Rheological analysis showcased that the viscosity of the composite filaments decreased compared to PLA (10-100 compared to 300-400 Pa·s), with a more shear-thinning behavior. Dynamic mechanical analysis exhibited increased elastic, flexural moduli, and flexural strength of composites (up to 16, 23, and 11%, respectively), whereas tensile strength and elongation decreased. The affordability of raw materials (with the future introduction of recycled ones) and the minimal processing steps can lead to the potential scaling up of the study.

Challenges and Advancements in Additive Manufacturing of Nylon and Nylon Composite Materials: A Comprehensive Analysis of Mechanical Properties, Morphology, and Recent Progress

Challenges and Advancements in Additive Manufacturing of Nylon and Nylon Composite Materials: A Comprehensive Analysis of Mechanical Properties, Morphology, and Recent Progress

WEAR RESISTANT OF CACO3/FLY-ASH CERAMIC MATRIX COMPOSITE

This study aimed to investigate the potential of utilising fly ash, a harmful byproduct of coal waste, in the manufacturing of composite materials to reduce its environmental impact. Calcium carbonate (CaCO3) and fly ash were mixed with zinc stearate using the powder metallurgy method to create wear-resistant samples. The compaction load was adjusted to achieve optimal low-pressure compaction, with pressures of 22.75 MPa, 23.45 MPa, 24.14 MPa, and 24.83 MPa used for single punch pressing. After 10 minutes of holding time, sintering was conducted at 900 OC for 1 hour. The raw materials were tested using X-ray diffraction (XRD) and sieved based on the mesh size. The composite was characterised through various tests, including density testing, wear testing, and scanning electron microscopy (SEM) to observe the microstructure. The density value increased with the compaction load, with a maximum apparent density of 1.794 g/cm3 and the highest porosity percentage at a pressure of 22.75 Mpa of 31.155%. Furthermore, the specific wear value decreased as the compaction load increased, with the lowest specific abrasion value of 1.17 x 10-6 mm2/kg. Therefore, using fly ash to produce composite materials is a promising solution to reduce the negative impact of coal waste while producing wear-resistant materials.