Effects of Filler Content and Compatibilizing Agents on Mechanical Behavior of the Particle-Reinforced Composites

The study was carried out to investigate the effects of filler content and two different compatibilizing agents (Eastman G-3003 and G-3216) on the mechanical properties of polypropylene reinforced with corn stalk and wood flour. In the sample preparation, three levels of filler loading (30, 40 and 50 wt%) and one level of compatibilizing agent content (2.5 wt%) were used. For overall trend, with addition of both grades of the compatibilizing agents, tensile and flexural properties of the composites significantly improved, as compared with the pure PP. Tensile and flexural properties reach a maximum at 40 wt% filler content and gradually decrease with a further increase in wood particle content. The composites treated with G-3003 gave better results in comparison with G-3216. This could be caused by the high melt viscosity of G-3003. In general, corn stalk flour filled composites showed superior mechanical properties.     

Rheological, Mechanical and Thermal Behaviour of Wood Polymer Composites Based on Recycled Polypropylene

The aim of this paper was to investigate the effect of recycled polypropylene (PP) on the rheological, mechanical and thermal properties of wood flour polypropylene composites. Beforehand, the influence of wood flour treated with a coupling agent on the rheological behaviour had been looked at. By analysing moduli and viscosity curves and studying the thermal and mechanical properties of samples with 10% filler it was possible to see that the recycled PP that was added change in either its physical properties or its rheology. In the other wood plastic composites (WPC) studied, slight changes in the rheology behaviour were observed. However, the same processing parameters may be used with and without recycled PP. Recycled PP is appropriate for these kinds of composites to maintain the optimal rheological properties that make it easier to process the material by extrusion. Furthermore, it is also possible to maintain the thermal and mechanical properties in comparison with the behaviour of virgin PP/wood flour composites.     

New Multi-Scale Hybrid System Based on Maple Wood Flour and Nano Crystalline Cellulose: Morphological,Mechanical and Physical Study

In the first part of this work, composites based on polypropylene (PP) and maple wood flour (MF) were prepared by melt compounding using twin-screw extrusion followed by compression molding. The morphological and mechanical properties of the composites were analyzed for three samples: PP, MF/PP and MF/PP containing maleic anhydride grafted polypropylene (MAPP) as coupling agent. The results showed that MF/PP composites have improved mechanical properties, especially tensile modulus (+33 %), with only 8 % increase in density. The addition of MAPP further improved the mechanical properties, in particular tensile modulus (up to 51 %), which could be related to better fiber/matrix adhesion. In the second step, nano crystalline cellulose (NCC) was added to all samples to produce NCC-MF/PP hybrid composites. From the mechanical analysis performed, the hybrid composites with MAPP have improved properties, especially tensile (+53 %) and flexural (+40 %) moduli. These results confirmed that multi-scale hybrid NCC-MF composites can substantially improve the mechanical properties of polyolefins with limited increase in density (14 %) leading to high specific properties.     

Effect of Lignocellulosic Type on Long-Term Hygroscopic Behavior of Natural Filler/HDPE Composites

Natural filler/high density polyethylene (HDPE) injection-molded composites of flour from different lignocellulosic sources were prepared, and their long-term water absorption and thickness swelling were studied. Filler samples from wheat straw, hybrid Euro-American poplar, and loblolly pine were mixed with the matrix at 35 wt% lignocellulosics content and either zero or 2% maleic anhydride grafted polyethylene (MAPE) as compatibilizer. Results indicated water absorption of all the composites followed the kinetics of a Fickian diffusion process. The water diffusion coefficient of the composites was clearly dependent upon the lignocellulosic type. The wheat straw composites showed the highest and the pine composites exhibited the lowest water absorption coefficients. The highest thickness swelling took place in the wheat straw composites, followed by the poplar and pine composites, respectively. Adding MAPE to the composites decreased the water diffusion coefficient and thickness swelling by improving the adhesion between natural filler and the HDPE.     

Utilization of Sunflower Stalk in Manufacture of Thermoplastic Composite

Dimensional stability and mechanical performance of polypropylene thermoplastic composites filled with sunflower stalk (SS) flour at 30, 40, 50, and 60 wt% contents of the SS flour were investigated. The thickness swelling and water absorption of the specimens increased with increasing SS flour content. The modulus in the flexural and tensile improved with increasing SS flour content while the tensile and flexural strengths of the specimens decreased. The use of maleic anhydride polypropylene (3 wt%) had a positive effect on the dimensional stability and mechanical properties of the polypropylene thermoplastic composites filled with SS flour. The melting temperature of polypropylene decreased with increasing content of the SS flour. The degree of crystallinity of filled polypropylene composites between fibre loading of 0–30 % by weight was higher than that of unfilled polypropylene composites. However, further increment in the filler content decreased the degree of crystallinity. The obtained results showed that SS flour could be potentially suitable raw material in the manufacture of polypropylene composites.     

Characterization of composites based on expanded polystyrene wastes and wood flour

This paper aims to evaluate the potential for the use of recycled expanded polystyrene and wood flour as materials for the development of wood plastic composites. The effects of wood flour loading and coupling agent addition on the mechanical properties and morphology of wood thermoplastic composites were examined. In addition, a methodology for the thermo-mechanical recycling of expanded polystyrene waste was developed. The results show that the mechanical properties decreased as the wood flour loading increased. On the other hand, the use of poly(styrene-co-maleic anhydride), SMA, as a coupling agent improved the compatibility between the wood flour and polystyrene matrix and the mechanical properties subsequently improved. A morphological study revealed the positive effect of the coupling agent on the interfacial bonding. The density values obtained for the composites were compared with the theoretical values and showed agreement with the rule of mixtures. Based on the findings of this work, it appears that both recycled materials can be used to manufacture composites with high mechanical properties and low density.     

Influence of Filler Particle Size on Physical Properties and Biodegradation of Biocomposites Based on Low-Density Polyethylene and Lignocellulosic Fillers

This study examined biocomposites based on low-density polyethylene (LDPE) and lignocellulosic fillers [wood flour (WF) and oil flax straw (FS)] selecting four size fractions of each lignocellulosic material as fillers for the composites. The primary aim was to evaluate the influence of fraction size on the composites’ basic properties; to accomplish this, the composites’ mechanical properties, thermal oxidation, thermophysical characteristics, and water absorption capacity were examined. Then microphotographs of the samples were created and length-to-diameter (L/D) ratio of the fillers was calculated, finding that the L/D ratio increased with increasing particle size. The particle size influenced the oxidative degradation and water absorption processes in composites with oil flax but not in those with WF. Biodegradation tests performed on the recovered soil found that the loss of mass in composites based on LDPE and FS was higher than in the same composites with WF. Moreover, at the initial stage of composting, the biodegradation rate correlated with the size of filler particles (i.e., the larger the particles, the higher the degradation rate of the biocomposite).     

Bio-based composites from waste agricultural residues

The main objective of this research was to study the potential of waste agricultural residues such as sunflower stalk, corn stalk and bagasse fibers as reinforcement for thermoplastics as an alternative to wood fibers. The effects of two grades (Eastman G-3003 and G-3216) of coupling agents on the mechanical properties were also studied. In the sample preparation, one level of fiber loading (30 wt.%) and three levels of coupling agent content (0, 1.5 and 2.5 wt.%) were used. For overall trend, with addition of both grades of the coupling agents, tensile, flexural and impact properties of the composites significantly improved, as compared with untreated samples. In addition, morphological study revealed that the positive effect of coupling agent on interfacial bonding. The composites treated with G-3216 gave better results in comparison with G-3003. This could be caused by the high melt viscosity of G-3003. In general, bagasse fiber showed superior mechanical properties due to its chemical characteristics.     

Effects of Waste Paper Sludge on the Physico-Mechanical Properties of High Density Polyethylene/Wood Flour Composites

The objective of this work was to determine some physical and mechanical properties of the high density polyethylene (HDPE) composites reinforced with various mixtures of the paper sludge and the wood flour, and to evaluate the coupling agent performance. The waste sludge materials originating from two different sources including paper making waste water treatment sludge (PS) and ink-eliminated sludge (IES) were characterized in terms of physico-chemical properties. In the experiment, four levels of paper sludge (20, 30, 40 and 60 wt%), three levels of wood flour (20, 40 and 60 wt%), and two levels of coupling agent (MAPE) content (2 and 3 wt%) were used. The flexural properties of the composites were positively affected by the addition of the sludge. Especially, tensile modulus improved with the increase of paper sludge content. With the addition of MAPE, flexural properties improved considerably compared with control specimens (without any coupling agent). The results showed that the water absorption (WA) and thickness swelling (TS) values of the samples decreased considerably with increasing sludge content in the composite, while they increased with increasing wood flour content. It is to be noted that with incorporation of MAPE in the composite formulation, the compatibility between the wood flour and HDPE was enhanced through esterification, which reduced the WA and TS and improved the mechanical properties. Composites made with IES exhibited superior physico-mechanical properties compared with the PS filled composites. Overall results suggest that the waste paper sludge materials were capable of serving as feasible reinforcing fillers for thermoplastic polymer composites.     

Hybrid Composites from Waste Materials

Hybrid composites of thermoplastic biofiber reinforced with waste newspaper fiber (NF) and poplar wood flour (WF) were prepared. The weight ratio of the lignocellulosic materials to polymer was 30:70 (w:w). Polypropylene (PP) and maleic anhydride grafted polypropylene (MAPP) were also used as the polymer matrix and coupling agent, respectively. The mechanical properties, morphology and thermal properties were investigated. The obtained results showed that tensile and flexural modulus of the composites were significantly enhanced with addition of biofibers in both types (fiber and flour), as compared with pure PP. However, the increasing in WF content substantially reduced the tensile, flexural and impact modulus, but improved the thermal stability. This effect is explained by variations in fiber morphological properties and thermal degradation. Increasing fiber aspect ratio improved mechanical properties. The effect of fiber size on impact was minimal compared to the effects of fiber content. Scanning electron microscopy has shown that the composite, with coupling agent, promotes better fiber–matrix interaction. The largest improvement on the thermal stability of hybrid composites was achieved when WF was added more. In all cases, the degradation temperatures shifted to higher values after addition of MAPP. This work clearly showed that biofiber materials in both forms of fiber and flour could be effectively used as reinforcing elements in thermoplastic PP matrix.     

Natural Fiber Reinforced Poly(vinyl chloride) Composites: Effect of Fiber Type and Impact Modifier

Poly(vinyl chloride) (PVC) and natural fiber composites were prepared by melt compounding and compression molding. The influence of fiber type (i.e., bagasse, rice straw, rice husk, and pine fiber) and loading level of styrene-ethylene-butylene-styrene (SEBS) block copolymer on composite properties was investigated. Mechanical analysis showed that storage modulus and tensile strength increased with fiber loading at the 30% level for all composites, but there was little difference in both properties among the composites from various fiber types. The use of SEBS decreased storage moduli, but enhanced tensile strength of the composites. The addition of fiber impaired impact strength of the composites, and the use of SEBS led to little change of the property for most of the composites. The addition of fiber to PVC matrix increased glass transition temperature (T_g), but lowered degradation temperature (T_d) and thermal activation energy (E_a). After being immersed in water for four weeks, PVC/rice husk composites presented relatively smaller water absorption (WA) and thickness swelling (TS) rate compared with other composites. The results of the study demonstrate that PVC composites filled with agricultural fibers had properties comparable with those of PVC/wood composite.     

The development of agro-residue densified fuel in China based on energetics analysis

Agro-residue is one of the important biomass resources in China and its efficient utilization is crucial for providing bio-energy, releasing risk of environmental pollution, and enhancing rural incomes. Densification is one of the important utilization routes of agro-residues. The objective of this paper is to explore the development of agro-residue densified fuel in China based on energetics analysis. The energetical property and energy potential of main agro-residues in China were firstly analyzed and then the development of agro-residue densified fuel in every region was evaluated based on energetics analysis. The results show that the main agro-residues in China are good feedstocks as densified fuel and they constitute enormous energy potential for developing densified fuel. However, the situation of every region should be considered for the development of agro-residue densified fuel. The primary energy embodied per unit of useful energy indicates that most of the regions in China are suitable for developing agro-residue densified fuel as it is energetically advantageous compared with coal, whereas only about 25% of regions near coal production locations are not suitable as they are less energetically advantageous.     

Fiber from DDGS and Corn Grain as Alternative Fillers in Polymer Composites with High Density Polyethylene from Bio-based and Petroleum Sources

The steady increase in production of corn based ethanol fuel has dramatically increased the supply of its major co-product known as distiller’s dried grain with solubles (DDGS). Large amount of DDGS and corn flour are used as an animal feed. The elusieve process can separate DDGS or corn flour into two fractions: DDGS fraction with enhanced protein and oil content or corn flour fraction with high starch content, and hull fiber. This study investigated the feasibility of using fiber from DDGS and corn grain as alternative fillers to wood fiber in high density polyethylene (HDPE) composites made with two different sources of polymers. Two fiber loading rates of 30 and 50% were evaluated for fiber from DDGS, corn, and oak wood (control) to assess changes in various physical and mechanical properties of the composite materials. Two HDPE polymers, a bio-based HDPE made from sugarcane (Braskem), and a petroleum based HDPE (Marlex) were also compared as substrates. The biobased polymer composites with DDGS and corn fibers showed significantly lower water absorption than the Marlex composite samples. The Braskem composite with 30% DDGS fiber loading showed the highest impact resistance (80 J/m) among all the samples. The flexural properties showed no significant difference between the two HDPE composites.     

Influence of Fiber Treatment on the Mechanical and Morphological Properties of Sawdust Reinforced Polypropylene Composites

In the present work, sawdust reinforced polypropylene composites were fabricated using an extruder and an injection molding machine. Raw sawdust was chemically treated with benzene diazonium salt in order to improve the mechanical properties of the composites. The effect of the chemically treated sawdust reinforced PP composites was evaluated from their mechanical and surface morphological properties. The values of the mechanical properties of the chemically treated sawdust–PP composites were found to be significantly higher than those of the raw ones. Water uptake tests revealed that composites prepared from the chemically treated sawdust absorb lower amount of water compared to the ones prepared from raw sawdust, suggesting that hydrophilic nature of the cellulose in the sawdust has significantly decreased upon chemical treatment. The surface morphology obtained from scanning electron microscopy (SEM) showed that raw sawdust–PP composites possess surface roughness with extruded filler moieties, and weak interfacial adhesion between the matrix and the filler while the chemically treated one showed improved filler–matrix interaction. This indicates that better dispersion of the filler with the PP matrix has occurred upon chemical treatment of the filler.     

Effect of Thermo-Mechanical Degradation of Polypropylene on Hygroscopic Characteristics of Wood Flour-Polypropylene Composites

In this research, the influence of thermo-mechanical degradation of polypropylene (PP) on water absorption and thickness swelling of beech wood flour–PP composites were studied. For this purpose, a virgin PP was thermo-mechanically degraded by two times extrusion under controlled conditions. The results showed that the melt flow index, water absorption and thickness swelling of PP significantly increase by extrusion and re-extrusion. The virgin PP and degraded polypropylene were compounded with wood flour (at 60% by weight wood flour loading) in a counter-rotating twin-screw extruder in presence or absence of MAPP to produce wood flour–PP composites. From the results, the composites containing recycled PP exhibited higher water absorption and thickness swelling. The use of MAPP decreased water absorption and thickness swelling in composites made of virgin or recycled PP.     

Mechanical, Thermal and Water Absorption Properties of Kenaf-Fiber-Based Polypropylene and Poly(Butylene Succinate) Composites

The use of composites made from non-biodegradable conventional plastic materials (e.g., polypropylene, PP) is creating global environmental concern. Biodegradable plastics such as poly(butylene succinate) (PBS) are sought after to reduce plastic waste accumulation. Unfortunately, these types of plastics are very costly; therefore, natural lignocellulosic fibers are incorporated to reduce the cost. Kenaf fibers are also incorporated into PP and PBS for reinforcing purposes and they have low densities, high specific properties and renewable sourcing. However without good compatibilization, the interfacial adhesion between the matrix and the fibers is poor due to differences in polarity between the two materials. Maleic anhydride-grafted compatibilizers may be introduced into the system to improve the matrix-fiber interactions. The overall mechanical, thermal and water absorption properties of PP and PBS composites prepared with 30 vol.% short kenaf fibers (KFs) using a twin-screw extruder were being investigated in this study. The flexural properties for both types of composites were enhanced by the addition of compatibilizer, with improvements of 56 and 16 % in flexural strength for the PP/KF and PBS/KF composites, respectively. Good matrix-fiber adhesion was also observed by scanning electron microscopy. However, the thermal stability of the PBS/KF composites was lower than that of the PP/KF composites. This result was confirmed by both DSC and TGA thermal analysis tests. The water absorption at equilibrium of a PBS composite filled with KFs is inherently lower than of a PP/KF composite because the water molecules more readily penetrate the PP composites through existing voids between the fibers and the matrix. Based on this research, it can be concluded that PBS/KF composites are good candidates for replacing PP/KF composites in applications whereby biodegradability is essential and no extreme thermal and moisture exposures are required.     

A Comparative Study Between Bio-composites Obtained with Opuntia ficus indica Cladodes and Flax Fibers

This work is aimed to study the suitability of the wooden backbone of Opuntia ficus indica cladodes as reinforcement for the production of bio-composites. The wooden backbone can be extracted from O. ficus indica cladodes, which constitute a very relevant agricultural scrap, and is characterized by a thick walled cellular structure. In view of its potential in poly-lactic acid (PLA) matrix bio-composite production, two different possible applications were examined. In the first alternative, the wooden backbone was used in replacement of flax fibers for the production of fully consolidated bio-composites. Results obtained have shown that, though being characterized by lower properties compared to those of flax fiber composites, the opuntia actually works as an efficient reinforcement for PLA/wood flour matrix, increasing the flexural strength and elongation at break. In the second alternative, the cellular structure was used for the production of a sandwich bio-composite with a PLA/wood flour skin. In this case, the very high interlaminar adhesion strength between the skin and the core was considered as an indication of the potentiality of this material for the production of high strength sandwich structures. As a confirmation of this, no interlaminar debonding was observed during short beam tests.     

Effect of Interfacial Modifiers on Mechanical and Physical Properties of the PHB Composite with High Wood Flour Content

To explore the commercial viability of Polyhydroxybutyrate (PHB)/wood flour (WF) composites, systems were produced at industry-standard levels of fiber loading. Further, four interfacial modifiers were selected to improve the mechanical properties of PHB/WF composites, including maleated PHB (PHB-g-MA), a low molecular weight epoxy, a low molecular weight polyester, and polymethylene-diphenyl-diisocyante (pMDI). Results showed that all modifiers resulted in improvements in tensile strength and modulus, however, pMDI showed the highest improvements. The pMDI modifier also improved water uptake of the composites. Study of the fracture surfaces showed signs of improved fiber bonding, as did morphological studies by dynamic mechanical analysis (DMA), and differential scanning calorimetry (DSC). Interpretation of the DSC and DMA results indicate possible reactions with lubricant, and interactions between PHB and wood fibers with the addition of pMDI.     

Fly ash reinforced thermoplastic vulcanizates obtained from waste tire powder

Novel thermoplastic composites made from two major industrial and consumer wastes, fly ash and waste tire powder, have been developed. The effect of increasing fly ash loadings on performance characteristics such as tensile strength, thermal, dynamic mechanical and magnetic properties has been investigated. The morphology of the blends shows that fly ash particles have more affinity and adhesion towards the rubbery phase when compared to the plastic phase. The fracture surface of the composites shows extensive debonding of fly ash particles. Thermal analysis of the composites shows a progressive increase in activation energy with increase in fly ash loadings. Additionally, morphological studies of the ash residue after 90% thermal degradation shows extensive changes occurring in both the polymer and filler phases. The processing ability of the thermoplastics has been carried out in a Monsanto processability testing machine as a function of shear rate and temperature. Shear thinning behavior, typical of particulate polymer systems, has been observed irrespective of the testing temperatures. Magnetic properties and percolation behavior of the composites have also been evaluated.     

Comparison of Polylactic Acid/Kenaf and Polylactic Acid/Rise Husk Composites: The Influence of the Natural Fibers on the Mechanical, Thermal and Biodegradability Properties

This paper investigates and compares the performances of polylactic acid (PLA)/kenaf (PLA-K) and PLA/rice husk (PLA-RH) composites in terms of biodegradability, mechanical and thermal properties. Composites with natural fiber weight content of 20% with fiber sizes of less than 100 μm were produced for testing and characterization. A twin-screw extrusion was used to compound PLA and natural fibers, and extruded composites were injection molded to test samples. Flexural and Izod impact test, TGA, soil burial test and SEM were used to investigate properties. All results were compared to a pure PLA matrix sample. The flexural modulus of the PLA increased with the addition of natural fibers, while the flexural strength decreased. The highest impact strength (34 J m⁻¹), flexural modulus (4.5 GPa) and flexural strength (90 MPa) were obtained for the composite made of PLA/kenaf (PLA-K), which means kenaf natural fibers are potential to be used as an alternative filler to enhance mechanical properties. On the other hand PLA-RH composite exhibits lower mechanical properties. The impact strength of PLA has decreased when filled with natural fibers; this decrease is more pronounced in the PLA-RH composite. In terms of thermal stability it has been found that the addition of natural fibers decreased the thermal stability of virgin PLA and the decrement was more prominent in the PLA-RH composite. Biodegradability of the composites slightly increased and reached 1.2 and 0.8% for PLA-K and PLA-RH respectively for a period of 90 days. SEM micrographs showed poor interfacial between the polymer matrix and natural fibers.