Structural and Mechanical Characterization of Sustainable Composites Based on Recycled and Stabilized Fly Ash

This paper reports the results on the use of an innovative inert, based on stabilized fly ash from municipal solid waste incineration as a filler for polypropylene. The starting material, which contains large quantities of leachable Pb and Zn, was stabilized by means of an innovative process using rice husk ash as a waste silica source, together with other fly ashes, such as coal fly ash and flue gas desulfurization residues. The use of all waste materials to obtain a new filler makes the proposed technology extremely sustainable and competitive. The new composites, obtained by using the stabilized material as a filler for polypropylene, were characterized and their mechanical properties were also investigated. A comparison with a traditional polypropylene and calcium carbonate based compound was also done. This research activity was realized in the frame of the COSMOS-RICE project, financed by the EU Commission.     

Analysis of the Mechanical Properties and Damage Mechanism of Carbon Fiber/Epoxy Composites under UV Aging

The UV durability of carbon fiber composites has been a concern. In this work, UV irradiation on carbon fiber-reinforced polymer (CFRP) materials was performed using an artificial accelerated UV aging chamber to investigate the effect of UV exposure on carbon fiber composites. UV aging caused some of the macromolecular chains on the surface resin to break, resulting in the loss of small molecules and loss of mass. After 80 days of UV irradiation exposure, a significant decline in the macroscopic mechanical properties occurred in the longitudinal direction, with the largest decrease of 23% in longitudinal compressive strength and a decreasing trend in the transverse mechanical properties at the later stage of aging. The microscopic mechanical properties of the CFRP specimens were characterized using nanoindentation, and it was found that UV aging had an embrittlement effect on the matrix, and its hardness/modulus values were higher than the initial values with UV exposure. The fibers were less affected by UV irradiation.     

Study of the Ultraviolet Effect and Thermal Analysis on Polypropylene Nonwoven Geotextile

The use of polymeric materials such as geosynthetics in infrastructure works has been increasing over the last decades, as they bring down costs and provide long-term benefits. However, the aging of polymers raises the question of its long-term durability and for this reason researchers have been studying a sort of techniques to search for the required renewal time. This paper examined a commercial polypropylene (PP) nonwoven geotextile before and after 500 h and 1000 h exposure to ultraviolet (UV) light by performing laboratory accelerated ultraviolet-aging tests. The state of the polymeric material after UV exposure was studied through a wide set of tests, including mechanical and physical tests and thermoanalytical tests and scanning electron microscopy analysis. The calorimetric evaluations (DSC) showed distinct behaviors in sample melting points, attributed to the UV radiation effect on the aged samples. Furthermore, after exposure, the samples presented low thermal stability in the thermomechanical analysis (TMA), with a continuing decrease in their thicknesses. The tensile tests showed an increase in material stiffness after exposition. This study demonstrates that UV aging has effects on the properties of the polypropylene polymer.     

Liquid Guayule Natural Rubber,a Sustainable Processing Aid,Enhances the Processability,Durability and Dynamic Mechanical Properties of Rubber Composites

Petroleum-based oils are widely used as processing aids in rubber composites to improve processability but can adversely affect rubber composite performance and increase carbon footprint. In this research, liquid guayule natural rubber (LGNR), produced from guayule natural rubber, was used as a renewable processing aid to replace naphthenic oil (NO) in Hevea natural rubber, styrene-butadiene rubber (SBR) and guayule natural rubber (GNR) composites. The rheological properties, thermal stability, glass transition temperature, dynamic mechanical properties, aging, and ozone resistance of rubber composites with and without NO or LGNR were compared. Natural and synthetic rubber composites made with LGNR had similar processability to those made with NO, but had improved thermal stability, mechanical properties after aging, and ozone resistance. This was due to the strong LGNR–filler interaction and additional crosslinks formed between LGNR and the rubber matrices. The glass transition temperature of SBR composites was reduced by LGNR because of its increased molecular mobility. Thus, unlike NO, LGNR processing aid can simultaneously improve rubber composite durability, dynamic performance and renewability. The commercialization of LGNR has the potential to open a new sustainable processing-aid market.     

Effects of In-Situ Filler Loading vs. Conventional Filler and the Use of Retention-Related Additives on Properties of Paper

In the present paper, aspects concerning the obtained and characterization of additive systems used for maximizing filler retention, and the effects on paper properties, were investigated. The effects of retention additives over properties of paper, containing fibers from in-situ loading (IS-CCP), were analyzed against the effects of additives over properties of paper containing fibers from conventional loading, obtained by the addition of calcium carbonate in precipitated form (CCP). The physico-mechanical properties were analyzed by various analyses and investigations: calcium carbonate content, X-ray diffraction, scanning electron microscopy (SEM) images, optical and mechanical properties, in order to develop the best systems of retention additives for obtaining higher retention loads for making paper with high content of nano-filler material. The obtained results reveal that at the same level of calcium carbonate content, all paper samples with in-situ loading had higher the optical and mechanical properties than the paper obtained by conventional loading in all cases the additives studied. For all studied properties, nanoparticles had a positively influence over paper properties.     

Influence of Natural Weather Conditions in the Long-Term Fracture Energy of Glass Fibre Reinforced Cement (GRC) Modified with Chemical Additions

The use of glass fibre-reinforced cement (GRC) in structural elements has been limited due to the reduction in the mechanical properties of the material with aging. Chemical additions have been used to modify the cement mortar formulation in order to minimise such loss, but no conclusive results have been obtained yet. Moreover, the application of accelerated aging methods in such modified GRC formulations still poses several uncertainties. An experimental campaign seeking to assess the reduction in the fracture energy of two GRCs manufactured with modified matrixes after five years of exposure to natural environment was performed. Furthermore, a comparison with results from the literature that used accelerated aging methods was performed. The results show that the use of the chemical additives might be capable of maintaining to a notable extent the mechanical properties of GRC after five years of natural aging. Regarding the accelerated aging method by means of immersion in hot water tanks, it seemed that the equivalences applied in previous research accurately match the degradation of the material after natural exposure to weather. Additionally, a digital image correlation analysis showed that aged GRCs seemed to distribute damage in a smaller area than young GRCs.     

Thermoplastic Hybrid Composites with Wood Fibers: Bond Strength of Back-Injected Structures

Due to their lightweight potential and good eco-balance, thermoplastic hybrid composites with natural fiber reinforcement have long been used in the automotive industry. A good alternative to natural fibers is wood fibers, which have similar properties but are also a single-material solution using domestic raw materials. However, there has been hardly any research into wood fibers in thermoplastic back-injected hybrid composites. This article compares the bond strength of an injection molded rib from polypropylene (PP) and wood fibers to different non-wovens. The non-wovens consisted of wood fibers (spruce) or alternatively natural fibers (kenaf, hemp), both with a polypropylene matrix. Pull-off and instrumented puncture impact tests show that, given similar parameters, the natural and wood-fiber-hybrid composites exhibit very similar trends in bond strength. Further tests using viscosity measurements, microscopy, and computed tomography confirm the results. Wood-fiber-reinforced thermoplastic hybrid composites can thus compete with the natural fiber composites in terms of their mechanical behavior and therefore present a good alternative in technical semi-structural applications.     

Common Nettle (Urtica dioica L.) as an Active Filler of Natural Rubber Biocomposites

Common nettle (Urtíca Dióica L.), as a natural fibrous filler, may be part of the global trend of producing biocomposites with the addition of substances of plant origin. The aim of the work was to investigate and explain the effectiveness of common nettle as a source of active functional compounds for the modification of elastomer composites based on natural rubber. The conducted studies constitute a scientific novelty in the field of polymer technology, as there is no research on the physico-chemical characteristics of nettle bio-components and vulcanizates filled with them. Separation and mechanical modification of seeds, leaves, branches and roots of dried nettle were carried out. Characterization of the ground plant particles was performed using goniometric measurements (contact angle), Fourier transmission infrared spectroscopy (FTIR), themogravimetric analysis (TGA) and scanning electron microscopy (SEM). The obtained natural rubber composites with different bio-filler content were also tested in terms of rheological, static and dynamic mechanical properties, cross-linking density, color change and resistance to simulated aging processes. Composites with the addition of a filler obtained from nettle roots and stems showed the highest mechanical strength. For the sample containing leaves and branches, an increase in resistance to simulated ultraviolet and thermo-oxidative aging processes was observed. This phenomenon can be attributed to the activity of ingredients with high antioxidant potential contained in the plant.     

Property Relationship in Organosilanes and Nanotubes Filled Polypropylene Hybrid Composites

Polypropylene composites with different filler contents were prepared by creating a masterbatch containing 3 wt%. filler. A variety of silanol groups were used to synthetized three compounds in different media trough a sol-gel process with acetic acid, formic acid and ammonium hydroxide as catalysts. Besides, four different nanotubular fillers were also used to analyze their behavior and compare it with the effect caused by the silanol groups. These tubular structures comprise: unmodified halloysite, carbon nanotubes and functionalized halloysite and carbon nanotubes. Morphological characterization in SEM and STEM/TEM showed dispersion in the polypropylene matrix. According to TGA and DSC measurements thermal behavior remain similar for all the composites. Mechanical test in tension demonstrate that modulus of the composites increases for all samples with a major impact for materials containing silanol groups synthetized in formic acid. Rheological measurements show a significantly increment in viscosity for samples containing unmodified and modified carbon nanotubes. No difference was found for samples containing silanol groups and halloysite when compared to neat polypropylene. Finally, the oxygen transmission rate increased for all samples showing high barrier properties only for samples containing natural and functionalized halloysite nanotubes.     

A Review on AA 6061 Metal Matrix Composites Produced by Stir Casting

In recent years, many alloys as well as composites of aluminium were developed for enhanced material performance. AA 6061 is an aluminium alloy that has extensive applications due to its superior material characteristics. It is a popular choice of matrix for aluminium matrix composite (AMC) fabrication. This study provides a review on AA 6061 aluminium alloy matrix composites produced through the stir-casting process. It focusses on conventional stir-casting fabrication, process parameters, various reinforcements used, and the mechanical properties of the AA 6061 composites. Several research studies indicated that the stir-casting method is widely used and suitable for fabricating AA 6061 composites with reinforcements such as SiC, B₄C, Al₂O₃, TiC, as well as other inorganic, organic, hybrid, and nanomaterials. The majority of the studies showed that an increase in the reinforcement content enhanced the mechanical and tribological properties of the composites. Furthermore, hybrid composites showed better material properties than single reinforcement composites. The usage of industrial and agricultural residues in hybrid composites is also reported. Future studies could focus on the fabrication of AA 6061 nanocomposites through stir casting and their material characterisation, since they have great potential as advanced materials.     

Casein/Apricot Filler in the Production of Flame-Retardant Polyurethane Composites

Polyurethane (PUR) composites reinforced with 1, 2, and 5 wt.% of apricot filler modified with casein were synthesized in the following study. The impact of 1, 2, and 5 wt.% of casein/apricot filler on the cellular structure and physico-mechanical performances of reinforced PUR composites were determined. It was found that the incorporation of 1 and 2 wt.% of casein/apricot filler resulted in the production of PUR composites with improved selected physical, thermal, and mechanical properties, while the addition of 5 wt.% of casein/apricot filler led to some deterioration of their physico-mechanical performance. The best results were obtained for PUR composites reinforced with 2 wt.% of casein/apricot filler. Those composites were characterized by a uniform structure and a high content of closed cells. Compared with the reference foam, the incorporation of 2 wt.% of casein/apricot filler resulted in improvement in compressive strength, flexural strength, impact strength, and dynamic mechanical properties—such as glass transition temperature and storage modulus. Most importantly, PUR composites showed better fire resistance and thermal stability due to the good thermal performance of casein. The main aim of this article is to determine the influence of the natural combination of the apricot filler and casein on the mechanical properties and flammability of the obtained composites.     

Bio-Based Packaging Materials Containing Substances Derived from Coffee and Tea Plants

The aim of the research was to obtain intelligent and eco-friendly packaging materials by incorporating innovative additives of plant origin. For this purpose, natural substances, including green tea extract (polyphenon 60) and caffeic acid, were added to two types of biodegradable thermoplastics (Ingeo™ Biopolymer PLA 4043D and Bioplast GS 2189). The main techniques used to assess the impact of phytocompounds on materials’ thermal properties were differential scanning calorimetry (DSC) and thermogravimetry (TGA), which confirmed the improved resistance to thermo-oxidation. Moreover, in order to assess the activity of applied antioxidants, the samples were aged using a UV aging chamber and a weathering device, then retested in terms of dynamic mechanical properties (DMA), colour changing, Vicat softening temperature, and chemical structure, as studied using FT-IR spectra analysis. The results revealed that different types of aging did not cause significant differences in thermo-mechanical properties and chemical structure of the samples with natural antioxidants but induced colour changing. The obtained results indicate that polylactide (PLA) and Bioplast GS 2189, the plasticizer free thermoplastic biomaterial containing polylactide and starch (referred to as sPLA in the present article), both with added caffeic acid and green tea extract, can be applied as smart and eco-friendly packaging materials. The composites reveal better thermo-oxidative stability with reference to pure materials and are able to change colour as a result of the oxidation process, especially after UV exposure, providing information about the degree of material degradation.     

Epoxy Resin Composite Based on Functional Hybrid Fillers

A study was carried out involving the filling of epoxy resin (EP) with bentonites and silica modified with polyhedral oligomeric silsesquioxane (POSS). The method of homogenization and the type of filler affect the functional and canceling properties of the composites was determined. The filler content ranged from 1.5% to 4.5% by mass. The basic mechanical properties of the hybrid composites were found to improve, and, in particular, there was an increase in tensile strength by 44%, and in Charpy impact strength by 93%. The developed hybrid composites had characteristics typical of polymer nanocomposites modified by clays, with a fine plate morphology of brittle fractures observed by SEM, absence of a plate separation peak in Wide Angles X-ray Scattering (WAXS) curves, and an exfoliated structure observed by TEM.     

Analysis of Mechanical Properties Related to Fiber Length of Closed-Loop-Recycled Offcuts of a Thermoplastic Fiber Composites (Organo Sheets)

Increasing demand for energy-efficient means of transport has steadily intensified the trend towards lightweight components. Thermoplastic glass fiber composites (organo sheets) play a major role in the production of functional automotive components. Organo sheets are cut, shaped and functionalized by injection molding to produce hybrid components, such as those used in car door modules. The cutting process produces a considerable amount of production waste, which has thus far been thermally recycled. This study develops a closed mechanical recycling process and analyzes the different steps of the process. The offcuts were shredded using two shredding methods and implemented directly in the injection-molding process. Using tensile tests and impact bending tests, the material properties of the recycled materials were compared with the virgin material. In addition, fiber length degradation via the injection-molding process and the influence of the waterjet-cutting process on the mechanical properties are investigated. Recycled offcuts are both comparable to new material in terms of mechanical properties and usability, and are also economically and ecologically advantageous. Recycling polypropylene waste with glass fiber reinforcement in a closed loop is an effective way to reduce industrial waste in a sustainable and economical production process.     

The Influence of MMA Esterification on Interfacial Adhesion and Mechanical Properties of Hybrid Kenaf Bast/Glass Fiber Reinforced Unsaturated Polyester Composites

The demand for natural fiber hybrid composites for various applications has increased, which is leading to more research being conducted on natural fiber hybrid composites due to their promising mechanical properties. However, the incompatibility of natural fiber with polymer matrix limits the performance of the natural fiber hybrid composite. In this research work, the mechanical properties and fiber-to-matrix interfacial adhesion were investigated. The efficiency of methyl methacrylate (MMA)-esterification treatments on composites’ final product performance was determined. The composite was prepared using the hand lay-up method with varying kenaf bast fiber (KBF) contents of 10, 15, 20, 25, 30, 35 (weight%) and hybridized with glass fiber (GF) at 5 and 10 (weight%). Unsaturated polyester (UPE) resin and methyl ethyl ketone peroxide (MEKP) were used as binders and catalysts, respectively. Scanning electron microscopy (SEM) and Fourier-transform infrared spectroscopy (FTIR) were used to examine the effects of MMA-esterification treatment on tensile strength and morphology (tensile fracture and characterization of MMA-esterification treatment) of the composite fabricated. The tensile strength of MMA-treated reinforced UPE and hybrid composites are higher than that of untreated composites. As for MMA treatment, 90 min of treatment showed the highest weight percent gain (WPG) and tensile strength of KBF-reinforced UPE composites. It can be concluded that the esterification of MMA on the KBF can lead to better mechanical properties and adhesion between the KFB and the UPE matrix. This research provides a clear reference for developing hybrid natural fibers, thus contributing to the current field of knowledge related to GF composites, specifically in transportation diligences due to their properties of being lightweight, superior, and involving low production cost.     

Experimental Study of Mechanical Properties of Epoxy Compounds Modified with Calcium Carbonate and Carbon after Hygrothermal Exposure

The objective of this paper is to analyze the effects of hygrothermal exposure on the mechanical properties of epoxy compounds modified with calcium carbonate or carbon fillers. In addition, comparative tests were carried out with the same parameters as hygrothermal exposure, but the epoxy compounds were additionally exposed to thermal shocks. The analysis used cylindrical specimens produced from two different epoxy compounds. The specimens were fabricated from compounds of epoxy resins, based on Bisphenol A (one mixture modified, one unmodified) and a polyamide curing agent. Some of the epoxy compounds were modified with calcium carbonate (CaCO₃). The remainder were modified with activated carbon (C). Each modifying agent, or filler, was added at a rate of 1 g, 2 g, or 3 g per 100 g of epoxy resin. The effect of the hygrothermal exposure (82 °C temperature and 95% RH humidity) was examined. The effects of thermal shocks, achieved by cycling between 82 °C and −40 °C, on selected mechanical properties of the filler-modified epoxy compounds were investigated. Strength tests were carried out on the cured epoxy compound specimens to determine the shear strength, compression modulus, and compressive strain. The analysis of the results led to the conclusion that the type of tested epoxy compounds and the quantity and type of filler determine the effects of climate chamber aging and thermal shock chamber processing on the compressive strength for the tested epoxy compounds. The different filler quantities, 1–3 g of calcium carbonate (CaCO₃) or activated carbon (C), determined the strength parameters, with results varying from the reference compounds and the compounds exposure in the climate chamber and thermal shock chamber. The epoxy compounds which contained unmodified epoxy resin achieved a higher strength performance than the epoxy compounds made with modified epoxy resin. In most instances, the epoxy compounds modified with CaCO₃ had a higher compressive strength than the epoxy compounds modified with C (activated carbon).     

Structure and Stability Characterization of Natural Lake Pigments Made from Plant Extracts and Their Potential Application in Polymer Composites for Packaging Materials

Natural dyes were extracted from various plant sources and converted into lake pigments based on aluminum and tin. Three different plants (weld, Persian berries, and Brazilwood) were chosen as representative sources of natural dyes. High-performance liquid chromatography (HPLC) and triple-quadrupole mass spectrometry (QqQ MS) were used to identify dyestuffs in the raw extracts. The natural dyes and lake pigments were further characterized by optical and scanning electron microscopy (SEM), UV-Vis spectrophotometry, and thermogravimetric analysis (TGA). The stabilization of the studied plant extracts onto aluminum and tin salts led to the formation of natural lake pigments characterized by different color shades. The natural lake pigments showed improved thermal and chemical stability, which was confirmed by their higher degradation temperatures and lower solubility in chemical agents compared to natural dyes extracted from plants. This improvement can be attributed to electrostatic attraction due to the process of chelation. Ethylene-norbornene (EN) composites colored with the lake pigments exhibited uniform color and improved resistance to long-term UV exposure aging. After 300 h of UV exposure, the aging factor of the neat EN copolymer reduced to 0.3, indicating an advanced aging process of polymer compared to colored samples. Prolonged UV exposure deteriorated the mechanical properties of EN by approximately 57%, compared to about 43% with the application of BW/Al lake pigment. Natural lake pigments could be used as effective substitutes for commercial colorants in plastics for packaging applications.     

Structure-Composition-Property Relationships in Polymeric Amorphous Calcium Phosphate-Based Dental Composites

Our studies of amorphous calcium phosphate (ACP)-based materials over the last decade have yielded bioactive polymeric composites capable of protecting teeth from demineralization or even regenerating lost tooth mineral. The anti-cariogenic/re-mineralizing potential of these ACP composites originates from their propensity, when exposed to the oral environment, to release in a sustained manner sufficient levels of mineral-forming calcium and phosphate ions to promote formation of stable apatitic tooth mineral. However, the less than optimal ACP filler/resin matrix cohesion, excessive polymerization shrinkage and water sorption of these experimental materials can adversely affect their physicochemical and mechanical properties, and, ultimately, limit their lifespan. This study demonstrates the effects of chemical structure and composition of the methacrylate monomers used to form the matrix phase of composites on degree of vinyl conversion (DVC) and water sorption of both copolymers and composites and the release of mineral ions from the composites. Modification of ACP surface via introducing cations and/or polymers ab initio during filler synthesis failed to yield mechanically improved composites. However, moderate improvement in composite's mechanical stability without compromising its remineralization potential was achieved by silanization and/or milling of ACP filler. Using ethoxylated bisphenol A dimethacrylate or urethane dimethacrylate as base monomers and adding moderate amounts of hydrophilic 2-hydroxyethyl methacrylate or its isomer ethyl-α-hydroxymethacrylate appears to be a promising route to maximize the remineralizing ability of the filler while maintaining high DVC. Exploration of the structure/composition/property relationships of ACP fillers and polymer matrices is complex but essential for achieving a better understanding of the fundamental mechanisms that govern dissolution/re-precipitation of bioactive ACP fillers, and, ultimately, the suitability of the composites for clinical evaluation.     

On the Use of Paper Sludge as Filler in Biocomposites for Injection Moulding

The potential use of paper sludge (PS) as filler in the production of bio-composites based on poly lactic acid (PLA) and polybutylene adipate terephthalate (PBAT) was investigated. PS/PLA/PBAT composites, with addition of acetyl tributyl citrate (ATBC) as biobased plasticizer, were produced with PS loadings up to 30 wt.% by twin-screw extrusion followed by injection moulding. The composites were characterized by rheological measurements, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and mechanical tests (tensile and impact resistance) to study the effect of PS on the processability, thermal stability, crystallinity and mechanical performance of polymeric matrix. The optimized composites at higher PS content were successfully processed to produce pots for horticulture and, in view of this application, preliminary phytotoxicity tests were conducted using the germination test on Lepidium sativum L. seeds. Results revealed that developed composites up to 30 wt.% PS had good processability by extrusion and injection moulding showing that PS is a potential substitute of calcium carbonate as filler in the production of bio-composites, and the absence of phytotoxic effects showed the possibility of their use in the production of pots/items for applications in floriculture and/or horticulture.     

Performance Evaluation of Jute/Glass-Fiber-Reinforced Polybutylene Succinate (PBS) Hybrid Composites with Different Layering Configurations

The hybridization of natural and synthetic fibers leads to composites’ optimum mechanical properties. In this study, an attempt was made to study the effect of the stacking sequence on PBS-based Glass-Jute (GJ) hybrid composites. Six types of hybrid composite, each containing five different layers of jute and glass fabric, were manufactured by the compression molding method. Mechanical properties, such as tensile, flexural, and impact resistance were studied and analyzed in detail. The surface characterization of the composites was performed through scanning electron microscopic images. The moisture absorption properties were also investigated by immersing the composites in distilled water for one week at ambient temperature. The TGA test was conducted to study their thermal properties. The experimental results showed that the stacking sequence of the fiber layers has a significant effect on the overall performance of GJ hybrid composites. Among the hybrid GJ composites, composites with glass fiber layers on their outer surfaces showed optimum mechanical, thermal, and water resistance properties.