Tensile Properties And Morphology Studies Of Polymeric Biocomposite.
UTeM Library (Pind.112007)
UNlVERSlTl TEKNIKAL MALAYSIA MELAKA
JUDUL: TENSILE PROPERTIES AND MORPHOLOGY STUDIES OF PO-LYMERIC
BIOCOMPOSTIE
SESI PENGAJIAN : 2007-2008
Saya CHENG YUAN WE
mengaku membenarkan tesis (PSMISarjanalDoktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Tesis adalah .hak milik Universiti Teknikal Malaysia Melaka .
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan (d)
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
dengan menvatakan sekali sebab dan temooh tesis ini oerlu dikelaskan seba~aiSULIT atau TERHAD.
UNlVERSlTl TEKNIKAL MALAYSIA MELAKA
Karung Berkunci 1200, Ayer Keroh, 75450 Melaka
Tel : 06-233 2421, Faks : 06 233 2414
Ernail : fko@kutkrn.edu.mv
FAKULTI KEJURUTERAAN PEMBUATAN
25 Mac 2008
Rujukan Kami (Our Ref) :
Rujukan Tuan (Your Ref):
Pustakawan
Perpustakawan Universiti Teknikal Malaysia Melaka
UTeM, No 1, Jalan TU 43,
Taman Tasik Utama, Hang Tuah Jaya,
Ayer Keroh, 75450, Melaka
Saudara,
PENGKELASAN TESIS SEBAGAI SULIT/TERHAD
-
TESIS
SARJANA MUDA
KEJURUTERAAN
PEMBUATAN
(F'AKULTI
KEJURUTERAAN PEMBUATAN): CHENG YUAN WE
TAJUK:
TENSILE
PROPERTIES
AND
MORPHOLOGY
STUDIES
OF
POLYMERIC BIOCOMPOSITE
Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk 'TENSILE
.
PROPERTEIS
MORPHOLOGY
AND
STUDIES
OF
POLYMERIC
BIOCOMPOSTE" mohon dikelaskan sebagai terhad untuk tempoh lima (5) tahun dari
tarikh surat ini memandangkan ia mempunyai nilai dan potensi untuk dikomersialkan di
masa hadapan.
Sekian dimaklumkan. Terima kasih.
"BERKHIDMAT UNTUK NEGARA KERANA A L L A H
Yang benar,
Pensyarah,
Fakulti Kejuruteraan Pembuatan
DECLARATION
I hereby, declared this thesis entitled "Tensile Properties and Morphology Study of
Polymeric Biocomposite"
is the results of my own research
... ..
.
except as cited in references.
Signature
+#--
Author's Name
CHENG YUAN WE
Date
25 MARCH 2008
Parents:I
.--
-
APPROVAL
...
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the
requirements for the degree of Bachelor of Manufacturing Engineering (Material
Engineering). The members of the supervisory committee are as follow:
PROF. DR. HJ. MD. DAN BIN HJ. MD. PALIL
Timbaian Dekan (Penyelidikon & Pengajiarl Siswazah}
Fakulti Keju~utewanPernbtlatan
Universiti Tzknikal Malaysia Melaka
Karung Berkunci 1200, Ayer Kemh
75450 Melaka
ABSTRACT
Polymeric bio-composite is a materialformed using a polymeric matrix (resin) and a
...
reinforcement of natural. fibers which are usually derived from plants or cellulose. The
objective of current research is to investigate the tensile properties of unsaturated
polyesterkenaf by using the resin infusion process (RIP) in comparison with hand lay up
method (HL). The effects of alkali treatment to the tensile properties of composite also
were investigated. Besides, the interphase and interfacial bonding of the bio-composite
especially the fracture surface of the composite will be analyzed by using SEM. The
composite were fabricated by using resin infusion process and hand lay up method. The
fibers were treated with different concentration and soaking time of sodium hydroxide.
After that, the samples were prepared for tensile test (ASTM D638-1). According to the
findings, it was observed that the optimum concentration and soaking time for composite
was,.6% and 12 hours. This is because in both processes (RIP and HL), the tensile
strength were 90.808MPa (RIP) and 71.217MPa (HL,) which was the highest compared
to other concentration and soaking time. This was clarified further by the SEM where
show smaller degree of fiber pulls out and rough surface fibers. Lastly, the tensile
properties of RIP were better than HL no matter in treated or untreated composites
because the results such as tensile strength, Young's modulus and maximum strain
shown that the value was higher than HL in overall.
ABSTRAK
...
.
Bio komposit merupakan sejenis bahan yang dapat diperbentukkan dengan
menggunakan matrik (resin) dan diperteguhkan dengan gentian semulajadi. .Gentiangentian ini adalah diperolehi melalui tumbuh-tumbuhan dan selulosa. Objektif bagi
kajian ini adalah untuk mengkaji perbezaan bagi sifat ketegangan dalam komposit
poliCster tak tepulkenaf dengan menggunakan proses penyerapan resin dibandingkan
dengan proses penyususnan secara lembap. Kesan daripada rawatan natrium hydroksida
kepada sifat ketegangan komposit juga dikaji. Selain itu, interfasa dan ikatan di antara
matriz dengan gentian yang wujud dalam bio komposit terutamanya pada kawasan patah
juga dianalisis dengan menggunakan SEM. Bio komposit dalam kajian ini akan
disediakan dengan menggunakan proses penyerapan resin dan proses penyusunan secara
lembap. Gentian kenaf juga akan dirawat dengan natrium hidroksida untuk kepekatan
dan masa rendaman yang berbeza sebelum diproses. Selepas itu, sampel akan disediakan
untuk ujikaji ketegangan (ASTM D638-1). Dengan merujuk kepada keputusan, didapati
bahawa kepekatan dan masa rendaman yang optimum adalah 6% dan 12 jam. Ini adalah
kerana kekuatan tegangan untuk kedua-dua proses tersebut adalah paling tinggi iaitu
mencapai lebih h r a n g 90.808MPa untuk proses penyerapan resin dan 72.217MPa untuk
proses penyusunan secara lembap. Ini boleh dibuktikan dengan analisa SEM di mana
bilangan gentian yang ditarik keluar adalah banyak dan permukaannya adalah kasar. Ini
menunjukkan satu ikatan yang h a t dan teguh di antara gentian dan matrik. Akhir kata,
sifat regangan untuk proses peyerapan resin adalah lebih baik daripada proses
penyusunan secare kmbap kerana keputusan seperti h a t a n regangan, Young's modulus,
dan pemanjangan maksimum menunjukkan nilai yang lebih tinggi.
ACKNOWLEDGEMENTS
First of all, I would like to acknowledge my supervisor, Prof. Md Dan Md Palil. He is
giving me a lot of advices and guidance for learning in polymeric bio-composite.
Besides, he is also show his willingness to comment my draft report all the while even it
is full with mistake and flaws. Without him, this report would not be completed in time.
Therefore, I would like to express my deepest appreciation to him
Secondly, I would like to grate the master student whom is Encik Khiralsalleh bin Abdul
Aziz and Phongsakorn A/L Prak Tom. In facts, Encik Khiral was explained and
demonstrated the processing method which is resin infusion process to me. Besides, he
is also provided some related information to me.
Lastly, I would like to thanks to the National Tobacco Authority (Lembaga Tembakau
Negara) which is situated in Terengganu for providing kenaf fibers.
TABLE OF CONTENTS
Abstract
Abstrak
Acknowledgement
iv
...
Table of Contents
List of Figures
Vlll
List of Tables
List of Abbreviations, symbols, specialized nomenclature
List of Appendices
1.0
INTRODUCTION
1.1
Background
1.2
Problem Statement
1.3
Objectives
1.4
Scope
.
2.0
. .
LITEMTURE REVIEW
2.1
Introduction to Composite
2.1.1
Polymeric Matrix Composite (PMC)
2.1 -2 Metal Matrix Composite (MMC)
2.1.3
2.2
Ceramic Matrix Composite (CMC)
Matrix
2.2.1
Thermoset
2.2.1.1 Unsaturated Polyester (UPE)
2.2.1.2 Epoxy resins
2.2.1.3 Vinyl Ester Resins
2.2.2
Thermoplastic
2.2.2.1 Polypropylene (PP)
xiv
2.2.2.2 Polyethylene (PE)
2.3
2.2.3
Bio-degradable polymer
2.2.4
Elastomer
Fiber
2.3.1 Synthetic Fibers
2.3.1 .1 Carbon fiber
2.3.1.2 Aramid fiber
2.3.1.3 Glass fiber
2.3.1.3.1
E-glass
2.3.1.3.2
S-glass
22
.. . . . .. .
23
2.3.1 -3.3 AR-glass
24
2.3.2 Natural fibers
24
2.3.2.1 Classification of Natural Fibers
25
2.3.2.2 Origin and Production of Natural Fibers
25
2.3.2.3 Chemical Composition of Natural Fibers
27
2.3.2.4 Mechanical Properties of Natural Fibers in comparison
29
with glass fibers
2.3.2.5 Advantages and Disadvantagesof Natural Fibers in
comparison with glass fibers
.
30
.
32
2.3.2.6 Kenaf
2.4
2.5
2.3 -2.6.1 Introduction
32
2.3.2.6.2
Processing of kenaf fibers
33
2.3.2.6.3
Application of kenaf composite
.. .
- -
.
.
35
Natural Fiber Reinforced Composite
36
2.4.1 Natural fiber reinforced thermoplastic
36
2.4.2 Natural fiber reinforced
thermosets
. . .
40
Rules of Mixture (ROM) Equation
44
2.5.1
Tensile Strength.
44
2.5.2
Ultimate Tensile Strength
44
2.5.3
Moduli of Elasticity
44
..
Processing Methods of Polymer Matrix Composite
2.6
2.6.1
2.7
3.0 -
Thermoset Resin Composite
Current Trend of Bio-composite
METHODOLOGIES
3.1
Introduction
3.2
Materials and Equipments
3.3
Sample Preparation
3 -3.1 Fiber Preparation
3.3.2
UPEIKenaf Composite Preparation by Using Resin Infusion
Process
3.3 -3 UPEIKenaf Composite Preparation by Using Hand Lay Up
Method
3.3.4
Testing Sample Preparation
3.3.5 Tensile Test
3.3.6 Testing Analysis
3 -3.7 Scanning Electron Microscopy (SEM)
4.0
RESULTS AND DISCUSSION
.
.
4.1
Introduction
4.2
Tensile Properties (Resin Infusion)
4.3
.
..
4.2.1
Stress Strain Curve Analysis
4.2.2
Comparison of Tensile Properties in Different Soaking Time
4.2.3
Comparison of Tensile Properties in Different Concentration
Tensile Properties (Hand Lay Up)
.
4.3.1
Stress Strain Curve Analysis
4.3.2
Evaluation of Tensile Strength, Maximum Strain, and Young's
Modulus for Testing Samples
4.4
77
Comparison of Tensile Properties between Resin Inhsion Process and
Hand Lay Up Method (HL)
80
4.5
5.0
Morphological Analysis
4.5.1
Morphology of Fiber Surface
4.5.2
Morphology of Tensile Fracture Surface (Resin Infusion)
4.5.3
Morphology of Tensile Fracture Surface (Hand Lay Up)
CONCLUSION AND FUTURE WORK RECONMMENDATIONS
5.1
Conclusion
5.2
Future Work Recommendations
REFERENCES
APPENDICES
A
List of Materials & Their Functions
B
List of Stress Strain Curve for Samples of Resin Inhsion Process
C
List of Stress Strain Curve for Samples of Hand Lay Up Method
D
Gantt Chart for PSM 1 and PSM 2
. . . .....
LIST OF FIGURES
2.1
Unsaturated Polyester Resins
2.2
Idealized Chemical Structure of A Typical Isophthalic Polyester
2.3
Illustration of Chemical Structure of A Simple Epoxy (ethylene oxide)
2.4
Illustration of Chemical Structure of A Typical Epoxy (diglycidyl ether
of bisphenol-A)
.. .
..
.
.. '... . .
2.5
Idealized Chemical Structure of a Typical Epoxy Based Vinyl Ester
2.6
Image of Chopped Strand Mat (CSM) for E-glass
2.7
Classification of Natural Fibers According to Origin ~ o ~ e t h with
er
Several Examples
2.8
Kenaf in The Field
2.9
Typical Stress-strain Curves of Polypropylene (PP) and Kenaf 37
33
composites. Number to The End of The Curve Indicate Wt. Amount of
Kenaf. All Coupled Blends Had 2% by Weight of Coupling Agents
2.10
Tensile Strengths of
Natural ' Fiber Reinforced
Polypropylene 38
Composites
2.11
Tensile Modulus Fiber Reinforced Polypropylene Composites
2.12
Effect of Alkali Treatment on Tensile Strength (TS) and Flexural 40
39
Strength (FS) of Polyester Coir Composite
2.13
Fracture Surface of Kenaf-UPRs composites
41
2.14
Scanning Electron Micrograph of The Composite Based on Glass Fibers 43
and: (a) Acrylic Resin and @) Polyester Resin
91
2.15
ESEM Micrographs (Magnification 150x, Scale 300pm) of Tensile 43
Fracture Surfaces of (a) Untreated Hemp Mat-UPE Composite and @)
Acrylonitrile Treated Hemp Mat-UPE composite
3.1
Research Flow Chart
49
3.2
Image of Kenaf Fiber which was treated with different concentration of 52
sodium hydroxide. Upper row from left to right show mechanical
processed fibers, UT (water treatment), T I (3 Percent for 12 hours), and
T2 (3 Percent for 24 hours). Lower row from left to right show fiber for
T3 (6 Percent for 12 hours), T4 (6 percent for 24 hours) and T5 (9
Percent for 12 hours)
3.3
Illustration of Vacuum Infusion Process for Overall Process
3.4
Illustration of Enlarging View of Installation for Resin Infusion Process 53
53
in Mold
3.5
Image Show the Installation of Peel Ply, Filter Jacket, and Vacuum Bag
3.6
The Stacking Sequence in Mold for Resin Infusion Process (Sectional 54
54
View)
3.7
Flow Chart of Resin Infusion Process
55
3.8
Image of Fabricated Composite by Using Resin InfuSion Process.
56
3.9
a) Layer of Kenaf Fibers on Steel Mould b) Layer of Kenaf Fibers being 57
Coat with GP Resin c) Resin Layer Pressed by Aluminium Roller
3.10
Combination Layers in the Composite Samples
57
3.11
Flow Chart of Hand Lay Up Method
58
3.12
Image of Fabricated Composite by Using Hand Lay Up Method
59
3.13
Hardness Plastic Specimen Cutting Machine
60
3.14
Illustration of Dumbbell-shaped Specimen Dimension for Type I in 61
ASTM D368
.
. .
Image of Tensile Sample after Test for Resin Infusion Process. From 62
Right to Left show Sample UT, TI, T2,T3, T4 and T5. Sample in Circle
wasT3
.
Image of Tensile Sample after Test for Hand Lay Up Method. From 63
Left to Right show Sample A (1-4), Sample B (5-8), and Sample UT
(9). Sample in Circle was A
Image show the Cracking Area of a) Sample T3 (Resin Infusion 63
Process) and b) Sample A (Hand Lay Up Method)
Image for Scanning Electron Microscopy (SEM) (Evo 50, Zeiss) 64
Located in Material laboratory in UTEM
Tensile Strength (MPa) of Samples T1 to UT
67
Maximum Strain (%) of Samples T1 to UT
67
Young's Modulus (GPa) of Samples T1 to UT
68
Stress Strain Curve for Sample T3 which was treated with 6 percentage 69
of NaOH for 12 hours
Stress Strain Curve for Sample UT which was Untreated
-.-
'
'
'
.
70
Tensile Strength for Different Concentration
73
Maximum Strain (Percent) for Different Concentration NaOH
73
Young's Modulus (GPa) for Different Concentration NaOH
74
Figure 4.9: Stress Strain Curve of Sample A which was Treated with 6
76
Percent of NaOH for 12 hours)
Stress Strain Curve of Sample UT which was Untreated
77
Line graph showing the Tensile Strength (TS) of Samples A (6 Percent 79
Treated with NaOH), B (9 Percent Treated with NaOH) and UT
c.
(Untreated) for Hand Lay Up Method
Line Graph showing the Maximum Strain (Percent) of Samples A (6 79
Percent Treated with NaOH), B (9 Percent Treated with NaOH) and UT
(Untreated) for Hand Lay Up Method
,Line Graph showing the Young's Modulus (GPa) of Samples A (6 80
Percent Treated with NaOH), B (9 Percent Treated with NaOH) and UT
(Untreated) for Hand Lay Up Method
Tensile Strength of KenafPolyester Composite for Resin Infusion and 81
Hand Lay Up Method. Sample 1 is 6 Percent Treated with NaOH for 12
Hours, Sample 2 is 9 Percent Treated with NaOH for 12 Hours and
Sample 3 is Untreated Composites
Maximum Strain (Percent) of KenaEIPolyester Composite for Resin 83
Infusion and Hand Lay Up Method. Sample 1 is 6 Percent Treated with
NaOH for 12 Hours, Sample 2 is 9Percent Treated with NaOH for 12
Hours and Sample 3 is Untreated Composites
Young's Modulus (GPa) of KenaWolyester Composite for Resin 84
Infus'ion and Hand Lay Up Method. Sample 1 is 6 percent treated with
NaOH for 12 Hours, Sample 2 is 9 percent Treated with NaOH for 12
Hours and Sample 3 is Untreated ~ o ~ p o s i t e s
SEM Micrograph of (a) Treated Kenaf Fibers with 3 Percent Sodium 85
Hydroxide (12h) and @) Treated Kenaf Fibers with 3 Percent Sodium
Hydroxide (24h)
SEM Micrograph of (a) Treated Kenaf Fibers with 6 Percent Sodium 86
Hydroxide (12h) and (d) Treated kenaf fibers with 6 Percent Sodium
Hydroxide (24h)
SEM Micrograph of (a) Treated Kenaf Fibers with 9 Percent 'sodium 86
Hydroxide (12h) and @) Untreated Kenaf Fibers
. . .
SEM Micrograph (Magnification 300X, 100pm) of (a) Sample T 1 88
(Treated with 3 Percent NaOH for 12 hours) and @) Sample T2
(Treated with 6 Percent NaOH for 24 Hours) which Show The Tensile
Fracture Surface
4.21
SEM Micrograph (a) (Magnification 100X7 200p-n) of Sample T3 89
(Treated with 6 Percent NaOH for 12 hours) and @) (Magnification
300X, IOOpm) of Sample T4 (Treated with 6 Percent NaOH for 24
hours) which Show The Tensile
4.22
rackr re Surface
SEM Micrograph (e) (Magnification 300X7 100j.m) of Sample T5 89
(Treated with 9 Percent NaOH for 12 hours) and (f) (Magnification
300X, 100pm) of Sample UT (untreated) which Show the Tensile
Fracture Surface
4.23
SEM Micrograph (a) (Magnification 300X, 100pm) of Sample A 91
(Treated with 6 Percent NaOH for 12 hours), @) (~agnification*300~,
100pm) of Sample B (Treated with 9 Percent NaOH for 12 hours) and
(c) (Magnification 300X7 100pm) of Sample UT (Untreated) which
show the Tensile Fracture Surface
xii
LIST OF TABLES
2.1
Comparison of Typical Ranges of Property Values for Thermosets and 9
Thermoplastics
2.2
Properties of Selected Thermoset and Thermoplastic Material
18
2.3
Comparative Graphite Fiber Properties
20
2.4
Typical Composition and Properties of Glass Fibers
.
.. .
23
...,. . . . . .
.
2.5
Annual production of Natural Fiber and Its Origin
2.6
Fiber and Countries of Origin
2.7
Chemical Composition, Moisture Content and Waxes of Natural Fiber
28
2.8
Comparison Properties of E-glass and Some Important Natural Fibers
29
2.9
Comparison between Natural and Glass Fibers
31
Mechanical Properties of Glass Fibre matlpolypropylene Composites
39
Results of Tensile Test for Each Composile
42
List of Treatment and Soaking Time for Fiber Preparation
51
Dumbbell-shaped Specimen Dimension for Type I in ASTM D368
61
26
.
.. .
.
List of results for Young's Modulus, Tensile Strength and Max Strain 66
for Samples of Resin Infusion
List of Sample' results of Young's Modulus, Tensile Strength, and Max. 75
Strain
.
.
LIST OF' ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
CMC
Ceramic Matrix Composite
CSM
Chopped Strand Mat
EOL
End'of Life
ESEM
Environmental Scanning Electron Microscopy
FS
Flexural Strength
HL
Hand Lay Up
MAF'P
Maleic Anhydride Polypropylene
MEJSP
Methyl Ethyl Ketone Peroxide
MMC
Metal Matrix Composite
PP
Polypropylene
PE
Polyethylene
PMC
Polymeric Matrix Composite
RIP
Resin Infusion Process
ROM
Rule of Mixture
RTM
Resin ~ransferMolding
SEM
Scanning Electron Microscopy
TS
Tensile Strength
UPE
Unsaturated Polyester
. . . .
...... . . . . .
xiv
..
CHAPTER 1
INTRODUCTION
1.0
Background
. . .. ..
.
Research in polymer composite often requires certain modifications in order to improve
their properties. Additional reinforcement and filler were used to improve the
mechanical and physical properties of the composite. Basically, the objective of this
project is to develop a new composite with kenaf as the reinforcement in the polymer
matrix which is unsaturated polyester through the resin infusion process and hand lay up
method. This is because unsaturated polyester resins are extremely versatile in properties
.. . .
and have been a popular thermoset used as the polymer matrix in composites. Besides,
they are widely produced industrially due to its advantages when compared with others
thermosetting resin including transparency, good meclianical properties and room
temperature cure capability. Furthermore, the reinforcement of polyesters with
cellulosed fibers has been widely reported. Polyester-jute, polyester-sisal, polyester-coir
polyester-banana-cotton, polyester-straw, polyester-pineapple leaf, and polyestercotton-kapok, are some of the promising systems (Aziz et al., 2004). As for kenaf
(hibiscus cannabinus), it is a member of the hibiscus family which is biodegradable and
environmentally friendly crop. It has been found to be an important source of fiber for
composites and other industrial applications.
The research work will focus on morphology study of the composite in telation of
strength properties in the laboratory scale. As for the processing technique, it will
involve several processing stage in fabricate the sample by using resin or known as
vacuum infusion process and hand lay up method. Follow by this, the testing stage will
be conduct in order to investigate tensile properties between these two types of process.
Besides, these two types of process will also have fiber treatment by using the sodium
hydroxide in order to compare its properties. Analysis of the 'finding will be compared
between the resin infusion process and hand lay up method with different concentration
of fiber treatment by using sodium hydroxide in order to verify that the new composite
has the potential to be use as the substitution material in structural and automotive
application.
1.1
... . . .
Problem Statement
In structural area, metals are used as major application. Even though metals are known
for their outstanding mechanical properties, the costs of their raw materials somehow
outweigh the inherent benefits. At the same time, the selection of materials in the market
has shifted to the lightweight materials. This scenario has opened an opportunity to
explore the possibility of producing a lightweight composite yet at the same time
maintaining the outstanding mechanical properties. The cost of manufacturing also could
be reduced sigdicantly if they are produced locally within Malaysia. In this research,
the main focus is to use kenaf as the substitute materials for the steel, as reinforcement in
polymer matrix in order to produce a high impact composite but lightweight. Nowadays,
in Malaysia, kenaf is used mainly for furniture like its counterpart the wood and bamboo.
Exploration in the bio-composite industry has unearthed its potential to be researched.
The usage of metals as high impact materials in structural application is no longer viable
due to the threat of over cost of the raw materials that heavily depend on natural source
and mining activities. This has force the researcher to find other substitution materials
and kenaf is believed has the potential to replacs this role as it functions as a good
reinforce in a suitable matrix material.
In addition, polymeric bio-composite is the advanced composite started to attracted
attention from manufacturer especially to the automotive and structural fields. This is
because of its eco-environmental friendly properties since it is bio-degradable. It is low
cost, low density, high modulus strength, and so on. However, its mechanical properties
are not good as normal polymeric composite which is based on the synthetic fibers such
as E-glass, S-glass, aramid, and so on. Therefore, it is crucial to find out which types of
composite and process is more suitable to apply in automotive and structural fields by
comparing the tensile properties, microstructure, and so on.
Objectives
1.2
i.
To investigate the tensile properties of polymeric bio-composite (Unsaturated
Polyester/kenaf) by using resin infusion process in comparison with hand lay
up method.
ii.
To investigate the effects of fiber treatment to the tensile properties of
polymeric bio-composites (Unsaturated Polyester Ikenaf).
iii.
To study the interface bonding of fiber matrix by scanning electron
microscopy.
1.3
Scope
This section states the choices made during the research process and the research will
conduct by follow the criteria as stated below:
i.
Use of kenaf fiber extracted using decorticating machine which already
available loqlly (the kenaf fiber is donated from Lembaga Tembakau Negeri
Terengganu).
ii.
The kenaf fibers are in long continuous and loose fiber forms.
'
.
in.
...
Use of simple and low cost fiber purification and treatment process.
iv.
Use of single polymer that can be processes in the room temperature.
v.
Use of single manufacturing process that involved low cost investment of
tool and equipment but capable to produce high performance materials.
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction to -composites
Composites consist of two (or more) distinct constituents orphases, which when married
together result in a material with entirely different properties from those of the
individual components (Paul et al., 2006). In other words, composites are materials that
comprise strong load carrying material (known as reinforcement) imbedded in weaker
material (known as matrix). Reinforcement provides strength and rigidity, helping to
support structural load. The matrix or binder (organic or inorganic) maintains the
position and orientation of the reinforcement (Taj et al., 2007). Besides, there are 3 types
of composite which are polymer matrix composite, metal matrix composite and ceramic'.
matrix composite. However, only the polymer matrix composite will be discuss in this
section since the matrix that will be uied in this research is unsaturated polyester.
In fact, polymer matrix composite is the most advanced composites. Basically, polymez
matrix composite can divided into two classes which are thermoplastic and thermoset.
Thermoplastic refers to polymer that can be melting processed by a variety of methods,
including extrusion and molding. These include polyethylene (PE), polypropylene (PP),
polystyrene (PS) and polyvinyl chloride (PVC). On the other hand, thermoset are
polymer whose individual chains have been chemically linked by covalent bonds during
polymerization or by subsequent chemical or thermal treatment. Once formed, the crosslinked networks resist heat softening, creep and solvent attack. Principle thermosets are
'
epoxies, polyesters and formaldehyde-based resins. Then, thermoplastic and thermoset
are reinforced by using fiber such as synthetic fibers and natural fibers.
2.1.1
Polymeric Matrik Composite (PMC)
The most common advanced composites are polymer matrix composites. These
composites consist of a polymer resin as the matrix with fibers as the reinforcement
. .... .. . .
medium (Callister, 2003). These materials can be fashioned into a variety of shapes and
sizes. They provide great strength and stiffness along with resistance to corrosion. The
reason for these being most common is their low cost, high strength and simple
manufacturing principles (Taj et al., 2007).
2.1.2
Metal M a t r i x Composites (MMC)
The word metal matrix composite (MMC) covers a variety of materials and not only
composites with continuous fiber reinforcement (John, 2003): .Metal matrix composites,
as the name implies, the matrix is ductile metal. These materials may be utilized at
higher service temperatures than their base metal counterparts. Some of the advantages
of these materials over the polymer-matrix composites include higher operating
temperatures, non-flammability, and greater resistance to degradation by organic fluids.
It is much more expensive than PMCs and therefore, its use is restricted (Callister, 2003).
Examples of matrices in such composites include aluminum, magnesium and titanium.
The typical fiber includes carbon and silicon carbide. Metals are mainly reinforced to
suit the needs of design. For example, the elastic stiffness and strength of metals can be
increased, while large co-efficient of thermal expansion and thermal and electrical
conductivities of metals can be reduced by the addition of fibers such as silicon carbide.
UNlVERSlTl TEKNIKAL MALAYSIA MELAKA
JUDUL: TENSILE PROPERTIES AND MORPHOLOGY STUDIES OF PO-LYMERIC
BIOCOMPOSTIE
SESI PENGAJIAN : 2007-2008
Saya CHENG YUAN WE
mengaku membenarkan tesis (PSMISarjanalDoktor Falsafah) ini disimpan di
Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat
kegunaan seperti berikut:
1. Tesis adalah .hak milik Universiti Teknikal Malaysia Melaka .
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan (d)
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
dengan menvatakan sekali sebab dan temooh tesis ini oerlu dikelaskan seba~aiSULIT atau TERHAD.
UNlVERSlTl TEKNIKAL MALAYSIA MELAKA
Karung Berkunci 1200, Ayer Keroh, 75450 Melaka
Tel : 06-233 2421, Faks : 06 233 2414
Ernail : fko@kutkrn.edu.mv
FAKULTI KEJURUTERAAN PEMBUATAN
25 Mac 2008
Rujukan Kami (Our Ref) :
Rujukan Tuan (Your Ref):
Pustakawan
Perpustakawan Universiti Teknikal Malaysia Melaka
UTeM, No 1, Jalan TU 43,
Taman Tasik Utama, Hang Tuah Jaya,
Ayer Keroh, 75450, Melaka
Saudara,
PENGKELASAN TESIS SEBAGAI SULIT/TERHAD
-
TESIS
SARJANA MUDA
KEJURUTERAAN
PEMBUATAN
(F'AKULTI
KEJURUTERAAN PEMBUATAN): CHENG YUAN WE
TAJUK:
TENSILE
PROPERTIES
AND
MORPHOLOGY
STUDIES
OF
POLYMERIC BIOCOMPOSITE
Sukacita dimaklumkan bahawa tesis yang tersebut di atas bertajuk 'TENSILE
.
PROPERTEIS
MORPHOLOGY
AND
STUDIES
OF
POLYMERIC
BIOCOMPOSTE" mohon dikelaskan sebagai terhad untuk tempoh lima (5) tahun dari
tarikh surat ini memandangkan ia mempunyai nilai dan potensi untuk dikomersialkan di
masa hadapan.
Sekian dimaklumkan. Terima kasih.
"BERKHIDMAT UNTUK NEGARA KERANA A L L A H
Yang benar,
Pensyarah,
Fakulti Kejuruteraan Pembuatan
DECLARATION
I hereby, declared this thesis entitled "Tensile Properties and Morphology Study of
Polymeric Biocomposite"
is the results of my own research
... ..
.
except as cited in references.
Signature
+#--
Author's Name
CHENG YUAN WE
Date
25 MARCH 2008
Parents:I
.--
-
APPROVAL
...
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the
requirements for the degree of Bachelor of Manufacturing Engineering (Material
Engineering). The members of the supervisory committee are as follow:
PROF. DR. HJ. MD. DAN BIN HJ. MD. PALIL
Timbaian Dekan (Penyelidikon & Pengajiarl Siswazah}
Fakulti Keju~utewanPernbtlatan
Universiti Tzknikal Malaysia Melaka
Karung Berkunci 1200, Ayer Kemh
75450 Melaka
ABSTRACT
Polymeric bio-composite is a materialformed using a polymeric matrix (resin) and a
...
reinforcement of natural. fibers which are usually derived from plants or cellulose. The
objective of current research is to investigate the tensile properties of unsaturated
polyesterkenaf by using the resin infusion process (RIP) in comparison with hand lay up
method (HL). The effects of alkali treatment to the tensile properties of composite also
were investigated. Besides, the interphase and interfacial bonding of the bio-composite
especially the fracture surface of the composite will be analyzed by using SEM. The
composite were fabricated by using resin infusion process and hand lay up method. The
fibers were treated with different concentration and soaking time of sodium hydroxide.
After that, the samples were prepared for tensile test (ASTM D638-1). According to the
findings, it was observed that the optimum concentration and soaking time for composite
was,.6% and 12 hours. This is because in both processes (RIP and HL), the tensile
strength were 90.808MPa (RIP) and 71.217MPa (HL,) which was the highest compared
to other concentration and soaking time. This was clarified further by the SEM where
show smaller degree of fiber pulls out and rough surface fibers. Lastly, the tensile
properties of RIP were better than HL no matter in treated or untreated composites
because the results such as tensile strength, Young's modulus and maximum strain
shown that the value was higher than HL in overall.
ABSTRAK
...
.
Bio komposit merupakan sejenis bahan yang dapat diperbentukkan dengan
menggunakan matrik (resin) dan diperteguhkan dengan gentian semulajadi. .Gentiangentian ini adalah diperolehi melalui tumbuh-tumbuhan dan selulosa. Objektif bagi
kajian ini adalah untuk mengkaji perbezaan bagi sifat ketegangan dalam komposit
poliCster tak tepulkenaf dengan menggunakan proses penyerapan resin dibandingkan
dengan proses penyususnan secara lembap. Kesan daripada rawatan natrium hydroksida
kepada sifat ketegangan komposit juga dikaji. Selain itu, interfasa dan ikatan di antara
matriz dengan gentian yang wujud dalam bio komposit terutamanya pada kawasan patah
juga dianalisis dengan menggunakan SEM. Bio komposit dalam kajian ini akan
disediakan dengan menggunakan proses penyerapan resin dan proses penyusunan secara
lembap. Gentian kenaf juga akan dirawat dengan natrium hidroksida untuk kepekatan
dan masa rendaman yang berbeza sebelum diproses. Selepas itu, sampel akan disediakan
untuk ujikaji ketegangan (ASTM D638-1). Dengan merujuk kepada keputusan, didapati
bahawa kepekatan dan masa rendaman yang optimum adalah 6% dan 12 jam. Ini adalah
kerana kekuatan tegangan untuk kedua-dua proses tersebut adalah paling tinggi iaitu
mencapai lebih h r a n g 90.808MPa untuk proses penyerapan resin dan 72.217MPa untuk
proses penyusunan secara lembap. Ini boleh dibuktikan dengan analisa SEM di mana
bilangan gentian yang ditarik keluar adalah banyak dan permukaannya adalah kasar. Ini
menunjukkan satu ikatan yang h a t dan teguh di antara gentian dan matrik. Akhir kata,
sifat regangan untuk proses peyerapan resin adalah lebih baik daripada proses
penyusunan secare kmbap kerana keputusan seperti h a t a n regangan, Young's modulus,
dan pemanjangan maksimum menunjukkan nilai yang lebih tinggi.
ACKNOWLEDGEMENTS
First of all, I would like to acknowledge my supervisor, Prof. Md Dan Md Palil. He is
giving me a lot of advices and guidance for learning in polymeric bio-composite.
Besides, he is also show his willingness to comment my draft report all the while even it
is full with mistake and flaws. Without him, this report would not be completed in time.
Therefore, I would like to express my deepest appreciation to him
Secondly, I would like to grate the master student whom is Encik Khiralsalleh bin Abdul
Aziz and Phongsakorn A/L Prak Tom. In facts, Encik Khiral was explained and
demonstrated the processing method which is resin infusion process to me. Besides, he
is also provided some related information to me.
Lastly, I would like to thanks to the National Tobacco Authority (Lembaga Tembakau
Negara) which is situated in Terengganu for providing kenaf fibers.
TABLE OF CONTENTS
Abstract
Abstrak
Acknowledgement
iv
...
Table of Contents
List of Figures
Vlll
List of Tables
List of Abbreviations, symbols, specialized nomenclature
List of Appendices
1.0
INTRODUCTION
1.1
Background
1.2
Problem Statement
1.3
Objectives
1.4
Scope
.
2.0
. .
LITEMTURE REVIEW
2.1
Introduction to Composite
2.1.1
Polymeric Matrix Composite (PMC)
2.1 -2 Metal Matrix Composite (MMC)
2.1.3
2.2
Ceramic Matrix Composite (CMC)
Matrix
2.2.1
Thermoset
2.2.1.1 Unsaturated Polyester (UPE)
2.2.1.2 Epoxy resins
2.2.1.3 Vinyl Ester Resins
2.2.2
Thermoplastic
2.2.2.1 Polypropylene (PP)
xiv
2.2.2.2 Polyethylene (PE)
2.3
2.2.3
Bio-degradable polymer
2.2.4
Elastomer
Fiber
2.3.1 Synthetic Fibers
2.3.1 .1 Carbon fiber
2.3.1.2 Aramid fiber
2.3.1.3 Glass fiber
2.3.1.3.1
E-glass
2.3.1.3.2
S-glass
22
.. . . . .. .
23
2.3.1 -3.3 AR-glass
24
2.3.2 Natural fibers
24
2.3.2.1 Classification of Natural Fibers
25
2.3.2.2 Origin and Production of Natural Fibers
25
2.3.2.3 Chemical Composition of Natural Fibers
27
2.3.2.4 Mechanical Properties of Natural Fibers in comparison
29
with glass fibers
2.3.2.5 Advantages and Disadvantagesof Natural Fibers in
comparison with glass fibers
.
30
.
32
2.3.2.6 Kenaf
2.4
2.5
2.3 -2.6.1 Introduction
32
2.3.2.6.2
Processing of kenaf fibers
33
2.3.2.6.3
Application of kenaf composite
.. .
- -
.
.
35
Natural Fiber Reinforced Composite
36
2.4.1 Natural fiber reinforced thermoplastic
36
2.4.2 Natural fiber reinforced
thermosets
. . .
40
Rules of Mixture (ROM) Equation
44
2.5.1
Tensile Strength.
44
2.5.2
Ultimate Tensile Strength
44
2.5.3
Moduli of Elasticity
44
..
Processing Methods of Polymer Matrix Composite
2.6
2.6.1
2.7
3.0 -
Thermoset Resin Composite
Current Trend of Bio-composite
METHODOLOGIES
3.1
Introduction
3.2
Materials and Equipments
3.3
Sample Preparation
3 -3.1 Fiber Preparation
3.3.2
UPEIKenaf Composite Preparation by Using Resin Infusion
Process
3.3 -3 UPEIKenaf Composite Preparation by Using Hand Lay Up
Method
3.3.4
Testing Sample Preparation
3.3.5 Tensile Test
3.3.6 Testing Analysis
3 -3.7 Scanning Electron Microscopy (SEM)
4.0
RESULTS AND DISCUSSION
.
.
4.1
Introduction
4.2
Tensile Properties (Resin Infusion)
4.3
.
..
4.2.1
Stress Strain Curve Analysis
4.2.2
Comparison of Tensile Properties in Different Soaking Time
4.2.3
Comparison of Tensile Properties in Different Concentration
Tensile Properties (Hand Lay Up)
.
4.3.1
Stress Strain Curve Analysis
4.3.2
Evaluation of Tensile Strength, Maximum Strain, and Young's
Modulus for Testing Samples
4.4
77
Comparison of Tensile Properties between Resin Inhsion Process and
Hand Lay Up Method (HL)
80
4.5
5.0
Morphological Analysis
4.5.1
Morphology of Fiber Surface
4.5.2
Morphology of Tensile Fracture Surface (Resin Infusion)
4.5.3
Morphology of Tensile Fracture Surface (Hand Lay Up)
CONCLUSION AND FUTURE WORK RECONMMENDATIONS
5.1
Conclusion
5.2
Future Work Recommendations
REFERENCES
APPENDICES
A
List of Materials & Their Functions
B
List of Stress Strain Curve for Samples of Resin Inhsion Process
C
List of Stress Strain Curve for Samples of Hand Lay Up Method
D
Gantt Chart for PSM 1 and PSM 2
. . . .....
LIST OF FIGURES
2.1
Unsaturated Polyester Resins
2.2
Idealized Chemical Structure of A Typical Isophthalic Polyester
2.3
Illustration of Chemical Structure of A Simple Epoxy (ethylene oxide)
2.4
Illustration of Chemical Structure of A Typical Epoxy (diglycidyl ether
of bisphenol-A)
.. .
..
.
.. '... . .
2.5
Idealized Chemical Structure of a Typical Epoxy Based Vinyl Ester
2.6
Image of Chopped Strand Mat (CSM) for E-glass
2.7
Classification of Natural Fibers According to Origin ~ o ~ e t h with
er
Several Examples
2.8
Kenaf in The Field
2.9
Typical Stress-strain Curves of Polypropylene (PP) and Kenaf 37
33
composites. Number to The End of The Curve Indicate Wt. Amount of
Kenaf. All Coupled Blends Had 2% by Weight of Coupling Agents
2.10
Tensile Strengths of
Natural ' Fiber Reinforced
Polypropylene 38
Composites
2.11
Tensile Modulus Fiber Reinforced Polypropylene Composites
2.12
Effect of Alkali Treatment on Tensile Strength (TS) and Flexural 40
39
Strength (FS) of Polyester Coir Composite
2.13
Fracture Surface of Kenaf-UPRs composites
41
2.14
Scanning Electron Micrograph of The Composite Based on Glass Fibers 43
and: (a) Acrylic Resin and @) Polyester Resin
91
2.15
ESEM Micrographs (Magnification 150x, Scale 300pm) of Tensile 43
Fracture Surfaces of (a) Untreated Hemp Mat-UPE Composite and @)
Acrylonitrile Treated Hemp Mat-UPE composite
3.1
Research Flow Chart
49
3.2
Image of Kenaf Fiber which was treated with different concentration of 52
sodium hydroxide. Upper row from left to right show mechanical
processed fibers, UT (water treatment), T I (3 Percent for 12 hours), and
T2 (3 Percent for 24 hours). Lower row from left to right show fiber for
T3 (6 Percent for 12 hours), T4 (6 percent for 24 hours) and T5 (9
Percent for 12 hours)
3.3
Illustration of Vacuum Infusion Process for Overall Process
3.4
Illustration of Enlarging View of Installation for Resin Infusion Process 53
53
in Mold
3.5
Image Show the Installation of Peel Ply, Filter Jacket, and Vacuum Bag
3.6
The Stacking Sequence in Mold for Resin Infusion Process (Sectional 54
54
View)
3.7
Flow Chart of Resin Infusion Process
55
3.8
Image of Fabricated Composite by Using Resin InfuSion Process.
56
3.9
a) Layer of Kenaf Fibers on Steel Mould b) Layer of Kenaf Fibers being 57
Coat with GP Resin c) Resin Layer Pressed by Aluminium Roller
3.10
Combination Layers in the Composite Samples
57
3.11
Flow Chart of Hand Lay Up Method
58
3.12
Image of Fabricated Composite by Using Hand Lay Up Method
59
3.13
Hardness Plastic Specimen Cutting Machine
60
3.14
Illustration of Dumbbell-shaped Specimen Dimension for Type I in 61
ASTM D368
.
. .
Image of Tensile Sample after Test for Resin Infusion Process. From 62
Right to Left show Sample UT, TI, T2,T3, T4 and T5. Sample in Circle
wasT3
.
Image of Tensile Sample after Test for Hand Lay Up Method. From 63
Left to Right show Sample A (1-4), Sample B (5-8), and Sample UT
(9). Sample in Circle was A
Image show the Cracking Area of a) Sample T3 (Resin Infusion 63
Process) and b) Sample A (Hand Lay Up Method)
Image for Scanning Electron Microscopy (SEM) (Evo 50, Zeiss) 64
Located in Material laboratory in UTEM
Tensile Strength (MPa) of Samples T1 to UT
67
Maximum Strain (%) of Samples T1 to UT
67
Young's Modulus (GPa) of Samples T1 to UT
68
Stress Strain Curve for Sample T3 which was treated with 6 percentage 69
of NaOH for 12 hours
Stress Strain Curve for Sample UT which was Untreated
-.-
'
'
'
.
70
Tensile Strength for Different Concentration
73
Maximum Strain (Percent) for Different Concentration NaOH
73
Young's Modulus (GPa) for Different Concentration NaOH
74
Figure 4.9: Stress Strain Curve of Sample A which was Treated with 6
76
Percent of NaOH for 12 hours)
Stress Strain Curve of Sample UT which was Untreated
77
Line graph showing the Tensile Strength (TS) of Samples A (6 Percent 79
Treated with NaOH), B (9 Percent Treated with NaOH) and UT
c.
(Untreated) for Hand Lay Up Method
Line Graph showing the Maximum Strain (Percent) of Samples A (6 79
Percent Treated with NaOH), B (9 Percent Treated with NaOH) and UT
(Untreated) for Hand Lay Up Method
,Line Graph showing the Young's Modulus (GPa) of Samples A (6 80
Percent Treated with NaOH), B (9 Percent Treated with NaOH) and UT
(Untreated) for Hand Lay Up Method
Tensile Strength of KenafPolyester Composite for Resin Infusion and 81
Hand Lay Up Method. Sample 1 is 6 Percent Treated with NaOH for 12
Hours, Sample 2 is 9 Percent Treated with NaOH for 12 Hours and
Sample 3 is Untreated Composites
Maximum Strain (Percent) of KenaEIPolyester Composite for Resin 83
Infusion and Hand Lay Up Method. Sample 1 is 6 Percent Treated with
NaOH for 12 Hours, Sample 2 is 9Percent Treated with NaOH for 12
Hours and Sample 3 is Untreated Composites
Young's Modulus (GPa) of KenaWolyester Composite for Resin 84
Infus'ion and Hand Lay Up Method. Sample 1 is 6 percent treated with
NaOH for 12 Hours, Sample 2 is 9 percent Treated with NaOH for 12
Hours and Sample 3 is Untreated ~ o ~ p o s i t e s
SEM Micrograph of (a) Treated Kenaf Fibers with 3 Percent Sodium 85
Hydroxide (12h) and @) Treated Kenaf Fibers with 3 Percent Sodium
Hydroxide (24h)
SEM Micrograph of (a) Treated Kenaf Fibers with 6 Percent Sodium 86
Hydroxide (12h) and (d) Treated kenaf fibers with 6 Percent Sodium
Hydroxide (24h)
SEM Micrograph of (a) Treated Kenaf Fibers with 9 Percent 'sodium 86
Hydroxide (12h) and @) Untreated Kenaf Fibers
. . .
SEM Micrograph (Magnification 300X, 100pm) of (a) Sample T 1 88
(Treated with 3 Percent NaOH for 12 hours) and @) Sample T2
(Treated with 6 Percent NaOH for 24 Hours) which Show The Tensile
Fracture Surface
4.21
SEM Micrograph (a) (Magnification 100X7 200p-n) of Sample T3 89
(Treated with 6 Percent NaOH for 12 hours) and @) (Magnification
300X, IOOpm) of Sample T4 (Treated with 6 Percent NaOH for 24
hours) which Show The Tensile
4.22
rackr re Surface
SEM Micrograph (e) (Magnification 300X7 100j.m) of Sample T5 89
(Treated with 9 Percent NaOH for 12 hours) and (f) (Magnification
300X, 100pm) of Sample UT (untreated) which Show the Tensile
Fracture Surface
4.23
SEM Micrograph (a) (Magnification 300X, 100pm) of Sample A 91
(Treated with 6 Percent NaOH for 12 hours), @) (~agnification*300~,
100pm) of Sample B (Treated with 9 Percent NaOH for 12 hours) and
(c) (Magnification 300X7 100pm) of Sample UT (Untreated) which
show the Tensile Fracture Surface
xii
LIST OF TABLES
2.1
Comparison of Typical Ranges of Property Values for Thermosets and 9
Thermoplastics
2.2
Properties of Selected Thermoset and Thermoplastic Material
18
2.3
Comparative Graphite Fiber Properties
20
2.4
Typical Composition and Properties of Glass Fibers
.
.. .
23
...,. . . . . .
.
2.5
Annual production of Natural Fiber and Its Origin
2.6
Fiber and Countries of Origin
2.7
Chemical Composition, Moisture Content and Waxes of Natural Fiber
28
2.8
Comparison Properties of E-glass and Some Important Natural Fibers
29
2.9
Comparison between Natural and Glass Fibers
31
Mechanical Properties of Glass Fibre matlpolypropylene Composites
39
Results of Tensile Test for Each Composile
42
List of Treatment and Soaking Time for Fiber Preparation
51
Dumbbell-shaped Specimen Dimension for Type I in ASTM D368
61
26
.
.. .
.
List of results for Young's Modulus, Tensile Strength and Max Strain 66
for Samples of Resin Infusion
List of Sample' results of Young's Modulus, Tensile Strength, and Max. 75
Strain
.
.
LIST OF' ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
CMC
Ceramic Matrix Composite
CSM
Chopped Strand Mat
EOL
End'of Life
ESEM
Environmental Scanning Electron Microscopy
FS
Flexural Strength
HL
Hand Lay Up
MAF'P
Maleic Anhydride Polypropylene
MEJSP
Methyl Ethyl Ketone Peroxide
MMC
Metal Matrix Composite
PP
Polypropylene
PE
Polyethylene
PMC
Polymeric Matrix Composite
RIP
Resin Infusion Process
ROM
Rule of Mixture
RTM
Resin ~ransferMolding
SEM
Scanning Electron Microscopy
TS
Tensile Strength
UPE
Unsaturated Polyester
. . . .
...... . . . . .
xiv
..
CHAPTER 1
INTRODUCTION
1.0
Background
. . .. ..
.
Research in polymer composite often requires certain modifications in order to improve
their properties. Additional reinforcement and filler were used to improve the
mechanical and physical properties of the composite. Basically, the objective of this
project is to develop a new composite with kenaf as the reinforcement in the polymer
matrix which is unsaturated polyester through the resin infusion process and hand lay up
method. This is because unsaturated polyester resins are extremely versatile in properties
.. . .
and have been a popular thermoset used as the polymer matrix in composites. Besides,
they are widely produced industrially due to its advantages when compared with others
thermosetting resin including transparency, good meclianical properties and room
temperature cure capability. Furthermore, the reinforcement of polyesters with
cellulosed fibers has been widely reported. Polyester-jute, polyester-sisal, polyester-coir
polyester-banana-cotton, polyester-straw, polyester-pineapple leaf, and polyestercotton-kapok, are some of the promising systems (Aziz et al., 2004). As for kenaf
(hibiscus cannabinus), it is a member of the hibiscus family which is biodegradable and
environmentally friendly crop. It has been found to be an important source of fiber for
composites and other industrial applications.
The research work will focus on morphology study of the composite in telation of
strength properties in the laboratory scale. As for the processing technique, it will
involve several processing stage in fabricate the sample by using resin or known as
vacuum infusion process and hand lay up method. Follow by this, the testing stage will
be conduct in order to investigate tensile properties between these two types of process.
Besides, these two types of process will also have fiber treatment by using the sodium
hydroxide in order to compare its properties. Analysis of the 'finding will be compared
between the resin infusion process and hand lay up method with different concentration
of fiber treatment by using sodium hydroxide in order to verify that the new composite
has the potential to be use as the substitution material in structural and automotive
application.
1.1
... . . .
Problem Statement
In structural area, metals are used as major application. Even though metals are known
for their outstanding mechanical properties, the costs of their raw materials somehow
outweigh the inherent benefits. At the same time, the selection of materials in the market
has shifted to the lightweight materials. This scenario has opened an opportunity to
explore the possibility of producing a lightweight composite yet at the same time
maintaining the outstanding mechanical properties. The cost of manufacturing also could
be reduced sigdicantly if they are produced locally within Malaysia. In this research,
the main focus is to use kenaf as the substitute materials for the steel, as reinforcement in
polymer matrix in order to produce a high impact composite but lightweight. Nowadays,
in Malaysia, kenaf is used mainly for furniture like its counterpart the wood and bamboo.
Exploration in the bio-composite industry has unearthed its potential to be researched.
The usage of metals as high impact materials in structural application is no longer viable
due to the threat of over cost of the raw materials that heavily depend on natural source
and mining activities. This has force the researcher to find other substitution materials
and kenaf is believed has the potential to replacs this role as it functions as a good
reinforce in a suitable matrix material.
In addition, polymeric bio-composite is the advanced composite started to attracted
attention from manufacturer especially to the automotive and structural fields. This is
because of its eco-environmental friendly properties since it is bio-degradable. It is low
cost, low density, high modulus strength, and so on. However, its mechanical properties
are not good as normal polymeric composite which is based on the synthetic fibers such
as E-glass, S-glass, aramid, and so on. Therefore, it is crucial to find out which types of
composite and process is more suitable to apply in automotive and structural fields by
comparing the tensile properties, microstructure, and so on.
Objectives
1.2
i.
To investigate the tensile properties of polymeric bio-composite (Unsaturated
Polyester/kenaf) by using resin infusion process in comparison with hand lay
up method.
ii.
To investigate the effects of fiber treatment to the tensile properties of
polymeric bio-composites (Unsaturated Polyester Ikenaf).
iii.
To study the interface bonding of fiber matrix by scanning electron
microscopy.
1.3
Scope
This section states the choices made during the research process and the research will
conduct by follow the criteria as stated below:
i.
Use of kenaf fiber extracted using decorticating machine which already
available loqlly (the kenaf fiber is donated from Lembaga Tembakau Negeri
Terengganu).
ii.
The kenaf fibers are in long continuous and loose fiber forms.
'
.
in.
...
Use of simple and low cost fiber purification and treatment process.
iv.
Use of single polymer that can be processes in the room temperature.
v.
Use of single manufacturing process that involved low cost investment of
tool and equipment but capable to produce high performance materials.
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction to -composites
Composites consist of two (or more) distinct constituents orphases, which when married
together result in a material with entirely different properties from those of the
individual components (Paul et al., 2006). In other words, composites are materials that
comprise strong load carrying material (known as reinforcement) imbedded in weaker
material (known as matrix). Reinforcement provides strength and rigidity, helping to
support structural load. The matrix or binder (organic or inorganic) maintains the
position and orientation of the reinforcement (Taj et al., 2007). Besides, there are 3 types
of composite which are polymer matrix composite, metal matrix composite and ceramic'.
matrix composite. However, only the polymer matrix composite will be discuss in this
section since the matrix that will be uied in this research is unsaturated polyester.
In fact, polymer matrix composite is the most advanced composites. Basically, polymez
matrix composite can divided into two classes which are thermoplastic and thermoset.
Thermoplastic refers to polymer that can be melting processed by a variety of methods,
including extrusion and molding. These include polyethylene (PE), polypropylene (PP),
polystyrene (PS) and polyvinyl chloride (PVC). On the other hand, thermoset are
polymer whose individual chains have been chemically linked by covalent bonds during
polymerization or by subsequent chemical or thermal treatment. Once formed, the crosslinked networks resist heat softening, creep and solvent attack. Principle thermosets are
'
epoxies, polyesters and formaldehyde-based resins. Then, thermoplastic and thermoset
are reinforced by using fiber such as synthetic fibers and natural fibers.
2.1.1
Polymeric Matrik Composite (PMC)
The most common advanced composites are polymer matrix composites. These
composites consist of a polymer resin as the matrix with fibers as the reinforcement
. .... .. . .
medium (Callister, 2003). These materials can be fashioned into a variety of shapes and
sizes. They provide great strength and stiffness along with resistance to corrosion. The
reason for these being most common is their low cost, high strength and simple
manufacturing principles (Taj et al., 2007).
2.1.2
Metal M a t r i x Composites (MMC)
The word metal matrix composite (MMC) covers a variety of materials and not only
composites with continuous fiber reinforcement (John, 2003): .Metal matrix composites,
as the name implies, the matrix is ductile metal. These materials may be utilized at
higher service temperatures than their base metal counterparts. Some of the advantages
of these materials over the polymer-matrix composites include higher operating
temperatures, non-flammability, and greater resistance to degradation by organic fluids.
It is much more expensive than PMCs and therefore, its use is restricted (Callister, 2003).
Examples of matrices in such composites include aluminum, magnesium and titanium.
The typical fiber includes carbon and silicon carbide. Metals are mainly reinforced to
suit the needs of design. For example, the elastic stiffness and strength of metals can be
increased, while large co-efficient of thermal expansion and thermal and electrical
conductivities of metals can be reduced by the addition of fibers such as silicon carbide.