Reprocessing of wood flour reinforced polypropylene composites: Impact of particle size and coupling agent on composite and particle properties

The Influence of Fly Ash on the Mechanical Properties of Water Immersed All Waste Composites

The paper presents new value-added composite materials prepared by recycling tire rubber, polyethene terephthalate (PET), high-density polyethene (HDPE), wood sawdust, and fly ash. The composites were manufactured through the compression molding technique for three temperatures (150 °C, 160 °C, and 190 °C) previously optimized. The addition of fly ash as reinforcement in polymer blends is a viable route to improve the composite” properties. The paper aims to assess the effect of fly ash on the mechanical properties and water stability of the new all waste composites considering their applications as outdoor products. The static tensile (stress-strain behavior) and compression properties of the composites were tested. The fly ash composites were characterized in terms of wetting behavior and surface energies (contact angle measurements); chemical structure of the new interface developed between composite” components (FTIR analysis), crystalline structure (XRD analysis), surface morphology and topography (SEM, AFM). The addition of fly ash promoted the development of the hybrid interfaces in the new composites, as FTIR analysis has shown, which, in turn, greatly improved the mechanical and water resistance. The novel all waste composites exhibited lower surface energies, larger contact angles, and smoother morphologies when compared to those with no fly ash. Overall, the study results have revealed that fly ash has improved the mechanical strength and water stability of the composites through the formation of strong hybrid interfaces. The study results show optimal water stability and tensile strength for 0.5% fly ash composites cured at 190 °C and optimal compressive strength with good water stability for 1% fly ash composite cured at 150 °C.

A Critical Review on Wood-Based Polymer Composites: Processing, Properties, and Prospects

Waste recycling is one of the key aspects in current day studies to boost the country's circular economy. Recycling wood from construction and demolished structures and combining it with plastics forms wood-polymer composites (WPC) which have a very wide scope of usage. Such recycled composites have very low environmental impact in terms of abiotic potential, global warming potential, and greenhouse potential. Processing of WPCs can be easily done with predetermined strength values that correspond to its end application. Yet, the usage of conventional polymer composite manufacturing techniques such as injection molding and extrusion has very limited scope. Many rheological characterization techniques are being followed to evaluate the influence of formulation and process parameters over the quality of final WPCs. It will be very much interesting to carry out a review on the material formulation of WPCs and additives used. Manufacturing of wood composites can also be made by using bio-based adhesives such as lignin, tannin, and so on. Nuances in complete replacement of synthetic adhesives as bio-based adhesives are also discussed by various researchers which can be done only by complete understanding of formulating factors of bio-based adhesives. Wood composites play a significant role in many non-structural and structural applications such as construction, floorings, windows, and door panels. The current review focuses on the processing of WPCs along with additives such as wood flour and various properties of WPCs such as mechanical, structural, and morphological properties. Applications of wood-based composites in various sectors such as automotive, marine, defense, and structural applications are also highlighted in this review.

Best Practices for Quasistatic Berkovich Nanoindentation of Wood Cell Walls

For wood and forest products to reach their full potential as structural materials, experimental techniques are needed to measure mechanical properties across all length scales. Nanoindentation is uniquely suited to probe in situ mechanical properties of micrometer-scale features in forest products, such as individual wood cell wall layers and adhesive bondlines. However, wood science researchers most commonly employ traditional nanoindentation methods that were originally developed for testing hard, inorganic materials, such as metals and ceramics. These traditional methods assume that the tested specimen is rigidly supported, homogeneous, and semi-infinite. Large systematic errors may affect the results when these traditional methods are used to test complex polymeric materials, such as wood cell walls. Wood cell walls have a small, finite size, and nanoindentations can be affected by nearby edges. Wood cell walls are also not rigidly supported, and the cellular structure can flex under loading. Additionally, wood cell walls are softer and more prone to surface detection errors than harder inorganic materials. In this paper, nanoindentation methods for performing quasistatic Berkovich nanoindentations, the most commonly applied nanoindentation technique in forest products research, are presented specifically for making more accurate nanoindentation measurements in materials such as wood cell walls. The improved protocols employ multiload nanoindentations and an analysis algorithm to correct and detect errors associated with surface detection errors and structural compliances arising from edges and specimen-scale flexing. The algorithm also diagnoses other potential issues arising from dirty probes, nanoindenter performance or calibration issues, and displacement drift. The efficacy of the methods was demonstrated using nanoindentations in loblolly pine (Pinus taeda) S2 cell wall layers (S2) and compound corner middle lamellae (CCML). The nanoindentations spanned a large range of sizes. The results also provide new guidelines about the minimum size of nanoindentations needed to make reliable nanoindentation measurements in S2 and CCML.

Properties of Wood-Plastic Composites Manufactured from Two Different Wood Feedstocks: Wood Flour and Wood Pellets

Driven by the motive of minimizing the transportation costs of raw materials to manufacture wood–plastic composites (WPCs), Part I and the current Part II of this paper series explore the utilization of an alternative wood feedstock, i.e., pellets. Part I of this study reported on the characteristics of wood flour and wood pellets manufactured from secondary processing mill residues. Part II reports on the physical and mechanical properties of polypropylene (PP)-based WPCs made using the two different wood feedstocks, i.e., wood flour and wood pellets. WPCs were made from 40-mesh wood flour and wood pellets from four different wood species (white cedar, white pine, spruce-fir and red maple) in the presence and absence of the coupling agent maleic anhydride polypropylene (MAPP). With MAPP, the weight percentage of wood filler was 20%, PP 78%, MAPP 2% and without MAPP, formulation by weight percentage of wood filler was 20% and PP 80%. Fluorescent images showed wood particles’ distribution in the PP polymer matrix was similar for both wood flour and ground wood pellets. Dispersion of particles was higher with ground wood pellets in the PP matrix. On average, the density of composite products from wood pellets was higher, tensile strength, tensile modulus and impact strength were lower than the composites made from wood flour. Flexural properties of the control composites made with pellets were higher and with MAPP were lower than the composites made from wood flour. However, the overall mechanical property differences were low (0.5–10%) depending on the particular WPC formulations. Statistical analysis also showed there was no significant differences in the material property values of the composites made from wood flour and wood pellets. In some situations, WPC properties were better using wood pellets rather than using wood flour. We expect if the material properties of WPCs from wood flour versus wood pellets are similar and with a greater reduction in transportation costs for wood pellet feedstocks, this would be beneficial to WPC manufacturers and consumers.

Are Natural-Based Composites Sustainable?

This paper assesses the aspects related to sustainability of polymer composites, focusing on the two main components of a composite, the matrix and the reinforcement/filler. Most studies analyzed deals with the assessment of the composite performance, but not much attention has been paid to the life cycle assessment (LCA), biodegradation or recyclability of these materials, even in those papers containing the terms "sustainable" (or its derivate words), "green" or "eco". Many papers claim about the sustainable or renewable character of natural fiber composites, although, again, analysis about recyclability, biodegradation or carbon footprint determination of these materials have not been studied in detail. More studies focusing on the assessment of these composites are needed in order to clarify their potential environmental benefits when compared to other types of composites, which include compounds not obtained from biological resources. LCA methodology has only been applied to some case studies, finding enhanced environmental behavior for natural fiber composites when compared to synthetic ones, also showing the potential benefits of using recycled carbon or glass fibers. Biodegradable composites are considered of lesser interest to recyclable ones, as they allow for a higher profitability of the resources. Finally, it is interesting to highlight the enormous potential of waste as raw material for composite production, both for the matrix and the filler/reinforcement; these have two main benefits: no resources are used for their growth (in the case of biological materials), and fewer residues need to be disposed.

Effects of impulse-cyclone drying and silane modification on the properties of wood fiber/HDPE composite material

Poplar fibers were pretreated under impulse-cyclone drying (ICD) and further modified by different types of silane with special chemical structures. The effects of ICD-assisted silane modification on the properties of wood plastic composites (WPCs) were investigated. The main findings indicated that the number of hydroxyl groups and the polarity of the fibers decreased after the ICD/silane co-modification, whereas the hydrophobicity and crystallinity of fibers, the compatibility and adhesion strength between fibers and plastics, and the mechanical properties, thermostability, and dynamic mechanical properties of WPCs were significantly improved. In this study, when the wood fibers were only modified by silane and the silane content was 5%, the WPCs had better properties, and the WPCs modified with vinyl tri-methoxysilane (A-171) had the best properties. Furthermore, the addition of a small amount of silane to the wood fibers modified by ICD provided even better physical and mechanical properties compared to those of the WPCs that were only modified by silane; when 3% silane was added, there were increases of 10.67%, 10.22% and 9.4%, in the tensile, flexural and impact strengths, respectively, and an increase of 6.84% in the contact angle of the composites. The water absorption rate of the composite significantly decreased as well.

How to manage biocomposites wastes end of life? A life cycle assessment approach (LCA) focused on polypropylene (PP)/wood flour and polylactic acid (PLA)/flax fibres biocomposites

Biocomposites has gained increasing attention in recent years. The environmental impacts of end-of-life (EoL) treatments of those emerging materials should be evaluated before they are produced and installed commercially, to ensure a minimal impact of these products all along their life cycle. Life cycle assessment (LCA) was carried out to evaluate environmental impacts of the EoL treatments of wood flour (WF) reinforced polypropylene (PP/WF) and flax fibers reinforced polylactic acid (PLA/Fl). The aim was to evaluate which EoL was the most environmental friendly to manage those emerging wastes in France and to help stakeholders of the waste sectors in their decisions. The attributional LCA was realized using the methodological framework of the international standard ISO 14040:2006. The study only focuses on the EoL of the biocomposites with four scenarios: incineration, landfill, composting and recycling. Mid-point indicators were evaluated thanks to the Recipe method. Results were also normalized to the annual mean environmental impact of a European inhabitant. For both biocomposites, recycling EoL scenario presents the lowest environmental impacts except for the freshwater eutrophication impact of the PP/WF EoL. Models should be completed in the future when new data will be available. Results obtained for both biocomposites are in agreement with the European waste hierarchy. If recycling of plastic is difficult to implement, incineration would be the preferable option for the PP/WF composite, while composting would be the other choice for PLA/Fl material.

Utilization of Recycled Material Sources for Wood-Polypropylene Composites: Effect on Internal Composite Structure, Particle Characteristics and Physico-Mechanical Properties

In this study, various wood material sources were used for the manufacture of wood-polymer composites (WPC). The materials were categorised as virgin wood particles (VWP), reprocessed WPC particles (RWP) and recycled thermoset composite particles (RCP) and derived from two virgin wood sources, three-layer particleboards, medium-density fibreboards (MDF) boards, or two different wood/polypropylene composites. All produced wood-polypropylene compounds contained 60% wood material and were manufactured using a co-rotating extruder. Malleated polypropylene was used as a coupling agent. Specimens were injection moulded and subsequently tested for their physico-mechanical properties. To characterize particles before and after processing, dynamic image analysis (DIA) measurement were performed. Additionally, X-ray micro-computed tomography (XµCT) was used to characterize the internal structure of the composites and to verify the obtained particle’s characteristics. It was found that length and aspect ratio of particles were remarkably different before and after processing (loss in length of 15–70% and aspect ratio of 10–40%). Moreover, there were notably differences between the particle sources (RCP retained the highest length and aspect ratio values, followed by VWP and RWP). The results suggest that increased aspect ratios can indeed significantly improve mechanical properties (up to 300% increase in impact bending strength and 75% increase in tensile strength, comparing WPC based either on virgin spruce or MDF material). This phenomenon is suggested to be partially superimposed by improved dispersion of particles, which is expected due to lower variance and increased mechanical properties of RWP composites. However, no notable alterations were observed for composite density. Reprocessed WPC and, particularly, RCP material have proved to be an appealing raw material substitute for the manufacturing of wood–polymer composites.

Using Forest Resources to Develop High Performance Plastic Compounds for the Automotive Industry

This study explores new applications for wood fibres through their incorporation on plastic matrices, developing high performance compounds for the automotive interior. Different automotive grades of polypropylene were reinforced with pine and eucalyptus fibres, in order to compare their properties with the specifications of different vehicle parts. The composites were produced using conventional plastics processing technologies, namely compounding with twin-screw extruder and injection molding. Mechanical properties, density, heat deflection temperature and Vicat softening point were determined. Other specific tests were carried to understand the feasibility of these composites use in automotive parts, namely fogging and flammability and also the determination of the tensile properties after climatic aging tests. The fibres morphology and its distribution and dispersion in the polymer matrices were evaluated by optical and scanning electron microscopy. The results show that it is possible to reinforce the raw-materials using wood and achieve the high standards of the automotive industry, producing environmentally friendlier materials, through the effective reduction of the use of plastic. This work enabled important conclusions regarding the incorporation of wood into PP matrices without compromising the specifications of certain dashboard parts and it also allowed evaluating the processability of these composites.

Improvement of the flame retardancy of wood-fibre/polypropylene composites with ideal mechanical properties by a novel intumescent flame retardant system

To improve the flame retardancy and maintain the ideal mechanical properties of the widely used wood fibre reinforced polypropylene composite, a novel intumescent flame retardant system consisting of PTPA and APP was developed.