COMPOSITE MATERIAL USING BANANA, AND SIC

FIBRE

ABSTRACT

Last few decades have seen composite materials being used predominantly in

various applications. Many types of natural fibers have been investigated for their

use in plastics including Flax, hemp, SiC, straw, wood fiber, rice husks, wheat,

barley, oats, cane (sugar and bamboo), grass reeds, kenaf, ramie, oil palm empty

fruit bunch, sisal, coir, water pennywort, kapok, paper-mulberry, raphia, banana

fiber, pineapple leaf fiber and papyrus. Their volume and number of applications

have grown steadily. Natural fibers offer both cost savings and reduction in density

when compared to glass fibers. Natural fibers are an alternative resource to synthetic

fibers, as reinforcement for polymeric materials for the manufacture is cheap,

renewable and environment friendly. This paper discusses in detail about the

fabrication of the composite material using the banana and the SiC and the strength

of the material is determined using various mechanical tests such as the hardness

test, bending test, compressive test and the tensile test.

 INTRODUCTION

Composites are materials that comprise strong load carrying material (known

as reinforcement) imbedded in weaker materials (known as matrix). Reinforcement

provides strength and rigidity, helping to support structural load. The matrix or

binder (organic or inorganic) maintains the position, orientation of the reinforcement

and transfers the external load to the reinforcement. Significantly, constituents of the

composites retain their individual, physical and chemical properties. Historical

examples of composites are abundant in literature. SiC has been used since ancient

times in Africa and Asia to provide cordage and weaving fiber from the stem and

food from the leaves. In several historical documents (Ain-e-Akbari by AbulFazal,

1590) during the era of the great Mughal Emperor Akbar (1542 –1605) states that

the poor villagers of India used to wear clothes made of SiC. Chinese papermakers

from very ancient times have selected almost all the kinds of plants as hemp, silk,

siC, cotton etc. for paper making. The East India Company which was the first SiC

trader in India was the planet's biggest producer of bananas and Alexander the Great

found them growing there in 327 BC, when he conquered India. Infantrymen of

Alexander the Great returned to Greece and Persia with bulbs from banana plants,

'Musa accuminata, ' where they were distributed and planted. Antonius Musa, the

private surgeon of Augustus Caesar, imported the first banana trees, 'Musa

accuminata, ' to Rome from Africa in 63 BC. Later, slaves from Portugal brought
bananas to Europe from Africa in the early 1400's. Although the banana is said to

have originated in India, (Eastern East Asia), it was established in Africa and Europe

as a basic food product many centuries back and came into North America through

Spanish missionaries. The leaves of banana trees are used as wrappers for steaming

other foods within, and the banana flower is also eatable.

Our project deals with the fabrication of a composite material in order to find

out the strength of the material using the banana and the SiC fibre. The fabrication

is done with the help of hand layup process. Also the various mechanical tests are

conducted on the fabricated material. Finally the results of the tests and the strength

of the material are discussed.

 LITERATURE REVIEW

A report from the National Institute of Research on SiC and Allied Fiber

Technology (NIRJAFT), Calcutta reveals that, usually for moulded SiC composites

with polyester resin, the resin intake can be maximum up to 40%. Both hot press

molding and hand lay-up technique can be used for its fabrication. The effect of

chemical treatment of natural fibers with sodium alginate and sodium Hydroxide has

also been reported for coir, banana and sisal fibers. This modification results in an

increase in adhesive bonding and thus improves ultimate tensile strength up to 30%.

Mitraet al. have reported that treatment of SiC with polycondensates such

asphenol-Formaldehyde, melamine formaldehyde and cashew nut shell with liquid

formaldehyde improves the wet ability of SiC fibers and reduces water regain

properties. Gassanet al. have improved the tensile, flexural strength and stiffness of

SiC-epoxy composites by treating the fibers with silane. The delignification by

bleaching produces better interfacial bond between the SiC fiber and the polyester

matrix, and hence results in better mechanical properties of the composites. The

absorption of steam by banana fiber/novalac resin composites has been found to

reduce after esterification of the –OH groups with the maleic anhydride. The tensile

strength of maleic anhydride treated fiber composites is higher than that of the

untreated fiber composites.

 Wambua et al bridged the gap and investigated the response of flax, hemp,

and SiC fabric reinforced polypropylene composites to ballistic impact by fragment

simulating projectiles. The effect of alkali (5% NaOH for 2hrs) and silane (1%

oligomericsiloxane with 96% alcohol solution for 1 hr) treatment on the flexural

properties of SiC epoxy and SiC polyester composites. For SiC epoxy composites

alkali over silane treatment resulted in about 12% and 7% higher strength and

modulus properties compared to the alkali treatment alone. Similar treatment led to

around 20% and 8% improvement for SiC polyester composites.

Dipa et al. have reported 4h alkali treated SiC- vinyl ester composites

accounted 20% and 19% increase in flexural strength and inter laminar shear

strength properties. Treated SiC fibers with NaOH solution of concentration1 and

8%for 48 h and observed130% improvement in the tensile strength of the fibers in

both the cases. Similarly, SiC fibers were treated with 2%NaOH solution for 1 h and

13% improvement in the tenacity of the fibers was reported.

Lina Herrera Estrada, Selvumpillay and Udayvaidy approved that 6% NaOH

treated banana fiber/ epoxy composites environmental resistance is higher than

banana fiber/polyester composites without any treatment. This is due to

improvement in fiber/ matrix interaction with the fiber chemical pretreatment in

epoxy composites and to deterioration of the inter phase in polyester composites.

The tensile testing of untreated SiC fabric-reinforced polyester composites was

studied and the average values of UTS, initial tangent modulus for these composites

are 60MPa, 7GPa. Researchers investigating thermal properties of SiC/bagasse

hybrid composites observed that thermal stability of hybrid composites increased by

increasing residual char left at 600°C.

Kamaker et al. reported that using 3wt% MAHgPP (type G-3002, with an

average molecular weight of 40,000 and containing 6 wt% of maleic anhydride, as

coupling agent in SiC/PP composite increases composite mechanical properties. The

tensile strength is doubled from 29.82 MPa to 59.13 MPa and the bending strength

increases from 49.97 MPa to 87.66 MPa in composite with 50 wt% fiber content.

Gassan et al. showed that the tensile, flexural and dynamic strength increase

up to 50% but impact energy decreases due to the lower energy absorption in the

interface of SiC/PP composite when SiC fibers are treated by 0.1wt% MAHgPP

solution in toluene for 5min at 100°C. Ray et al. used a solution of NaOH 5% to treat

the SiC fibre for 0, 2, 4, 6 and 8 hours at 30°C. For the vinyester resin composites

reinforced by 35 wt% SiC fibre treated for 4 h, an improvement of 20% for the

flexural strength, of 23% for the flexural modulus and of 19% for the laminar shear

strength was observed.

The acetylation of SiC fiber was investigated by Rana et al. and showed an

improvement in thermal resistance compared to untreated fiber. Treatment of the

SiC fiber with PF and CNSL-PF carried out by Mitra et al. showed a reduction of

the thermal stability of the treated fiber. Kita et al. reported that the degradation of

lignin in cellulose fiber sets in at around 200°C, and other polysaccharides, mainly

cellulose, are oxidized and degraded at higher Temperature. The influence of the

injection molded processing on the final fiber length of the polypropylene

composites based on abaca, SiC and flax fibers investigated by Biagotti et al. showed

the minor effect with the higher fiber content and a more significant size reduction

of the flax fibre due to its more rigid behavior. The swelling of the SiC fibre in the

polypropylene composite was found by Karmaker et al. to have positive effects on

the mechanical properties. The influence of fibre surface treatment by MAHgPP on

the dynamic mechanical properties of SiC reinforced polypropylene was

investigated by Gassan and Bledzki. It was shown that maleic anhydride

polypropylene copolymer increases the level of adhesion between polypropylene

and SiC fibre. Roe, P et al. reported that the reinforcement of polyesters with SiC

fibers. Due to presence of hydroxy and other polar groups in various constituents of

SiC fibre, the moisture uptake is high (approx. 12.5% at 65% relative humidity &

20o C) by dry fiber. Polymeric coating of SiC fiber with phenol formaldehyde or

resorcinol formaldehyde resins by different approaches is highly effective in

enhancing the reinforcing character of SiC fiber, giving as high as 20-40%

improvements in flexural strength and 40-60% improvements in flexural modulus.

These modifications improve the fiber-matrix resin wet ability and lead to improved

bonding.
 COMPOSITE MATERIAL

A fiber-reinforced composite (FRC) is a high-performance composite

material made up of three components - the fibers as the discontinuous or dispersed

phase, the matrix acts as the continuous phase, and the fine interphase region or the

interface.

The matrix is basically a homogeneous and monolithic material in which a

fiber system of a composite is embedded. It is completely continuous. The matrix

provides a medium for binding and holding reinforcements together into a solid. It

offers protection to the reinforcements from environmental damage, serves to

transfer load, and provides finish, texture, color, durability and functionality.

Types of Composite Matrix Materials

There are three main types of composite matrix materials:

 Ceramic matrix - Ceramic matrix composites (CMCs) are a subgroup of

composite materials. They consist of ceramic fibers embedded in a ceramic

matrix, thus forming a ceramic fiber reinforced ceramic (CFRC) material. The

matrix and fibers can consist of any ceramic material. CMC materials were

designed to overcome the major disadvantages such as low fracture toughness,

brittleness, and limited thermal shock resistance, faced by the traditional

technical ceramics.
 Metal matrix - Metal matrix composites (MMCs) are composite materials that

contain at least two constituent parts – a metal and another material or a different

metal. The metal matrix is reinforced with the other material to improve strength

and wear. Where three or more constituent parts are present, it is called a hybrid

composite. In structural applications, the matrix is usually composed of a lighter

metal such as magnesium, titanium, or aluminum. In high temperature

applications, cobalt and cobalt-nickel alloy matrices are common. Typical

MMC's manufacturing is basically divided into three types: solid, liquid, and

vapor. Continuous carbon, silicon carbide, or ceramic fibers are some of the

materials that can be embedded in a metallic matrix material. MMCs are fire

resistant, operate in a wide range of temperatures, do not absorb moisture, and

possess better electrical and thermal conductivity. They have also found

applications to be resistant to radiation damage, and to not suffer from

outgassing. Most metals and alloys make good matrices for composite

applications.

 Polymer matrix - Polymer matrix composites (PMCs) can be divided into three

sub-types, namely, thermoset, thermoplastic, and rubber. Polymer is a large

molecule composed of repeating structural units connected by covalent chemical

bonds. PMC's consist of a polymer matrix combined with a fibrous reinforcing

 dispersed phase. They are cheaper with easier fabrication methods. PMC's are

less dense than metals or ceramics, can resist atmospheric and other forms of

corrosion, and exhibit superior resistance to the conduction of electrical current.

Composite Matrix Material Applications

The following are common application areas of composite matrix materials:

 Electrical moldings

 Decorative laminates

 High performance Cookware

 Sealants and gaskets

 Heat shield systems (capable of handling high temperatures, thermal shock

conditions and heavy vibration)

 Components for high-temperature gas turbines such as combustion chambers,

stator vanes and turbine blades

 Brake disks and brake system components used in extreme thermal shock

environments

 Components for slide bearings under heavy loads requiring high corrosion and

wear resistance

 Carbide drills are made from a tough cobalt matrix with hard tungsten carbide

particles inside
 Components for burners, flame holders, and hot gas ducts

METAL MATRIX COMPOSITE

A metal matrix composite (MMC) is composite material with at least two

constituent parts, one being a metal. The other material may be a different metal or

another material, such as a ceramic or organic compound. When at least three

materials are present, it is called a hybrid composite. An MMC is complementary to

a cermet.

Composition

MMCs are made by dispersing a reinforcing material into a metal matrix. The

reinforcement surface can be coated to prevent a chemical reaction with the matrix.

For example, carbon fibers are commonly used in aluminium matrix to synthesize

composites showing low density and high strength. However, carbon reacts with

aluminium to generate a brittle and water-soluble compound Al4C3 on the surface of

the fiber. To prevent this reaction, the carbon fibers are coated

with nickel or titanium boride.

Matrix

The matrix is the monolithic material into which the reinforcement is

embedded, and is completely continuous. This means that there is a path through the

matrix to any point in the material, unlike two materials sandwiched together. In

structural applications, the matrix is usually a lighter metal such as

aluminium, magnesium, or titanium, and provides a compliant support for the

reinforcement. In high temperature applications, cobalt and cobalt-nickel alloy

matrices are common.

Reinforcement

The reinforcement material is embedded into the matrix. The reinforcement

does not always serve a purely structural task (reinforcing the compound), but is also

used to change physical properties such as wear resistance, friction coefficient,

or thermal conductivity. The reinforcement can be either continuous, or

discontinuous. Discontinuous MMCs can be isotropic, and can be worked with

standard metalworking techniques, such as extrusion, forging or rolling. In addition,

they may be machined using conventional techniques, but commonly would need

the use of polycrystalline diamond tooling (PCD).

Continuous reinforcement uses monofilament wires or fibers such as carbon

fiber or silicon carbide. Because the fibers are embedded into the matrix in a certain
direction, the result is an anisotropic structure in which the alignment of the material

affects its strength. One of the first MMCs used boron filament as reinforcement.

Discontinuous reinforcement uses “whiskers", short fibers, or particles. The most

common reinforcing materials in this category are alumina and silicon carbide.

CLASSIFICATION OF THE COMPOSITE MATERIALS WITHIN THE GROUP OF

MATERIALS
 FABRICATION PROCESS

HAND LAYUP PROCESS

Hand lay-up is the simplest and oldest open molding method of the composite

fabrication processes. It is a low volume, labor intensive method suited especially

for large components, such as boat hulls. Glass or other reinforcing materials or

woven fabric or roving is positioned manually in the open mold, and resin is poured,

brushed, or sprayed over and into the glass plies. Entrapped air is removed manually

with squeegees or rollers to complete the laminates structure. Room temperature

curing polyesters and epoxies are the most commonly used matrix resins. Curing is

initiated by a catalyst in the resin system, which hardens the fiber reinforced resin

composite without external heat. For a high quality part surface, a pigmented gel

coat is first applied to the mold surface.

 Hand lay-up technique is the simplest method of composite processing. The

infrastructural requirement for this method is also minimal. The processing steps are

quite simple. First of all, a release gel is sprayed on the mold surface to avoid the

sticking of polymer to the surface. Thin plastic sheets are used at the top and bottom

of the mold plate to get good surface finish of the product. Reinforcement in the

form of woven mats or chopped strand mats are cut as per the mold size and placed

at the surface of mold after perspex sheet. Then thermosetting polymer in liquid form

is mixed thoroughly in suitable proportion with a prescribed hardner (curing agent)

and poured onto the surface of mat already placed in the mold. The polymer is

uniformly spread with the help of brush. Second layer of mat is then placed on the

polymer surface and a roller is moved with a mild pressure on the mat-polymer layer

to remove any air trapped as well as the excess polymer present. The process is

repeated for each layer of polymer and mat, till the required layers are stacked. After

placing the plastic sheet, release gel is sprayed on the inner surface of the top mold

plate which is then kept on the stacked layers and the pressure is applied. After

curing either at room temperature or at some specific temperature, mold is opened

and the developed composite part is taken out and further processed. The schematic

of hand lay-up is shown in figure 1. The time of curing depends on type of polymer

used for composite processing. For example, for epoxy based system, normal curing

time at room temperature is 24-48 hours. This method is mainly suitable for
thermosetting polymer based composites. Capital and infrastructural reuirement is

less as compared to other methods. Production rate is less and high volume fraction

of reinforcement is difficult to achieve in the processed composites. Hand lay-up

method finds application in many areas like aircraft components, automotive parts,

boat hulls, diase board, deck etc.

COMMON MATERIALS USED

Matrix Epoxy, polyester, polyvinyl ester, phenolic resin, unsaturated

polyester, polyurethane resin

Reinforcement Glass fiber, carbon fiber, aramid fiber, natural plant fibers

(sisal, COIRa, nettle, hemp, flax etc.)

(all these fibers are in the form of unidirectional mat,

bidirectional (woven) mat, stitched into a fabric form, mat of

randomly oriented fibers)

SL.NO BANANA SiC RESIN

SAMPLE 1 46% 4% 50%