Darshil U. Shah

Developing plant fibre composites for structural applications by optimising composite parameters: a critical review

Plant fibres, perceived as environmentally sustainable substitutes to E-glass, are increasingly being employed as reinforcements in polymer matrix composites. However, despite the promising technical properties of cellulose-based fibres and the historic use of plant fibre reinforced plastics (PFRPs) in load-bearing components, the industrial uptake of PFRPs in structural applications has been limited. Through an up-to-date critical review of the literature, this manuscript presents an overview on key aspects that need consideration when developing PFRPs for structural applications, including the selection of (I) the fibre type, fibre extraction process and fibre surface modification technique, (II) fibre volume fraction, (III) reinforcement geometry and interfacial properties, (IV) reinforcement packing arrangement and orientation and (V) matrix type and composite manufacturing technique. A comprehensive materials selection chart (Ashby plot) is also produced to facilitate the design of a PFRP component, based on the (absolute and specific) tensile properties.

Modelling the effect of yarn twist on the tensile strength of unidirectional plant fibre yarn composites

The structural potential of plant fibres as reinforcing agents can only be realized when the highest reinforcement efficiency is employed. Hence, aligned plant fibre composites are of interest. However, due to the short length of technical plant fibres, the reinforcement needs to be in the form of staple fibre yarns, which have a twisted structure. Although twist facilitates yarn processability, it has several detrimental effects on the composites produced from such twisted yarn reinforcements; one of which is fibre obliquity and misalignment. This results in a drastic drop in composite mechanical properties. No analytical model currently exists to accurately predict the effect of yarn twist on aligned plant fibre composite tensile strength. In this paper, a novel mathematical model is developed. The model is based on (i) a modified rule of mixtures for plant fibre composites, (ii) well-defined structure-property relationships in an idealised twisted staple fibre yarn and (iii) the Krenchel orientation efficiency factor. The developed model includes a corrected orientation efficiency factor of cos2(2α), where α is the yarn surface twist angle. The model is validated with extensive experimental data from Goutianos and Peijs (Goutianos S, Peijs T (2003) Adv Compos Lett 12(6):237) and is found to be a near-perfect fit (R2 = 0.960). Experimental data from other studies are also used for further verification.

Hydroxyethylcellulose surface treatment of natural fibres: the new ‘twist’ in yarn preparation and optimization for composites applicability

The use of low-cost renewable natural fibres as reinforcements for structural composites is attractive but requires specific considerations over that of textile industry requirements. Textile yarns are twisted for processability and increased tensile strength. However, reinforcements employing twisted yarns produce poorer composites due to hindered yarn impregnation, inadequate wettability and compromised orientation efficiency. Whilst assessing the physical properties of select plant fibre yarns that determine reinforcement/composite properties, a strong correlation between yarn twist and compaction is observed. This manuscript also examines a novel plant fibre treatment method using hydroxyethylcellulose (HEC). HEC treatment not only enables intra- and inter-yarn binding thus allowing easy preparation of aligned fabrics, but also improves yarn mechanical properties whilst maintaining physical properties such as low twist. It is noticed that low twist yarns are more responsive to HEC treatment; the tenacity and stiffness of low twist flax is observed to increase by 230 and 75%, respectively.

Why do we observe significant differences between measured and ‘back-calculated’ properties of natural fibres?

The drive towards sustainability, even in materials technologies, has fuelled an increasing interest in bio-based composites. Cellulosic fibres, such as flax and jute, are being considered as alternatives to technical synthetic fibres, such as glass, as reinforcements in fibre reinforced polymer composites for a wide range of applications. A critical bottleneck in the advancement of plant fibre composites (PFRPs) is our current inability to predict PFRP properties from data on fibre properties. This is highly desirable in the cost- and time-effective development and design of optimised PFRP materials with reliable behaviour. This study, alongside limited other studies in literature, have found that the experimentally determined (through single fibre tests) fibre properties are significantly different from the predicted (‘back-calculated’ using the popular rule-of-mixtures) fibre properties for plant fibres. In this note, we explore potential sources of the observed discrepancy and identify the more likely origins relating to both measurement and errors in predictions based on the rule-of-mixtures. The explored content in this discussion facilitates the design of a future investigation to (1) identify the sensitivity of the discrepancy between measured and predicted fibre properties to the various potential origins, (2) form a unified hypothesis on the observed phenomenon, and (3) determine whether the rule-of-mixtures model (in specific cases) can be improved and may be able to predict properties precisely.

Mechanical Property Characterization of Aligned Plant Yarn Reinforced Thermoset Matrix Composites Manufactured via Vacuum Infusion

This article evaluates the mechanical properties of vacuum-infused unidirectional plant fiber composites (PFRPs), composing of bast fiber yarns and thermoset matrices. PFRPs are found to have lower fiber volume fractions than E-glass composites (GFRPs). Apart from the expected (30–40%) lower density of PFRPs, they have 60–80% lower tensile strength, 30–60% lower tensile stiffness, 5–10 times lower impact strength, and 20–30% lower interlaminar shear strength than GFRPs. Importantly, critical fiber lengths are of the same order (0.2–0.5 mm). Composites reinforced with flax rovings exhibit exceptional fiber tensile modulus of 65–75 GPa and fiber tensile strength of about 800 MPa.

Thermal conductivity of engineered bamboo composites

Here we characterise the thermal properties of engineered bamboo panels produced in Canada, China, and Colombia. Specimens are processed from either Moso or Guadua bamboo into multi-layered panels for use as cladding, flooring or walling. We utilise the transient plane source method to measure their thermal properties and confirm a linear relationship between density and thermal conductivity. Furthermore, we predict the thermal conductivity of a three-phase composite material, as these engineered bamboo products can be described, using micromechanical analysis. This provides important insights on density-thermal conductivity relations in bamboo, and for the first time, enables us to determine the fundamental thermal properties of the bamboo cell wall. Moreover, the density-conductivity relations in bamboo and engineered bamboo products are compared to wood and other engineered wood products. We find that bamboo composites present specific characteristics, for example lower conductivities—particularly at high density—than equivalent timber products. These characteristics are potentially of great interest for low-energy building design. This manuscript fills a gap in existing knowledge on the thermal transport properties of engineered bamboo products, which is critical for both material development and building design.

Bioinspired supramolecular fibers drawn from a multiphase self-assembled hydrogel

Significance Fiber materials have great impact on our daily lives, with their use ranging from textiles to functional reinforcements in composites. Although the manufacturing process of manmade fibers is potentially limited by extensive energy consumption, spiders can readily spin silk fibers at room temperature. Here, we report a class of material that is based on a self-assembled hydrogel constructed with dynamic host–guest cross-links between functional polymers. Supramolecular fibers can be drawn from this hydrogel at room temperature. The supramolecular fiber exhibits better tensile and damping properties than conventional regenerated fibers, such as viscose, artificial silks, and hair. Our approach offers a sustainable alternative to current fiber manufacturing strategies. Inspired by biological systems, we report a supramolecular polymer–colloidal hydrogel (SPCH) composed of 98 wt % water that can be readily drawn into uniform (∼6-μm thick) “supramolecular fibers” at room temperature. Functionalized polymer-grafted silica nanoparticles, a semicrystalline hydroxyethyl cellulose derivative, and cucurbit[8]uril undergo aqueous self-assembly at multiple length scales to form the SPCH facilitated by host–guest interactions at the molecular level and nanofibril formation at colloidal-length scale. The fibers exhibit a unique combination of stiffness and high damping capacity (60–70%), the latter exceeding that of even biological silks and cellulose-based viscose rayon. The remarkable damping performance of the hierarchically structured fibers is proposed to arise from the complex combination and interactions of “hard” and “soft” phases within the SPCH and its constituents. SPCH represents a class of hybrid supramolecular composites, opening a window into fiber technology through low-energy manufacturing.

On recycled carbon fibre composites manufactured through a liquid composite moulding process

The recovery of carbon fibres from waste and end-of-life carbon fibre reinforced plastic materials is both economically lucrative and environmentally necessary. Here, we characterise the physical and mechanical properties of recycled carbon fibre reinforced plastics (rCFRPs) composed of random and oriented non-woven recycled carbon fibre mats that were impregnated with liquid epoxy matrices using a vacuum-infusion set-up. The low areal density and poor compactability of the non-woven mats implied that press-moulding upon impregnation was essential to control laminate thickness and improve fibre content; this may limit the applications of the resulting rCFRPs. Moreover, the press consolidation process is thought to degrade fibre length, and is a likely cause for the lower-than-expected tensile properties of the rCFRPs. Expectedly, the oriented rCFRPs exhibited better tensile and compressive properties than the random rCFRPs. Notably, while the tensile strength of the rCFRPs was only up to 2.5 times better than the matrix, the tensile modulus was 4–10 times enhanced. Through a comparative literature survey, we found that the liquid composite moulded rCFRPs were outperformed by rCFRPs fabricated through other manufacturing processes (e.g. prepregging), particularly those employing high compaction pressures, and utilising long fibres recovered through pyrolysis and chemical processes, rather than the fluidised-bed process.

Chemical composition of processed bamboo for structural applications

Natural materials are a focus for development of low carbon products for a variety of applications. To utilise these materials, processing is required to meet acceptable industry standards. Laminated bamboo is a commercial product that is currently being explored for structural applications, however there is a gap in knowledge about the effects of commercial processing on the chemical composition. The present study utilised interdisciplinary methods of analysis to investigate the effects of processing on the composition of bamboo. Two common commercial processing methods were investigated: bleaching (chemical treatment) and caramelisation (hygrothermal treatment). The study indicated that the bleaching process results in a more pronounced degradation of the lignin in comparison to the caramelised bamboo. This augments previous research, which has shown that the processing method (strip size) and treatment may affect the mechanical properties of the material in the form of overall strength, failure modes and crack propagation. The study provides additional understanding of the effects of processing on the properties of bamboo.

Predicting the pore-filling ratio in lumen-impregnated wood

Lumen impregnation, unlike most other wood modification methods, is typically assessed by the pore-filling ratio (PFR) (i.e. the fraction of luminal porosity filled) rather than by weight percentage gain (WPG). During lumen impregnation, the impregnants act on the voids in the wood rather than on the solid mass (e.g. cell walls), but the PFR cannot be measured as conveniently as the WPG during processing. Here, it is demonstrated how the PFR can be calculated directly from the WPG if the bulk density of the untreated wood is known. The relationship between the WPG and bulk density was examined experimentally by applying a pressured impregnation on knot-free specimens from Sitka spruce with a liquid mixture of methacrylate monomers. Based on the validated model, it was possible to further study the effect of different process-related parameters, such as hydraulic pressure, on lumen impregnation. Skeletal density is another key parameter in this model, which directly reflects the amount of inaccessible pores and closed lumens, and can be independently determined by helium pycnometry. The permeability can be qualitatively evaluated by PFR as well as skeletal density. For instance, poor permeability of knotty wood, due to the large extractives content around knots, was reflected by a lower skeletal density and inefficient lumen impregnation (low PFR). Although this model was examined on a laboratory scale, it provides guidance on the precise effect of different parameters on lumen impregnation, thereby improving the fundamental understanding of and enabling better control over the modification of wood by impregnation.