Water Absorption and Dimensional Stability of Short Kenaf Fiber-Filled Polypropylene Composites Treated with Maleated Polypropylene

T. T. Law, Z. A. Mohd Ishak

School of Materials and Mineral Resources Engineering, Engineering Campus,Universiti Sains Malaysia, 14300, Nibong Tebal, Penang, Malaysia

Received 4 November 2009; accepted 13 August 2010 DOI 10.1002/app.33184Published online 19 October 2010 in Wiley Online Library (wileyonlinelibrary.com).

ABSTRACT: The purpose of this research was to investi-gate the water absorption behavior and associated dimen-sional stability of kenaf-polypropylene-filled (PP/KF) composites. Composites with different fiber loadings, rang-ing from 0 to 40 wt %, were prepared with a twin-screw ex-truder followed by hot press molding. The influence of the compatibilizer was also studied for PP/KF composite with 5 wt % maleated PP (MAPP). Water absorption testing was carried out at room temperature for 7 weeks. Tensile, flex-ural, and impact tests were also performed on control, wet, and re-dried specimens. Increasing the fiber content resulted in higher water absorption and thickness swelling. The infe-rior mechanical properties of the wet composites were attrib- uted to the effect of water, which deteriorates the interfacial properties of composites. On re-drying, all properties were almost recovered because of the recovery of interfacial area as evident in scanning electron micrographs. Incorporation of the MAPP significantly improved the compatibility between the fiber and matrix and the mechanical properties of the composites compared with those without MAPP. It also diminished the water absorption as well as the related thickness swelling in the composites. VC 2010 Wiley Periodicals, Inc. J Appl Polym Sci 120: 563572, 2011

Key words: kenaf-polypropylene composite; water absorption; dimensional stability; maleated polypropylene

INTRODUCTION

Lignocellulosic natural fibers such as sisal, coir, jute, ramie, pineapple leaf, and kenaf have the potential to be used as a replacement for glass or other tradi-tional reinforcement materials in composites. These fibers have many properties that make them an attractive alternative to traditional materials. They have high specific properties such as stiffness, impact resistance, flexibility, and modulus.14

Combining kenaf fibers (KF) with other resources provides a strategy for producing advanced compos-ite materials that take advantage of the properties of both types of resources. It allows the scientist to design materials based on end-use requirements within a framework of cost, availability, recyclability, energy use, and environmental considerations.5

End-use applications of natural fiber composites for decking, flooring, outdoor facilities, window frames, various construction materials, and bath-room parts, for example, and their exposure to the atmosphere or contact with aqueous media has

Correspondence to: Z. A. M. Ishak (zarifin.ishak@gmail. com).

Journal of Applied Polymer Science, Vol. 120, 563572 (2011) VC 2010 Wiley Periodicals, Inc.

made it necessary to evaluate their water uptake characteristics.6 Water absorption is one of the most important characteristics of KF-filled polypropylene (PP/KF) composite exposed to environmental condi-tions, which determines their end-use applications. Therefore, as a limiting parameter, water absorption has to be taken into account in the design of PP/KF composites for final applications. Similar to water absorption, fiber content and processing can affect thickness swelling and the dimensional stability of PP/KF composites, which is of great importance in outdoor applications such as decking and railing.7

In addition, lignocellulosic fibers used for rein-forcement in nonpolar thermoplastics, such as poly-ethylene, PP, and polystyrene, have to be modified because effective wetting of fibers and strong interfa-cial adhesion are required to obtain composites with optimized mechanical properties.8 Good wetting of the fiber by the matrix and adequate fibermatrix bonding can decrease the rate and amount of water absorbed in the interphase region of the composite. The water absorption behavior of natural fiber ther-moplastic composites has been studied by a number of researchers, and the effectiveness of compatibil-izers in reducing the amount and rate of water absorption has been well documented.9 Extensive research has been carried out with different kinds of coupling agents for surface modification of natural564

LAW AND ISHAK

TABLE I

Designation and Composition of Materials

DesignationMaterialsPP (wt %)KF (wt %)MAPP (wt %)

PPPP100

PP/KF20PP kenaf fiber8020PP/KF30PP kenaf fiber7030PP/KF40PP kenaf fiber6040PP/KF30/M5PP kenaf fiber MAPP65305

PP/KF40/M5PP kenaf fiber MAPP55405

fibers to increase the adhesive action with the ther-moplastic matrix. Maleated PP wax was used as a coupling agent to improve the properties of compo-sites prepared from jute and kenaf-reinforced PP.10 All the studies indicated that there was a substantial increase in the surface properties of the fibers with the addition of the coupling agents.

The objectives of this study were to investigate the long-term water absorption of PP/KF composites at room temperature and its effect on mechanical prop-erties such as tensile, flexural, and impact properties. In addition, the dimensional stability after water absorption was determined by indicating the degree of thickness swelling of samples. Besides studying the effect of fiber loading on PP/KF, the purpose of this study was also to explore the use of KF in PP-based thermoplastic composites both with and without a compatibilizer to address the weak interfacial bonding between natural fibers and polymer matrices.

EXPERIMENTAL

Materials

PP TitanproVR SM950, with a melt flow index of 21.67 g/10 min (tested at 190C with 2.16 kg load) and a density of 0.9 g/cm3, was supplied by Titan Chemi-cals Corp. Bhd. (Kuala Lumpur, Malaysia), and was used as the polymer matrix. It is an impact copoly-mer and also a nucleated extra high-flow material, which possesses good toughness at low temperature and easy processing properties. In addition, com-mercially available pellets of maleic anhydride-modified homopolymer PP (MAPP), Polybond 3200 from Chemtura Corp. (Chemtura Gastonia, NC), were used as a compatibilizer to improve the com-patibility and adhesion between KF fiber and the PP. The KF used was obtained from a herbaceous plant, Hibiscus cannabinus, and was supplied by For-est Research Institute Malaysia (FRIM) in the form of bundles.

Raw material preparations

Bundles of KF fibers were manually cut into 10 mm length with paper cutter and were crushed to 35 mm length by a crusher. Compounding and molding

The KF, 35 mm in length, was initially dried in a vacuum oven at 80C for 24 hr. PP, KF, and MAPP were extruded using a co-rotating twin-screw extruder (Model PSW30) according to the compositions given in Table I. The extrusion zone temperature ranged from 155C to 175C. The extrudate was then pellet-ized with the extruder pelletizer (Model PSH10).

After compounding, the tensile, flexural, and impact samples were prepared by melt pressing pel-lets of compounded material on a hot press machine from Kao Tieh GoTech Testing Machine Inc. (Taipei, Taiwan). Before molding, all compounded pellets were initially dried in a vacuum oven at 80C for 24 hr to remove moisture entrapped in the materials. All PP/KF composites were compression molded at a temperature of 185C and were preheated without pressure for 10 min, compressed under pressure of 10 MPa for 4 min, and cooled under pressure for 4 min.

Fiber length distribution

After compounding and molding, KF were taken from a small piece of sample using a chemical diges-tion technique where xylene was used as the sol-vent. The fiber length distributions of 100 fibers were determined with an image analyzer.

Water absorption and dimensional stability test

Water absorption tests were carried out according to ASTM D-570 specifications. Flexural specimens were cut from the compression-molded plates and used for the measurements of water absorption and thick-ness swelling. After vacuum drying at 80C for 24 hr to a constant weight to a precision of 0.001 g, the weight of specimens before water immersion (Wd) were measured with a balance and thickness was measured with a thickness gauge (T0). The speci-mens were immersed in water at room temperature for 7 weeks.

The weights of the specimens were measured at regular intervals using an analytical balance. The surfaces of these specimens were thoroughly dried with tissue papers, and they were weighed immedi-ately to determine the weight of the specimens (Ww).

Journal of Applied Polymer Science DOI 10.1002/app

Tensile testTensile tests were performed to verify the residual tensile properties of the composites. The tensile tests were performed at room temperature according to ASTM D 638-08, using a tensile tester, Instron model

where T0 and Tw are the thicknesses (mm) of the sample before and after immersion, respectively.

where k is the initial slope of the plot of Mt versus t1/2, Mm is the maximum weight gain, and h is thethickness of composite.The thickness swelling (TS) was calculated accord-ing to the eq. (4):

where Wd and Ww denote the weight of the dry ma-terial (the initial weight of materials before water immersion) and the weight of materials after water immersion, respectively. The specimens were immersed until they were saturated. The diffusion coefficient (D) and the maximum water absorbed (Mm) can be obtained by considering the Ficks law diffusion model.The equation of Ficks law has been simplified by Shen and Springer,12 to show that the initial absorp-tion is given by:WATER ABSORPTION AND DIMENSIONAL STABILITY OF PP/KF565

The percentage gain at any time t (Mt) as a result of water absorption was determined by eq. (1)11:

Ww Wd

Mt % Wd 100(1)

3366, at a crosshead speed of 5 mm/min. Five sam-ples of every composition were tested to obtain an average value.

Flexural test

1Mt 4 Dt 2 Mm h p Three-point bending flexural tests were conducted using an Instron model 3366 at a crosshead speed of 5 mm/min and a span length of 50 mm, according to ASTM D790-07. Five samples of every composi-tion were tested to obtain an average value.

Impact test

Charpy impact tests were carried out using a Zwick Impact tester at room temperature, according to ASTM D6110-08 (notched samples) and ASTM D4812-06 (unnotched sample). Both the notched and unnotched samples were tested under impact energy

(2)of 7.5 joules.

where Mt is the percentage of weight gain at anyConditioning of specimens

time t, Mm is the maximumpercentageof waterBecause of the hydrophilic nature of PP/KF compos-

absorbed at saturation, D is the mass diffusivity in

ite, all testing specimens were placed in a vacuum

the composite, h is the thickness of specimen, and t

oven at 80C for 24 hr before testing. On removal

is the time of immersion.

from the oven, the specimens were allowed to cool

The diffusion propertiesof compositesdescribed

to room temperature inside desiccators to maintain

by Ficks laws were evaluated by weight gain meas-

standard moisture content for all specimens. These

urements of predried specimen immersed in water

specimens are then regarded to be in the as-received

by considering the slopeofthefirstpart ofthe

state. For the water absorption study, the specimens

weight gain curve versussquarerootoftimeby

were immersed in distilled water at room tempera-

using the following equation. The coefficient of dif-

ture and regarded to be in the wet state. Once the

fusion (D) is defined as the slope of the normalized

water uptake in the specimens had reached a satura-

mass uptake against t1/2 and has the form:

tion limit, tensile, flexural, and impact tests were

2

carried out. Further investigation into the extent of

kh

deterioration of these mechanical tests was carried

D p 4Mm

(3)out by re-drying the specimens in a vacuum oven at

80C for 24 hr.

TS % Tw T0 100T0 Scanning electron microscopy

Impact fracture surfaces of samples were examined with a field-emission Scanning Electron microscope model Zeiss Supra 35VP. To increase the conductiv-ity of the samples and reduce the charging effects,

the fracture surface was coated with a thin layer of gold using a VG Microtech-Polaron Sputter Coater before the scanning electron microscopy (SEM) examination.

RESULTS AND DISCUSSION

Fiber length distribution

Figure 1 shows the fiber length distribution of KF before and after compounding. It can be seen that the length of the fibers was shortened to an average

Journal of Applied Polymer Science DOI 10.1002/app