Mechanical, Structural and Gravimetric Properties … · Mechanical, Structural and Gravimetric Properties of Rice Husk Particle Reinforced Polypropylene Composite ... Key words:

International Journal of Scientific Research and Innovative Technology ISSN: 2313-3759 Vol. 4 No. 10; October 2017

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Mechanical, Structural and Gravimetric Properties of Rice Husk Particle Reinforced Polypropylene Composite Odhong O.V.*1, Okumu V.A 2 1. Department of Mechanical and Mechatronics Engineering, Multimedia University of Kenya Box 15653 – 00503, NAIROBI, KENYA. Email: [email protected]. Cell phone +254 723 649 058 * The corresponding author 2. Faculty of Engineering and Technology, Multimedia University of Kenya Box 15653 – 00503, NAIROBI, KENYA. Sponsoring information This research was funded by Multimedia University of Kenya through its internal research fund kitty to the tune of Kshs 500,000 for a period of one calendar year 2016 -2017. ABSTRACT Plant fibre reinforced polymer composites are gaining prominence in light load structural applications. In this research, properties of rice husk particle reinforced polypropylene composite produced from agricultural wastes and polymer wastes were investigated. Injection moulding and film stacking techniques were used to produce round test pieces and particle boards respectively. Universal Mechanical Testing Machine and charpy impact testing machines were used for destructive tests. Moisture ingress tests, morphological investigation and nail retention tests were also done. The optimum results from various tests were: impact strength (78 J/mm2), compressive strength (69 MPa), bending strength (50 MPa), tensile strength (58 MPa) and hardness (BVN 520). Nail withdrawal strength was 63 MPa while moisture ingress - short term (0. 5%) and long term (0.55%). The material was recommended for light load structural applications where resistance against extreme temperatures was desirable such as in constructing all weather low cost houses. Key words: composites, mechanical, morphological, particles, structural.


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1. INTRODUCTION Plant based particles used to reinforce polymer matrix in composites are emerging as a viable alternative to synthetic fiber reinforced composites. The particles have a larger surface area being in contact with the matrix at the interface hence providing a stronger material suitable for use as packaging and as building materials supporting light structural loads In recent years, a special concern has been manifested towards “green chemistry” (Mansour et al, 2007;Sofiane & Sonebib, 2016). Some of the effort has been based on the use of new waste sources, with the aim to obtain biologically active fillers which can be applied as reinforcement in composite materials (Mohanty et al, 2002; Dai, 2003). Rice husks (with a biological name as oryza sativa) are lignocellulosic and are an important by-product of rice milling process that can be used as reinforcement in composite products. Rice husk is one such widely available agricultural waste material (Han-Seung et al, 2004; Odhong et al, 2017). Hammer milling of rice husk to specified sizes produce particles which form reinforcement phase in a particle reinforced polymer composite. Polypropylene can be found in its raw material form or as a waste material from packaging of various products (Odhong et al, 2012). Rice husk particles of very small sizes were used as the reinforcing phase to be mixed with very small sizes of shredded polypropylene wastes being used as the matrix (continuous phase). They formed a strong bond at the interface thus producing composite of sufficient interfacial strength (Ndazi et al, 2006; Kumar et al, 2010). 1.1 Nature of the problem Need for environment friendly materials has been increasing exponentially with increase in world population. The development of an eco friendly composite material to tap the potential superior properties in the composite constituents that guarantee comfort of occupants using structures built from the rice husk particle reinforced polypropylene composites is a mile stone that could radically change both the cost of building in informal settlements as well as their rapidity of deployment. Affordability would ensure increased applicability thus reducing pressure on use of depleting resources such as timber. Rice husk particle reinforce polypropylene composite production for low cost housing targets products such as poles and sheets / particle boards which could widely be used in construction industry. 1.2 Previous work (Ndazi et al, 2006), in their work ‘Production of rice husks composites with Acacia mimosa tannin-based resin’ presented and discussed results on the production of composites boards from a mixture of rice husks and wattle (Acacia mimosa) tannin based resin. The experimental results had shown that the ‘as received rice husks’ when blended with alkali-catalyzed tannin resin did not result in optimum composite panel properties. However, it was found that a slight physical modification of the rice husk particles by hammer-milling resulted in drastic improvements in the interfacial bond strength and stiffness of the composites panels from 0.041 MPa to 0.200 MPa and 1039 MPa to 1527 MPa, respectively. This work did not check on specific variation of interfacial bond strength with various sizes of hammer milled rice husk to the particle size category. (Dhawan et al, 2013), in their work ‘Effect of Natural Fillers on Mechanical Properties of GFRP Composites’ studied the effect of natural fillers on the mechanical characteristics of FRPs. Rice husk, wheat husk, and


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coconut coir were used as natural fillers in glass fiber reinforced plastics (GFRPs). In general, the addition of fillers lead to improvement in mechanical strengths but lowered water absorption. (Odhong et al, 2017), in their work ‘Recovering Impact Strength of Fractured Rice Husks Fibre Reinforced Polypropylene Composites Using Healing Agents’ studied the possibility of repair of fractured rice husk fibre reinforced polypropylene composite by use of healing agent infiltration method involving the injection of healing agents to fractured surfaces with a view to restoring the composite’s original structural applicability. This was possible through re-introducing desirable impact strengths to a fractured rice husk fibre reinforced polypropylene composite completely separated by impact forces. Highest % impact strength recovery of 98.3 was achieved. However the study did not investigate probability of achieving higher strengths with smaller sizes of the reinforcement phase to the size level of rice particles. Also other properties such as moisture ingress, heat transfer and nail retention were not investigated. (Bledzki et al, 2016), in their work ‘Characterization of grain by-products and properties of its biodegrade composites’ inspected and compared mechanical properties of different grain by-products and wood fibre composites as well as the addition of coupling agent effect on microstructure and mechanical properties. Particle size distribution, particle shape, bulk density, thermal behaviour water absorption and solubility properties were investigated and properties compared with standard engineering material softwood fibre. However, this work did not specifically investigate variation of the reinforced composite properties with specific particle sizes. 1.3 Purpose The purpose of this research was to produce rice husk particle reinforced polypropylene composite and also investigate its properties with a view to recommending it for use in applications areas having extreme weather conditions. 1.4 Contribution of the paper The research paper significantly contribute knowledge and techniques necessary in the production and testing of plant based fibre reinforced polymer composites in line with the intended functionality. It also introduces a method of functional characterization pegged on various test results. The proprietary strengths were clearly a function of particle sizes as well as inherent properties of the matrix. The results could be used as a basis for choice of a suitable material for a desired function.


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2. MATERIALS AND METHODS 2.1 Preparation of composite constituents Rice husks were hammer milled and sieved to average particle size of between 0.1 to 1 µm. The size of particles was measured using optical measuring equipment (universal projectile) as in plate 1.

Plate 1 universal projectile Plate 2 measuring size of rice husk particle The particles were then mixed with diazonium salt in alkali media for surface modification then dried in an oven at 850C for 24 hours to completely remove the moisture (Wayan et al, 2014; Ismat et al, 2015). Polypropylene wastes were cleaned, shredded to 1 mm by 1 mm pieces and then dried in an oven at 800C for 24 hours (Dhawan et al, 2013; Ismat et al, 2015). 2.2 Tools and equipment Injection moulding machine having a fabricated mould with upper and lower dies was used to produce round test pieces which were 150 mm long and 10 mm in diameter for tensile and bending tests, the opposite side of the mould had a cavity for producing 75 mm by 10 mm by 10 mm test pieces for charpy impact tests. Another moulding fixture was fabricated to produce test pieces which were 63 mm long and 35 mm in diameter for brinel hardness test. Test pieces for compressive strength test were cut to 63 mm from those meant for tensile test by use of hacksaw. Measurement of weight fractions for both polypropylene wastes and rice husks were done using electronic weighing machine. The same machine was also used to weigh test pieces before and after immersing them in water during moisture ingress test.


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2.3 Test piece production Composite material sheets were prepared using film stacking technique in which a layer of rice husk particles of sizes between 0.1 to 1 µm (a given size at a time) were poured on top of a similar layer of shredded polypropylene wastes in a fabricated fixture as shown in plate 3 and 4.

Plate 3 fabricated fixture having rice husk particles Plate 4 shredded polypropylene The particle volume fraction used was 42%. The fabricated fixture was heated in a furnace to a temperature of 2000C. The fixture was loaded to a compressing fixture attached to a Universal Mechanical Testing Machine as shown in plate 5. The machine compressed the heated material layers at a pressure of 5kPa and the formed composite sheets (1.8 mm thick) rolled out (Ismat et al, 2015). For each particle size, several test pieces were produced for initial tests aimed at finding out the best possible particle size that gave optimal mechanical properties. Round test pieces were prepared in a heating and moulding chamber, then compressed at 10 MPa using a hydraulic press machine fitted with appropriate controls. The test pieces produced were five for every destructive test. Their cross sections and sizes were determined by cavities produced in the upper and lower dies of the mould.


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Plate 5 machine with set up for film stacking 2.4 Design of experiments 2.4.1 Effect of particle size Experimental design involved varying rice husk particle size during the production of composites so as to investigate their influence on mechanical properties for rice husks particle reinforced polypropylene composites. The particle size was varied in increasing steps of 0.1 from 0.1 µm to 1 µm. The composites produced were tested destructively to determine their optimal mechanical strengths.

International Journal of Scientific Research a 2.4.2 Mechanical properties Impact strength tests (ASTM D 6110-10Each group of five round test pieces produsing charpy / izod equipment shown in p

Plate 6 charpy /izod impact testing machinA charpy impact testing machine havingspecimens. The test results recorded wereFlexural strength tests (ASTM D 7264) Each group of five round composite testfitted into a Universal Mechanical Testinhead speed of 5 mm/min at 24 0C. A meaas per particle sizes.. Compressive strength (ASTM D 6641 / DEach group of five round test pieces proUniversal Mechanical Testing Machine sresults were recorded for all the test pieceTensile strength tests (ASTM D 3039 / D Each group of five round test pieces prodMechanical Testing Machine shown in pla

rch and Innovative Technology ISSN: 2313-3759 Vol. 4

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10) s produced as in section 2.3 were subjected to charpyn in plate 6. The test set up was as shown in plate 7.

machine Plate 7 test set up for impact test having pendulum impact energy of 142 Joules was were a mean for five test pieces produced as per part te test pieces having 100 mm gauge length and diam Testing Machine shown in plate 5. They were loadeA mean strength was recorded for every group of five41 / D 6641 M – 14) es produced as in section 2.3 were subjected to comhine shown in plate 5. The test set up was as show pieces produced as per particle sizes. 9 / D 3039M – 14) s produced as in section 2.3 were subjected to tensile in plate 5 (magnification ×50). The test set up was

ol. 4 No. 10; October 2017 harpy impact strength tests te 7.

s was used to fracture the er particle sizes. d diameter of 10 mm were loaded to failure at cross-of five test pieces produced to compressive tests using shown in plate 8. The test ensile tests using Universal as shown in plate 9.


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Plate 8 test set up for compressive strength Plate 9 tensile test set up The test results were recorded for all the test pieces produced for various rice husk particle sizes. Morphological investigation/ Optical microscopy Fractured surfaces from the composite test pieces which were subjected to destructive tests were each arranged and fitted into Am Scope microscope for investigation of internal structure after failure. The set up was as shown in plate 10.


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Plate 10 Morphological investigation Hardness tests (ASTM E10) Hardness of the rice husk particle reinforced polypropylene composite was determined by using Brinel Hardness Testing Machine. The specimen size used was a circular composite of length 65 mm and a diameter of 35 mm. The specifications of the machine were ball indenter of diameter 20 mm and a maximum load of 4000 N. The formula used to determine the BHN of the specimen was given as below (Chandramonan & Marimuthu, 2011). BHN = P/A Where P - Load applied to the specimen= 2500N (applied load), A - Area of the indentation. = πD/2 * ((D- (D2-d2))0.5, and D - Diameter of the ball intender. d - Diameter of the indentation. The mean hardness test results were recorded for each of the five groups for all the test piece samples.


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2.4.3 Thermal Properties Heat transfer properties of the composite were investigated by arranging a high heat generating bulb (100W) on one side of the composite plate (side A) and then fitting a thermocouple, one on each side of the composite plate (side A and B). The temperature differences were monitored over a 12 hour period. The results were recorded to help determine heat transfer indicated by a temperature rise on side B. 2.4.4 Nail retention/withdrawal strength Nail retention test was conducted using a set up in Universal Mechanical Testing Machine that mimics set up for tensile test. A six inch nail was drawn half way into one end of a composite test piece using a carpenter’s hammer. The nail was then firmly fixed into the upper jaw of a Universal Mechanical Testing Machine. The other end of the test piece was held in the lower jaw of the machine. Machine was started and loading was automatically done by the controller unit of the testing machine. Forces required to withdraw the nail were read from both computer VDU and the digital readout of the machine and then recorded appropriately. 2.4.5 Moisture ingress test as per ASTM D 1037- 99 Test pieces were oven dried at 500C. Moisture ingress tests were done for short term and long term using immersion technique in petri – dishes. Water absorbed was determined by immersion of 1.8 mm thick reinforced composite sheet samples in distilled water at room temperature (240C) for 400 hours. The changes in weight of the test pieces were measured at regular time intervals (Rosa et al, 2009). The test pieces were weighed before immersing in water for short period (64 hours – weighing being done in intervals of 8 hours), then weighed again after using filter paper to wipe water from the composite surface to enable calculating weight gain i.e. moisture weight. A similar sample was weighed before immersing in water for long period – beyond 64 hours i.e. upto 400 hours in a similar manner as for short term (Chandramonan & Marimuthu, 2011; Reaszuddin et al, 2017). The weighing was done using electronic weighing machine having 0.01 mg resolution (Rosa et al, 2009; Grace & Altan, 2012). Pseudo equilibrium position (initial saturation) moisture ingress was determined from short period test. 3. RESULTS AND DISCUSSION 3.1 Effect of particle size The test pieces having various rice husk particle sizes were produced in groups of 5 and tested destructively. The test results were a mean for the five test pieces. Optimum strengths varied for various tests with variation of test piece particle sizes.


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3.2 Mechanical properties from destructive tests Maximum impact strength was 78 J/mm2 obtained from test pieces having 0.4 µm rice husk particle size as shown in TABLE 1. Table 1 Charpy impact test results Particle size for composite in µm 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Impact strength in J/mm2 61 67 75 78 66 64 60 55 51 50 Compressive strength results were a maximum of 69 MPa also obtained from test pieces having 0.4 µm rice husk particle size as shown in TABLE 2. Table 2 Compressive strength results Particle size for composite in µm 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Compressive strength in MPa 58 61 67 69 68 66 65 60 56 55 Maximum brinel hardness for the samples was BHN 520 also obtained from test pieces having 0.4 µm rice husk particle size as shown in TABLE 3. Table 3 Brinel hardness test results Particle size for composite in µm 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Hardness BHN 516 516 517 520 515 511 511 510 500 497 The three results above were attributed to close packing of the rice husk particles in the composite based on the smallness of the particle size. There was better tessellation of the rice husk particles with the shredded polypropylene wastes thus forming a more compact rice husk particle reinforced polypropylene composite. Maximum tensile strength was 58 MPa obtained from test pieces having 0.9 µm rice husk particle size as shown in TABLE 4. Table 4 Tensile strength results Particle size for composite in µm 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Tensile strength in MPa 50 51 52 53 53 54 56 56 58 57 Maximum bending strength was 50 MPa obtained from test pieces having 0.9 µm rice husk particle size as shown in TABLE 5. Table 5 Bending strength test results Particle size for composite in µm 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 Bending strength in MPa 34 34 39 39 40 43 45 49 50 47


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Based on crack opening and displacement approach, stress field at the nail tip must exceed yield strength for crack to continue to propagate in order for the nail to be drawn further into the reinforced composite. In withdrawing the nail, the stress required was slightly less than the fracture stress but more than the yield strength. The maximum nail withdrawal strength was 63 MPa also obtained from test pieces having 0.9 µm rice husk particle size as shown in fig. 1

Figure 1 nail withdrawal / retention test results Tensile, bending and nail withdrawal strengths were maximum in the predominant direction of orientation of the particles.

010203040506070

0 10 20 30

Stress, MPa

% ∆ L

0.8 mic.m- Frac. Stress = 61 MPa0.1 mic. M -Fracture Stress = 35 MPa"0.3 mic. m- Frac. Stress = 41 MPa"0.5 mic. M -Frac. Stress = 52 MPa"0.2 mic. m- Fracture Stress = 37 MPa"0.9.mic. M -Frac. Stress = 63 MPa"0.6 mic. M - Fract. Stress = 58 MPa"0.4 mic. M - Frac. Stress = 42 MPa"0.7 mic. M - Frac. Stress = 60 MPa"


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3.3 Optical microscopy Internal structure of fractured surfaces was observed under an AmScope microscope (ME 1200 B/T series) using 50× magnification as well as fine focusing sensitivity of 0.002 mm (Odhong et al, 2017). The fractured surface was analysed and the morphology was as shown in fig. 2.

Fig. 2 internal structure of fractured rice husk particle reinforced composite. The micrograph showed clear particle surfaces from which matrix had separated from particles. Areas from which matrix had cracked could also be seen. Some rice husk particles which have cracked could also be seen. The internal structure of the rice husk particle reinforced polypropylene composite as seen from the micrographs of the fractured surfaces reveal a failure associated with matrix cracking as well as particle – matrix disbond. Rice husk particle surfaces clear of matrix (polypropylene) are evidence of that disbond. The disbond affect load transfer between the fibres and the matrix. 3.4 Other properties Heat transfer Heat that was transmitted from one side of the composite particle to the other was not more than 10C in 12 hours as shown in TABLE 6. The covalent bonds in the reinforced composite constituents as well as both chemical and frictional bond at the interface impeded conductivity of both heat and electricity. Therefore high temperatures on one side of the rice husk particle reinforced composite plate was hardly transmitted to the opposite side. Table 6 Heat transfer test results Time in Hours 1 2 3 4 5 6 7 8 9 10 11 12 Side A (Temp in 0C) 24 25 25 26 28 33 35 36 39 41 41 41 Side B (Temp in 0C) 24 24 24 24 24 24 24 24 24 25 25 25 This material property was very useful especially for construction materials intended to be used for housing structures since they mitigate against adverse weather conditions that could affect occupants of such houses.


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Moisture ingress Mass of moisture in the composite was obtained by subtracting weight of dry rice husk particle reinforced polypropylene composite from weight of the composite having moisture. The result was plotted against the square root of time taken by the composite while immersed in water. The result with minimum moisture ingress was obtained from test pieces having 0.5 µm rice husk particle size. The results were as shown in Table 8 and figure 3. Moisture mass was obtained using the formula below: 100(%) 0 0×

−= W WWM tt …………………….. (1) where Mt is the amount of water absorbed at time t, Wt is the weight of the sample at time t and W0 is the initial weight of the sample (Grace & Altan, 2012; Reaszuddin et al, 2017). Table 8 Moisture ingress data Days 0 0.05 0.1 0.15 0.2 0.22 0.28 0.35 1.8 Mass 0 0.1 0.2 0.3 0.4 0.5 0.6 0.8 0.9

Fig. 3 moisture ingress graph Nonhygroscopic nature of the rice husk particle reinforced polypropylene composite predominated when the rice husk particles were well encirculated by polypropylene in the composite (Kumar et al, 2010;Pickering et al, 2016). The rice husk particle reinforced polypropylene composite hardly absorbed moisture. This was exhibited by the low % of moisture mass penetrating the rice husk particle reinforced polypropylene composite in both short term and long term moisture ingress tests. The moisture absorbed by the composite before it reached pseudo-equilibrium was equally low (0.8 gm in 64 hours) and moisture ingress short term was 0. 5% and long term was 0.55%


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4. CONCLUSION The light weight associated with rice husk particle reinforced polypropylene composite materials, immunity to attack by fungi and termites, renewability of rice husk particles after only a cycle time of three months, and the presence of silica in them which contributed to strength enhancement at the interface of the reinforced composite resulted in superior mechanical properties thus making the material preferred to replace traditional engineering materials for the same application. Structural suitability for the rice husk particle reinforced polypropylene composite in terms of jointing capability was exhibited in high nail withdrawal / retention strengths. With enhanced interfacial strengths arising from larger surface areas containing silica in the particles at the interface, a nail had to be subjected to higher withdrawal forces in order to drive it out of the rice husk particle reinforced polypropylene composite material. This implied that for rice husk particle reinforced polypropylene composite parts jointed by use of a nail or such other fasteners, there was a high level of structural integrity of the composite structure thus expanding its potential functional areas. Moreover, the very low heat transfer rates of the material could guarantee comfort if used to construct structures for human habitation. Both short term and long term moisture ingress % were very low. This ensured dimensional stability of the material as well as suitability for use in all weather conditions. The structural integrity of the rice husk particle reinforced polypropylene composites therefore could expand their functional areas and assure their conformity to performance standards with regards to both mechanical and structural functions. ACKNOWLEDGEMENTS We acknowledge the support given to us by Multimedia University of Kenya administration in terms of timely funding for this research and also logistic support. We recognize and appreciate technical support given to us by technical staff of Technical University of Kenya, The University of Nairobi, Technical trainers college (KTTC) and Eldoret Polytechnic technical staff REFERENCES Bledzki ,A. K., Mamun, A.A., Volk, J. (2016). Characterization of grain by-products and properties of its biodegrade composites. Naro.tech Messe und Kongresse fü nachwa chsende Rohstoffe; Sept 6-9. Chandramonan D. and Marimuthu K. (2011). Tensile and Hardness Tests on Natural Fiber. Reinforced Polymer Composite Material. International journal of advanced engineering sciences and technologies. 6 (1), 097 – 104. ISSN: 2230-7818 Dai, W.L., 2003). Blendability and processing methodology of an environmental material rice husk/ PVA composites, Materials Letters, 57, 3128-3136. Dhawan, V., Singh, S., and Singh,I. . (2013). Effect of Natural Fillers on Mechanical Properties of GFRP Composites. Journal of Composites. Volume 2013 Article ID 792620, 8 pages http://dx.doi.org/10.1155/2013/792620 Grace, L.R., Altan, M.C. (2012). Characterization of anisotropic moisture absorption in polymeric composites using hindered diffusion model. Elservier. Composites: Part A 43 (2012) 1187–1196 Han-Seung, Y., Hyun-Joong, K., Jungil, S., Hee-Jun, P., Bum-Jae, L., Taek-Sung, H . (2004). Rice-husk flour filled polypropylene composites; mechanical and morphological study. Composite Structures, 63, 305–312. Elsevier.


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Mechanical, Structural and Gravimetric Properties … · Mechanical, Structural and Gravimetric Properties of Rice Husk Particle Reinforced Polypropylene Composite ... Key words: