DESIGN OF KENAF FIBER POLYMER COMPOSITE

FOR INTERIOR CAR DOOR PANEL APPLICATION

By:

AL AZIM FAIZ BIN ZULKIFILI

(Matrix no.: 141395)

Supervisor:

Assoc. Prof. Ir. Dr. Abdus Samad Bin Mahmud

July 2022

This dissertation is submitted to

Universiti Sains Malaysia
As partial fulfillment of the requirement to graduate with honors degree in
BACHELOR OF ENGINEERING (MECHANICAL ENGINEERING)

School of Mechanical Engineering

Engineering Campus
Universiti Sains Malaysia
DECLARATION

This work has not previously been accepted in substance for any degree and is not being
concurrently submitted in candidature for any degree.

Signed…… …… (AL AZIM FAIZ BIN ZULKIFILI)

Date: 25/7/2022

Statement 1:

This thesis is the result of my own investigation, except where otherwise stated. Other
sources are acknowledged by giving explicit references. Bibliography / references are
appended.

Signed…… …… (AL AZIM FAIZ BIN ZULKIFILI)

Date: 25/7/2022

Statement 2:

I hereby give consent for my thesis, if accepted, to be available for photocopying and
for interlibrary loan, and for the title and summary to be made available outside
organizations.

Signed…… …… (AL AZIM FAIZ BIN ZULKIFILI)

Date: 25/7/2022

I
ACKNOWLEDGEMENT

Firstly, I would like to thank the School of Mechanical Engineering, Universiti

Sains Malaysia for providing the equipment and necessary materials to complete my
Final Year Project (FYP). In addition, the help of my supervisor, Assoc. Prof. Ir. Dr.
Abdus Samad Bin Mahmud, has been greatly appreciated. In spite of challenges I have
encountered, my supervisor has always encouraged and guided me. I have been able to
complete this project to the best of my ability with his assistance and valuable feedback
whenever I approach him. Also, I would like to acknowledge with much appreciation
the vital role played by the staff at the Applied Mechanics Lab of the School of
Mechanical Engineering, Mr. Fakruruzi Fadzil has always been willing to teach and
lend a hand in operating the machines such as the Universal Tensile Machine (UTM).
His help in teaching me the skills needed to operate the UTM machine for the tensile
and flexural testing have sped up my progress significantly. As well, I would like to
acknowledge and thank the technician of Composite Lab of School of Aerospace
Engineering, Mr. Hasfizan bin Hashim, who willing to share the knowledges and
teaches me the manufacturing processes to produce composites for my project
specimen. He also helped me during the processes to produced my project specimens
and also give me advised when I have a problem during the process makes my project
run smoothly. Furthermore, thank you to the rest of my family and friends who have
supported me throughout this process. They have supported and put their trust in me
during the ups and downs of this project and in general. As a final note, I must
acknowledge the assistance and guidance provided by the other supervisors and the
panellists, especially when presenting the project.

II
TABLE OF CONTENTS

DECLARATION ........................................................................................................................ I
ACKNOWLEDGEMENT ......................................................................................................... II
TABLE OF CONTENTS .......................................................................................................... III
LIST OF FIGURES ................................................................................................................... V
LIST OF TABLES ................................................................................................................... VII
LIST OF ABBREVIATIONS ................................................................................................. VIII
ABSTRACT (BM) .................................................................................................................... IX
ABSTRACT (BI) ....................................................................................................................... X
CHAPTER 1 INTRODUCTION ............................................................................................... 1
1.1 Project Overview ....................................................................................................... 1
1.2 Problem Statement ..................................................................................................... 3
1.3 Objective .................................................................................................................... 4
1.4 The Scope of The Project ........................................................................................... 4
CHAPTER 2 LITERATURE REVIEW .................................................................................... 5
2.1 Kenaf fiber polymer composites ................................................................................ 5
2.2 Factors that effects natural fiber polymer composites properties .............................. 5
2.3 Design and manufacturing process of natural fiber polymer composites .................. 6
2.4 Chemical treatment on the natural fiber ..................................................................... 7
2.5 Resins used in natural fiber polymer composites....................................................... 7
2.6 Hybrid natural fiber polymer composites (HNFC) .................................................... 8
2.7 Application of natural fiber reinforced in automotive industry. ................................ 9
CHAPTER 3 RESEARCH METHODOLOGY ...................................................................... 12
3.1 Raw material preparation ......................................................................................... 12
3.2 Kenaf fiber orientation ............................................................................................. 14
3.3 Kenaf fiber polymer composite fabrication ............................................................. 15
3.4 Testing methods ....................................................................................................... 19
3.4.1 Tensile properties testing method (ASTM D3039) .......................................... 20
3.4.2 Flexural strength testing method (ASTM D790): ............................................ 22
CHAPTER 4 RESULTS AND DISCUSSION ........................................................................ 25
4.1 Tensile properties testing results (ASTM D3039): .................................................. 25
4.1.1 Polyester resin and hardener ............................................................................ 25
4.1.2 Unidirectional (0°) orientation of Kenaf Fiber Polymer Composite (KFPC) .. 27
4.1.3 Random orientation of Kenaf Fiber Polymer Composite (KFPC) ................... 29
4.2 Flexural strength testing results (ASTM D790):...................................................... 31

III
 4.2.1 Polyester resin and hardener ............................................................................ 31
4.2.2 Unidirectional orientation of Kenaf Fiber Polymer Composite (KFPC) ......... 33
4.2.3 Random orientation of Kenaf Fiber Polymer Composite (KFPC) ................... 35
4.3 Results comparison and discussion .......................................................................... 37
CHAPTER 5 CONCLUSION AND FUTURE WORK .......................................................... 43
5.1 Conclusion ............................................................................................................... 43
5.2 Future work .............................................................................................................. 43
REFERENCES ........................................................................................................................ 45
APPENDICES ......................................................................................................................... 48

IV
LIST OF FIGURES

Figure 1.1: Example of bio-based car door inner panel [7] ................................................... 3
Figure 2.1 Schematic diagram of hybridization of a woven kenaf with carbon fibre [16] ....... 9
Figure 2.2: Natural fiber and fiberglass reinforced composite trade off [20] ........................ 11
Figure 2.3: Value chain of natural fiber composite for automotive interior production [20] .. 11
Figure 3.1: Grade B kenaf fiber ....................................................................................... 12
Figure 3.2: Random orientation (left) and unidirectional orientation (right) ........................ 14
Figure 3.3: Hand layup process........................................................................................ 16
Figure 3.4: Vacuum bagging process ............................................................................... 17
Figure 3.5: Finished KFPC plates for random (left) and unidirectional (right) orientation. ... 17
Figure 3.6: Cut samples of random KFPC followed ASTM standard for tensile (left) and
flexural (right) tests. ....................................................................................................... 18
Figure 3.7: Cut samples of unidirectional (0°) KFPC followed ASTM standard for tensile
(left) and flexural (right) tests. ......................................................................................... 18
Figure 3.8: Polyester resin and hardener samples followed ASTM standard for tensile (left)
and flexural (right) tests. ................................................................................................. 19
Figure 3.9: Tensile testing specimen drawing in SI ........................................................... 21
Figure 3.10: Three-part failure mode code ........................................................................ 21
Figure 3.11: Tensile testing using universal testing machine (UTM) .................................. 22
Figure 3.12: Flexural testing specimen drawing ................................................................ 23
Figure 3.13: Flexural testing using universal testing machine (UTM) ................................. 24
Figure 4.1: Polyester resin and hardener samples after tensile testing ................................. 26
Figure 4.2: Graph of tensile stress against tensile strain of polyester and hardener samples .. 26
Figure 4.3: Unidirectional orientation KFPC samples after tensile testing ........................... 28
Figure 4.4: Graph of tensile stress against tensile strain of unidirectional orientation KFPC . 28
Figure 4.5: Random orientation KFPC samples after tensile testing .................................... 30
Figure 4.6: Graph of tensile stress against tensile strain of random orientation KFPC .......... 30
Figure 4.7: Polyester resin and hardener samples after flexural testing................................ 32
Figure 4.8: Graph of flexural stress against flexural strain of polyester and hardener samples
...................................................................................................................................... 32
Figure 4.9: Unidirectional orientation KFPC samples after flexural testing ......................... 34
Figure 4.10: Graph of flexural stress against flexural strain of unidirectional orientation KFPC
...................................................................................................................................... 34

V
Figure 4.11: Random orientation KFPC samples after flexural testing ................................ 36
Figure 4.12: Graph of flexural stress against flexural strain of random orientation KFPC .... 36
Figure 4.13: Tensile properties comparison between random orientation KFPC sample,
unidirectional orientation KFPC sample and polyester resin sample. .................................. 38
Figure 4.14: Flexure properties comparison between random orientation KFPC sample,
unidirectional orientation KFPC sample and polyester resin sample. .................................. 40
Figure 4.15 FYP sample comparison with existed interior car door panel that used in
industries (Tensile stress and Flexural modulus). .............................................................. 42

VI
LIST OF TABLES

Table 2.1:Material characteristics and properties comparison............................................. 10

Table 3.1: Basic properties of grade B kenaf fiber ............................................................. 12
Table 3.2: Specifications of polyester resin....................................................................... 13
Table 3.3: Typical properties of polyester......................................................................... 14
Table 3.4: Project variables ............................................................................................. 15
Table 3.5: Description of test method ............................................................................... 19
Table 3.6: Tensile testing specimen geometries ................................................................ 20
Table 3.7: Flexural testing specimen geometries ............................................................... 23
Table 4.1: Tabulated results of tensile testing of polyester and hardener samples ................ 27
Table 4.2: Tabulated results of tensile testing of unidirectional orientation KFPC ............... 29
Table 4.3: Tabulated results of tensile testing of random orientation KFPC ........................ 31
Table 4.4: Tabulated results of flexural testing of polyester and hardener samples ............... 33
Table 4.5: Tabulated results of flexural testing of unidirectional orientation KFPC ............. 35
Table 4.6: Tabulated results of flexural testing of random orientation KFPC....................... 37

VII
LIST OF ABBREVIATIONS

NFPC Natural Fiber Polymer Composite

KFPC Kenaf Fiber Polymer Composite
UTM Universal Testing Machine
ASTM American Society for Testing and Materials
LKTN Lembaga Kenaf dan Tembakau Negara
UTS Ultimate Tensile Strength

VIII
ABSTRACT (BM)

Sejak kebelakangan ini, serat semulajadi telah menjadi tumpuan para

penyelidik, jurutera dan saintis sebagai bahan pengukuhan alternatif yang digunakan
dalam menghasilkan komposit polimer terutamanya dalam industri automotif. Dalam
industri automotif, penggunaan serat semulajadi mempunyai banyak kelebihan
berbanding dengan gentian sintetik seperti mempunyai kos yang rendah, rintangan
kepada lelasan, boleh dikitar semula, boleh diperbaharui dan meningkatkan kecekapan.
Walau bagaimanapun, banyak komposit serat semulajadi yang ada dipasaran tidak
direka untuk kegunaan khusus menyebabkan sifat mekanikal komposit tersebut tidak
sesuai digunakan dalam komponen automotif seperti panel pintu dalaman. Projek ini
bertujuan untuk mengkaji dan menghasilkan komposit serat kenaf untuk digunakan
sebagai panel pintu dalaman di dalam industri automotif. Susunan serat kenaf di dalam
komposit akan mempengaruhi sifat mekanikal seperti kekuatan tegangan dan kekuatan
lenturan telah dikaji dalam projek ini. Serat kenaf disusun secara rawak dan lurus (0°)
sebelum proses seperti meratakan resin dan pembungkusan vakum untuk menghasilkan
sampel komposit. Selepas itu, ujian tegangan dan lenturan dijalankan ke atas sampel
komposit mengikut piawaian ASTM yang ditetapkan. Dalam kajian ini, didapati
bahawa kehadiran serat kenaf telah meningkatkan kekuatan tegangan dan kekuatan
lenturan komposit dengan memindahkan beban antara serat dan memberikan komposit
bentuk akhirnya. Selain itu, serat kenaf yang disusun lurus meningkatkan sifat
mekanikal seperti kekuatan tegangan dan lenturan dengan lebih banyak berbanding
serat kenaf yang disusun secara rawak. Hal ini kerana serat kenaf yang disusun lurus
mempunyai nisbah aspek yang baik dan serat yang sejajar memindahkan tekanan secara
sama rata diantar helaian serat.

IX
ABSTRACT (BI)

Recently, natural fibers have gained popularity among researchers, engineers,

and scientists as alternative reinforcing materials used in manufacturing polymer
composites, especially in the automotive industry. In the automotive industry, the use
of natural fibers provides many advantages over synthetic conventional components
such as low cost, low density, abrasion resistance, recyclability, renewability, and eco-
efficiency. However, many natural fiber composites available today are not designed
for one specific application cause the mechanical properties of the composites are not
suitable to use in certain automotive components such as inner door panels. This project
aims to study and fabricate the kenaf fiber composite to use as an inner door panel in
an automotive application. The effects of kenaf fibers orientation in the composites on
the mechanical properties such as tensile and flexural strength were investigated in this
project. Kenaf fibers were arranged in random orientation and unidirectional (0°)
orientation before it undergoes the hand layup and vacuum bagging process to produce
the composite samples. After that, tensile and flexural tests were done on the composite
samples following the designated ASTM standards. In this study, it was found that the
presence of kenaf fibers were increasing the tensile strength and flexural strength of the
composite by transferring loads between fibers and giving the composite its net shape.
In addition, for the natural fiber orientation, the unidirectional orientation of kenaf
fibers can drastically increase the tensile and flexural strength of the composite
compared to the random orientation of kenaf fibers. The unidirectional orientation
increases mechanical properties because of its aspect ratio is good enough and the fibers
are aligned making the load can transfer equally between the fibers.

X
 CHAPTER 1

INTRODUCTION

1.1 Project Overview

Fibers are threads of material that resemble hair and look as continuous filaments
[1]. Synthetic and natural fibers are the two types of fiber. Synthetic fibers are fibers
made by human through chemical synthesis and synthesized polymers of small
molecules. Synthetic fibers made form the compound of raw materials such as
petroleum-based chemicals that polymerized into a chemical bonds two adjacent carbon
atoms. Fibers obtained from natural sources are derived from geological processes or
animals and plants. A natural fiber can be used in composite materials in which the
orientation of the fiber affects the properties. Natural fibers are classified into three
types: cellulose-based, protein-based, and mineral-based fibers [2]. Natural fiber
compositions can be classified into three basic components: cellulose, hemicellulose,
and lignin. Natural fibers are made up of a variety of elements including cellulose,
lignin, pectin, and other materials, giving them distinct physical and chemical
properties [3]. Composites made from high-strength natural fibers mixed with polymers
are called natural fiber polymer composites (NFPC). Natural fibers that can work with
polymer composites include kenaf, jute, hemp, sugar palm, coir, cotton, bamboo, oil
palm, pineapple leaf, and banana stem [4]. Natural fiber composites are eco-friendly
materials that have gotten a lot of attention in the product production engineering
industry.

The properties of Natural Fiber Polymer Composite (NFPC) depend on several

factors like orientation of natural fiber, volume fraction of the composites, application
of chemical treatment and manufacturing process. These factors can influence the
mechanical properties of NFPC like tensile strength, flexural strength, fatigue
resistance, fracture toughness and impact resistance. The orientation of the fibers is
crucial in determining the composite's mechanical properties. Mechanical properties
alter noticeably when the angle of orientation changes from 0 to 90 degrees [5]. The
angle of orientation was also shown to affect the damping properties of composites.
Chemical treatment on the natural fiber can modifying the fiber surface properties so
the poor compatibility between fiber and matrix can be ignored [6]. The surface and

1
strength of fibers can be enhanced by chemically treating them to improve adhesion to
polymer matrixes. There are a number of different processes used to fabricate
composite materials, and each process is applicable to a particular material. The
manufacturing processes that can be used to produce natural fiber polymer composites
are hand layup, spray-up, vacuum bag moulding, resin transfer moulding, vacuum
infusion, compression moulding, injection moulding and etc. The efficiency of a
manufacturing processes depends on the type and volume of matrix material used,
because each material has its own physical properties, such as melting point, stiffness,
tensile strength, flexural strength and interlaminar shear strength. As a result,
manufacturing processes are defined based on the material used.

The initial phase in the manufacturing process is design; several crucial decisions
must be taken at this point that will affect the final product [2]. As a result, various
factors must be considered early in the design process, including manufacture,
assembly, cost, sales, maintenance, disposal, and recycling. Natural fiber composite
product design follows the same principles as other product design methods. Designers
require three things: material, machinery, and manufacturing methods. This means that
designers are responsible not only for creating high-quality designs, but also for
suggesting and choosing acceptable materials so that the product may be manufactured
at a reasonable cost. In this final year project, natural fiber polymer composite will be
designed and fabricated for the used in automotive application such as interior door
panel using several manufacturing process and chemical treatment. The intended
application of this fiber composite requires the following material properties: uniform
composite composition, anisotropic, good fracture toughness, and etc. The mechanical
behavior of the composite will be quantified using testing equipment that include tensile
strength, flexural strength and interlaminar shear strength.

In the design of future vehicles, bio-composite will play a major role in reducing
their weight and emissions, which will lead to a savings of 250 million barrels of crude
oil for each 25% reduction in vehicle weight [7]. Doors, seatbacks, headliners, package
trays, dashboards, and interior parts made from natural fiber composites have been
adopted by European car manufacturers and suppliers. Composites reinforced with
natural fibers are used primarily as low-cost materials for various applications including
vehicle interior linings. The automotive industry has renewed interest in natural fibers,
particularly as a glass fiber substitute. As the automotive industry recognizes its

2
significance, it improves the recyclability of new products and develops bio-based
products, especially for the vehicle's body, in order to reduce weight. Fig. 1.1 shows
example of bio-based car door inner panel that been processed using natural fiber
blending with thermoplastic matrix. The car door inner panel is manufactured by hot
press process that curing the resin such as epoxy or polyurethane resins under heat
before using it to coated non-woven based on natural fibers.

Figure 1.1: Example of bio-based car door inner panel [7]

1.2 Problem Statement

Natural fiber polymer composites are applied in the automotive industry by

requiring certain material properties, such as uniform composition, synergistic
properties, high fracture toughness, high rigidity, good thermal and sound insulation,
etc... There is a problem with many fiber composites available now because they are
not designed for one specific application, so their properties will not completely meet
the needs of the part. The fiber composites can be easily designed, if the designed
composites are limited to only one application, such as automotive, in terms of how the
fiber and polymer are used, the treatment process, the fiber orientation, etc. In addition,
the use of natural fiber make the automotive industry more sustainable because they are
not hazardous and environmentally friendly. Natural fiber also are 100% biodegradable
that can completely dissolves into carbon, oxygen, hydrogen and further minerals.

3
1.3 Objective

• To design and fabricate the natural fiber polymer composites (NFPC) from
kenaf fiber and polyester resin which is used in automotive application such as
interior door panel.
• To quantify mechanical properties of NFPC such as tensile strength and flexural
strength by doing several experiments and tests.
• To determine the effects of the presence of natural fiber in the composite and
fiber orientation on mechanical properties of the composite.

1.4 The Scope of The Project

In this project, the kenaf fiber polymer composites (KFPC) is fabricate by combine
the natural fiber which is kenaf fiber with the concentration of polyester resins and
hardener. The manufacturing processes used to produce KFPC is hand layup and
vacuum bagging process. Two KFPC samples will be produced that has different
orientation of kenaf fiber which are random orientation and unidirectional (0°)
orientation. One sample will be produced from concentration of polyester resin and
hardener without kenaf fiber. The chemical treatment such alkaline and silane does not
carry out in this project. The dimensions of the specimens for tensile strength and
flexural strength will be followed the ASTM D3039 and ASTM D790 respectively. All
samples will be undergoing several experiments and tests using Universal Testing
Machine (UTM) to determine the properties such as tensile strength and flexural
strength. Based on the testing results, the comparison for three samples can be done.

4
 CHAPTER 2

LITERATURE REVIEW

2.1 Kenaf fiber polymer composites

Southeast and East Asian countries actively cultivate kenaf and it needs to go
through separation process first to get the fiber that use in composites. For the fiber
separation process for kenaf, the bast fibers can be separated from the core fibers using
processes called decortating and retting [14]. Decortating is the process of employing a
decorticator to separate the bast fiber from the core fiber. Retting can be done in three
different ways, including mechanical, chemical, and water processes. Kenaf
biocomposite was made from a mixture of matrix (resin) and natural fibers derived from
the kenaf plant. Important parameters to consider in the production of a biocomposite
are typically pressing pressure and pressing temperature (heat). As well as mechanical
properties such as modulus of rupture (MOR), modulus of elasticity (MOE), and
internal bonding (IB), Kenaf fiber polymer composites have physical properties such
as swelling in thickness (TS) and water absorption (WA) [15]. As a result of low
digestion pressure, fibers generated longer lengths, so panels made with these fibers
showed higher TS with MOR and MOE than those made with other fibers. Mild refining
conditions resulted in longer fiber with a higher aspect ratio, which gave the panels
good bending strength but poor IB and physical properties. In contrast, severe refining
conditions resulted in short fiber with a low aspect ratio, higher IB and physical
properties, but lower bending strength.

2.2 Factors that effects natural fiber polymer composites properties

There are several factors that can influenced the properties of Natural Fiber
Polymer Composites (NFPCs) [8]. Fiber orientation, fiber aspect ratio, shape factor,
and fiber resin interfacial interaction are all elements that influence composite strength.
The mechanical properties of NFRCs, on the other hand, are dependent not only on the
chemical composition of the fiber, but also on physical and geometric parameters that
have been discovered to have a significant impact on their mechanical properties [5].
Fiber length and volume fraction heavily influence the mechanical properties of Natural

5
Fiber reinforced composites, including tensile and flexural strength. The mechanical
properties of natural fiber composites were heavily influenced by fiber orientation and
the angle of orientation is seen to influence the damping properties of composites.
Depending on the manufacturing process, the orientation of the fibers in the composites
varies [8]. Due to varying fiber orientations, the composites' strength varies between
samples. In addition, a hybrid composite combining two or more different types of
fibers can enhance flexibility, strength, fatigue resistance, bending and membrane
properties, fracture toughness, and impact resistance [9]. Designing hybrid composites
requires careful consideration of suitable fibers and fiber characteristics. Chemical
treatment like alkaline and silane also can improve the tensile properties of natural fiber
by fixed the bonding problem with the polymer[10]. Moreover, the processing
parameters such as temperature, time, and speed also influenced on tensile properties
[11]. The tensile properties, flexural properties, and impact strength are affected by the
different fiber size.

2.3 Design and manufacturing process of natural fiber polymer composites

For the natural fiber polymer composite (NFPC) manufacturing process,

compression moulding is a more practicable approach than injection moulding because
of its ease of operation and improved surface smoothness [8]. Composites made in the
experimental setup of injection and compression moulding processes have higher
tensile strengths compare to injection moulding process [8]. For the natural fiber
composition in composite, the tensile modulus of 20 percent fiber composites was
higher than virgin silicone because of the reinforcing effect of short fibres in
composites. For example, the hardness of silicone fiber composites increased as the
fiber composition increased from 5% to 10%, 15%, and 20%. The addition of fiber
strengthened the composites, making them tougher and more rigid. For the mixing
process temperature of natural fiber composite, the best mixing temperature is 190°C
because the maximum strength at this temperature indicates stronger interfacial
bonding [11]. For the chosen fiber size in manufacturing process, from the smallest
fiber to the medium size, strength grew, then reduced after reaching the medium size.
With fiber sizes between 125 and 300 μm, the maximum strength indicates stronger
interfacial bonding and wettability [11]. The low strength of small fiber is most likely

6
due to the increased surface area of smaller fiber, which leaves more surfaces
nonreactive to the matrix. In addition, NFPC product can be fabricate using the design
for sustainability (DFS) approach. The mold of NFPC product is fabricate using 3D
printing method and a hand lay-up process [2].

2.4 Chemical treatment on the natural fiber

Chemical treatments to affect the surface properties of natural fibers for use in
natural fiber-reinforced composites [12]. Alkali, silane, acetylation, benzoylation,
acrylation, maleated coupling agents, isocyanates and permanganate are the chemical
treatments that can be used on natural fiber. Kenaf fiber is frequently treated with
alkaline, which is one of the most widely used chemical treatments on natural fibers
when reinforcing thermoplastics and thermosets. As a result of treating fibers with an
alkaline solution for a predetermined period of time, lignin, wax, and oils are removed
from the fiber's external cell wall, cellulose is depolymerized, and short length
crystallites are exposed [12], [13]. The alkaline treatment caused the globular
pultrusions that were present in the untreated fibre to vanish, resulting in the creation
of more voids. The mechanical bonding of fibre and matrix may be aided by these voids.
In general, alkaline treatment reduced cement materials inside the fibre structure, which
was followed by the removal of unstable components with rupture bonds. For alkaline
treatment, the tensile strength of the treated natural fiber was much higher than that of
the untreated fiber [10]. In addition, the concentration percentage of NaOH that used to
treat the natural fiber have an effect on the treatment causing different mechanical
properties in natural fuber. For example, natural fiber treated with 6% NaOH has the
maximum tensile strength compared to natural fiber treated with 2%, 4%, and 8%
NaOH.

2.5 Resins used in natural fiber polymer composites

Modified resins are now widely used in the fabrication of natural fiber-reinforced
composites and the manufacture of various industrial products because of their better
mechanical, thermal, and electrical qualities [18]. Melamine formaldehyde, urea
formaldehyde, phenol formaldehyde, resorcinol formaldehyde, polyurethane,

7
polyesters, and epoxies are the most common large-volume thermosetting resin systems
but this article more focus on epoxy resin. In automotive and aerospace components
and products, natural fiber-reinforced epoxy composites and nanocomposites provide
better physical, mechanical, and thermal properties to produce high quality product.
Moreover, thermoset resin molecules crosslink in this phase, resulting in exothermy,
chemical shrinkage (Sh), and the formation of thermo-physical and thermo-mechanical
properties [19]. Matrix shrinkage/expansion is a crucial element in determining the
residual tension in a composite product as well as the form distortion that occurs during
curing. These stresses cause a large number of defects in a composite part. Matrix
shrinkage can be reduced by controlling and optimising the curing process to producing
high-quality composite products. The linear component of apparent shrinkage in a
thermoset resin casting system during cure was explored in a large number of studies
now, including decoupling from T.E, Rheometer, and optical sensors.

2.6 Hybrid natural fiber polymer composites (HNFC)

The process of combining two or more fibres from different groups within a
single matrix to manipulate the properties of fiber-reinforced composite materials is
known as hybridization [16]. Natural–natural fibre, natural–synthetic fibres, natural
fibre with carbonaceous materials, and natural fibre with metal can all be used to
hybridise natural fiber-reinforced polymer composites. The behaviour of hybrid
composites seems to be just the weighted sum of the constituent parts, which is affected
by factors including the fiber matrix interface, fiber length, chemical composition of
the reinforcement, and hybrid design. Van der Waals forces, hydrogen bonds, and weak
electrostatic interactions can cause the HNFC interactions to be weak or strong
depending on how the components interact chemically. The resulting composite which
is hybrid composites is a unique product with improved mechanical and thermal
properties than single fibre-reinforced polymer composites [17]. In addition, the factors
that influenced the mechanical properties of hybrid composites are influenced by the
treatment and modification of fiber, fiber orientation, and fiber physical properties.
Lastly, Hybrid biocomposites made comprised of a bio fibre and a nano-reinforced bio-
based polymer can be used to prevent environmental difficulties while maintaining

8
desired industrial qualities. Fig. 2.1 shows examples of the hybridization of a woven
kenaf with carbon fibers mat-reinforced epoxy composite.

Figure 2.1 Schematic diagram of hybridization of a woven kenaf with carbon fibre
[16]

2.7 Application of natural fiber reinforced in automotive industry.

The automotive industry sector contributes to global pollution because it uses

materials that cannot be recycled and emits harmful substances from its fuel emissions,
creating an environmental issue [20]. However, the automotive interior industry has
shifted in recent years and increasingly utilized natural fiber based bio-composite, as
opposed to conventional materials like fiberglass, carbon, silicon carbide, and acrylic
oxide. The potential and competitiveness of natural fiber based bio-composite as a
possible car interior material can be analyse using methods such as market trend,
material comparison, value chain analysis, and economic analysis.

Based on the market trend, Europe has the largest market share because car
manufacturers that use natural fibre-based bio-composite are mostly from Europe, but
the market share in Asia is expected to increase from 3% to 9% in 2016, while the
market share in other territories is decreasing. However, Europe still has the largest
market share (59%) from total sales of more than € 4.5 billion, so it can be stated that
Europe has the highest demand for natural fibre compared to other territories, and it can
be concluded that natural fibre suppliers have a good prospect in the European
automotive market. According to a 1999 study, each of the 53 million vehicles produced
globally each year uses up to 20 kg of natural fibre. It also means that 1000 – 3000
tonnes of natural fibre are used each year to produce a new model of car. Based on the
data presented above, we can estimate that the global demand for natural fibre is around
1.06 billion kg per year. When the demand for natural fibres continues to rise year after

9
year, it is viewed as an appealing field for investment in natural fibre plantation and
production to meet the demand.

The main characteristics of car interior materials are durability, weight, and price.
Material comparison method will analyse the characteristics of each material used for
car interiors as shown in Table 2.1. In order for the temperature inside the car not to
keep rising, the material of the car interior must have a low thermal conductivity. Based
on table 1, All of the comparative materials have a thermal conductivity of 0.19 W/
(m.K), except for fiberglass which only has 0.04 W/ (m.K) and can be concluded that
it is a better heat insulator than other materials. The material with the longest range of
sound absorption is jute fiber, but Fiberglass still has a higher noise reduction
coefficient (NRC). Even with lower tensile strength than fiberglass, natural fiber has a
better price, lower energy consumption, lighter weight, and is recyclable for sustainable
manufacturing, as shown in Figure 2.1. As part of the chosen strategic plan for the
company, value chain analysis evaluates all the activities that add value in order to gain
an advantage. For example, Figure 2.2 shows the value chain of natural fiber based bio-
composite for car interiors. Lastly, economic analysis will compare the natural fiber
with synthetic fiber to determine whether natural fiber worth it to use or not in interior
automotive application.

Table 2.1:Material characteristics and properties comparison

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 Figure 2.2: Natural fiber and fiberglass reinforced composite trade off [20]

Figure 2.3: Value chain of natural fiber composite for automotive interior production
[20]

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 CHAPTER 3

RESEARCH METHODOLOGY

3.1 Raw material preparation

The kenaf fiber was obtained from the Lembaga Kenaf dan Tembakau Negara
(LKTN) as main material for this project and act as reinforcing fibres for the
composites. The grade of kenaf fiber was chosen from the list given by the LKTN and
the grade of kenaf fiber that has been selected is Grade B bio retting fiber (SKM2-Bio
Grade B). The basic properties of the selected grade B kenaf fiber was shown in the
table 3.1.

Figure 3.1: Grade B kenaf fiber

Table 3.1: Basic properties of grade B kenaf fiber [34]

Colour Light brown (>80%)

Colour rating Fairly good
Lustre Good
Brightness (L) 61 to 70
Humidity <12%
Mixing of impurities <2%
Unretted fiber <5%

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 Length 700 mm – 1200 mm
Major defect Permitted up to 10% of total major defect
Type of defect Center root, entangled croppy end fiber,
gummy fibre and over ratted fibre/dazed
fibre

A polymer matrix or resin that used in this project is polyester resin and its
hardener. Polyester resin and hardener were got from CL Composites SDN BHD. The
type of polyester resin was got from this company is Resin Reversol P-9801W DURA+
is a rigid, low reactivity, waxed, thixotropic, economy general purpose orthophthalic
unsaturated polyester resin. Methyl Ethyl Ketone Peroxide (MEKP) is used as a
catalyst/hardener and is pre-promoted for ambient temperature curing. The
environment's temperature and the type of catalyst being used can affect how long it
takes to cure and demould. In general, use more catalyst in cold or rainy conditions and
less in hot ones. Polyester resin has the advantages of being appropriate for spray-up
and hand lay-up applications, slower glass fibre wetting, and simple air release during
rollout. General fiberglass-reinforced manufactured components, maritime
applications, and other applications for structural fibre reinforcement are typical uses
for polyester resin. The specifications and typical properties of selected polyester resin
were shown in table 3.2 and table 3.3 respectively.

Table 3.2: Specifications of polyester resin [35]

Appearance Pink
Non-Volatile, % 57.5 ± 2.5
Viscosity at 25 °C, cps 500 – 600
Thixotropic Index 2.0 – 3.0
Gel time at 25 °C, minutes 25 – 30

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 Table 3.3: Typical properties of polyester [35]

Property Value Test Method

Tensile Strength, MPa 52 BS2782-320C
Tensile Modulus, MPa 3358 BS2782-320C
Elongation at Break, % 1.6 BS2782-320C
Water Absorption 24hr at 25 °C, mg 18 BS2782-430C
Deflection Temperature (1.80MPa 59 BS2782-121A
Load), °C
Barcol Hardness (Model GYZJ 934-1) 42 BS2782-1001

3.2 Kenaf fiber orientation

Kenaf fibers were arranged two orientation which are random and unidirectional
(0°) as shown in Figure 3.3 before applied the mixture of polyester resin and hardener
using hand layup and vacuum bagging process. The objective to has two different
orientation is to determine the effects of different orientation on kenaf fiber polymer
composite (KFPC) mechanical properties such as tensile and flexural strength. In
addition, one specimen was produced by using the mixture of polyester resin and
hardener only without kenaf fiber. The comparison can be done between specimen of
kenaf fiber polymer composite and specimen of mixture of polyester resin and hardener
to determine the effect of natural fiber in composite as reinforced fiber.

Figure 3.2: Random orientation (left) and unidirectional orientation (right)

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 Table 3.4: Project variables

Specimen Type of Type of resin Fiber Manufacturing

natural fiber orientation process
1 Kenaf fiber Polyester resin Random Vacuum
bagging
2 Kenaf fiber Polyester resin Unidirectional Vacuum
bagging
3 - Polyester resin - Resin casting

3.3 Kenaf fiber polymer composite fabrication

The kenaf fiber that obtained from LKTN was cut into the length of 20 cm to 35
cm. The cut kenaf fiber were arranged in two orientation which are random and
unidirectional. For the random orientation, the adhesive spray was used during
arrangement process for effectively stick kenaf fibers make it easily to arranged the
kenaf fiber. For unidirectional orientation, the kenaf fibers were arranged in straight
line and at the end of the arrangement the kenaf fiber is sewn so that the kenaf fiber
does not loose during fabricated process. The two of arranged kenaf fiber were dried in
hot air oven at a temperature of 60 °C for 24 hours. The weight for both arranged kenaf
fiber were taken and both have the weight around 62.5 g. After all the materials and
apparatus for vacuum bagging were prepared, the 250 g of polyester resin was mixed
with the 5 g of Methyl Ethyl Ketone Peroxide (hardener) by using the mixing ratio of
2%. The weight of polyester resin needed to be 4 times the weight of natural fiber. The
mixture of polyester and hardener was applied on the kenaf fiber using hand layup
techniques at room temperature. Rollers are used to spread resin to kenaf fibers that are
in the form of random and unidirectional mat. In order to create a stronger interaction
between the reinforcement and the matrix material, the roller is used to force into the
resin into the kenaf fiber.

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 Figure 3.3: Hand layup process

After that, the hand layup kenaf fiber was undergoing vacuum bagging process.
After hand layup process, A layer of sealant tape was lay down around the perimeter of
the part, leaving some space between it and the laminated kenaf fiber. The area where
the tape is put down was cleaned from polyester residue and stray fibers. Then, release
fabric was laid directly on top of the wet laminated kenaf fiber. The fabric is released
with a textured finish, which reduces the amount of surface preparation needed before
secondary bonding. The 300 mm x 300 mm steel plate was put on the release fabric as
a weight and the produced kenaf fiber polymer composite (KFPC) will take the shape
of the plate. The breather fabric was laid directly on top of the plate. The breather fabric
will absorb the vacuum pressure consolidates the KFPC when it squeezed-out the
KFPC. Vacuum bag was used to enclose and seal the KFPC from the environment. The
vacuum bag was cut oversized and carefully stick with the sealant tape in step 10.
Vacuum pump was turned on to applied the vacuum pressure. After 15 minutes, the
vacuum pump was turned off when making sure no air escapes and the vacuum bag did
not loose. The KFPC in the vacuum bag was left to cure for 1 day at room temperature.
The finished specimens were cut using saw followed the dimensions give in the ASTM
standard for tensile and flexural testing.

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 Figure 3.4: Vacuum bagging process

Figure 3.5: Finished KFPC plates for random (left) and unidirectional (right)
orientation.

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 Figure 3.6: Cut samples of random KFPC followed ASTM standard for tensile (left)
and flexural (right) tests.

Figure 3.7: Cut samples of unidirectional (0°) KFPC followed ASTM standard for
tensile (left) and flexural (right) tests.

In addition, the samples of polyester and hardener also was produced by using
resin casting process. The moulds that has shape and dimensions of the specimens that
followed ASTM standard for the tensile and flexural tests were took from the
Composite Lab at School of Aerospace Engineering. The mixture of 100g polyester and
2 g hardener were brewed by using the mixing ratio of 2%. The mixture of polyester
and hardener was carefully poured to fill the mould cavity until its full. The poured
mixtures were left to cure for 1 day at room temperature.

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Figure 3.8: Polyester resin and hardener samples followed ASTM standard for tensile
(left) and flexural (right) tests.

3.4 Testing methods

There are two testing methods were used in my final year project to tested my
specimens which are tensile test and flexural test. For the tensile test, tensile strength
of the specimens was tested until its break. For the flexural test or also call 3-point
bending test, the the flexural strength of the specimen was tested by bended the
specimen until its reach 5.0% of deflection or until its fracture. The methods that used
for the tensile and flexural tests were shown in the Table 3.5.

Table 3.5: Description of test method

Test Method Equipment

Tensile properties ASTM D3039 (Standard Test Universal Testing Machine
Method for Tensile Properties of (UTM)
Polymer Matrix Composite
Materials)
Flexural strength ASTM D790 (Standard Test
Methods for Flexural Properties
of Unreinforced and Reinforced
Plastics and Electrical Insulating
Materials)

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3.4.1 Tensile properties testing method (ASTM D3039)

In this test method, the in-plane tensile properties of polymer matrix composite
materials reinforced with kenaf fibers are determined. The tensile test specimens were
made in accordance with ASTM D3039 standards. At a constant stroke rate of 2
mm/min, the specimen was loaded in tension.

The first operation is specimen insertion, which involves aligning the gripped
specimen's long axis with the test direction before inserting the specimen into the
testing machine's grips. Tightening the grips while monitoring the pressure applied on
pressure controlled (hydraulic or pneumatic) grips is recommended. Then, transducer
installation that attach the strain-indicating transducer(s) symmetrically along the mid-
span and mid-width of the specimen if strain response is to be determined. The strain-
recording instrumentation should be attached to the specimen's transducers. After that,
the load was applied on the specimen at the specified rate until failure and the data was
recorded. Load versus strain (or transducer displacement) was recorded continuously
or at frequent regular intervals for data collection. If a transition zone or first ply failures
are seen, the load, strain, and manner of damage at such places are recorded. The
maximum load, the failure load, and the strain (or transducer displacement) was
recorded at the moment of rupture if the specimen is to be failed. The mode and location
of failure of the specimen were recorded for failure mode, and a standard description
utilising the three-part failure mode code was chosen. Finally, for grip or tab failures,
re-examine the mechanisms of load introduction into the material if a large number of
failures in a sample population occur within one specimen width of the tab or grip.
Several factors should be taken into consideration, including tab alignment, tab
material, tab angle, tab adhesive, grip type, grip pressure, and grip alignment.

Specimen geometries:
Table 3.6: Tensile testing specimen geometries

Thickness 2.5 mm
Overall length 250 mm
Span length 150 mm
width 25
Tab type Emery cloth
Specimen shape Rectangular bar

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Figure 3.9: Tensile testing specimen drawing in SI

Figure 3.10: Three-part failure mode code

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 Figure 3.11: Tensile testing using universal testing machine (UTM)

3.4.2 Flexural strength testing method (ASTM D790):

The test methods described here are designed to determine the flexural
properties of kenaf fiber polymer composites (KFPC) as rectangular bars molded
directly or cut from sheets, plates, or molded shapes. Flexural strength was determined
using 3-point bending method in ASTM D790 using universal testing machine (UTM).
The support span length of the sample is 60 mm and the strain rate were 2mm/min.

A rectangular-sectioned bar (KFPC samples) is supported by two supports and

loaded through a loading nose located midway between the supports. Except in the case
of certain laminated materials, a support span-to-depth ratio of 16:1 was used. The
loading nose and supports was aligned so that their axes are parallel and the loading

22
nose is midway between the supports. The apparatus's parallelism was checked using a
plate with parallel grooves into which the loading nose and supports will fit when
properly aligned. The specimen was placed on the supports with its long axis
perpendicular to the loading nose and supports. The load was applied to the specimen
at the specified crosshead rate and the load-deflection data simultaneously recorded.

Next, deflection was measured using either a gauge under the specimen in
contact with it at the centre of the support span, with the gauge mounted stationary
relative to the specimen supports, or by measuring the motion of the loading nose
relative to the supports. Load-deflection curves was used to calculate flexural strength,
chord or secant modulus, or tangent modulus of elasticity, as well as total work as
measured by the area under the load-deflection curve. Toe compensation is required to
correct for specimen seating and indentation, as well as machine deflections. The test
was terminated when the maximum strain in the outer surface of the test specimen has
reached 0.05 mm/mm [in./in.] or at break if break occurs prior to reaching the maximum
strain.

Specimen geometries:
Table 3.7: Flexural testing specimen geometries

Thickness Less than 3.2 mm

Overall length 125 mm
Span length 60 mm
Width 12.7 mm
Specimen shape Rectangular bar

Figure 3.12: Flexural testing specimen drawing

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Figure 3.13: Flexural testing using universal testing machine (UTM)

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