This study developed sustainable, cost-effective hybrid composites using high-density polyethylene (HDPE) reinforced with kaolinite particles (KP) and alfa short fibers (ASF) in varying volume fractions (15/0, 10/5, 7.5/7.5, 5/10, 0/15). Injection-molded composites were analyzed for mechanical, thermal, and rheological properties, revealing significant improvements in Young’s modulus (up to 61.60%) with KP and ASF additions. Hybrid composites (7.5:7.5 and 10:5) showed superior elasticity, while the 5:10 formulation achieved the highest storage modulus of 1874 MPa, outperforming pure HDPE (1035 MPa). Thermal analysis indicated stable KP-rich composites and progressive crystallization disruption with increasing filler content. To align experimental and theoretical results, the Young’s modulus for KP and ASF was estimated at 5000 MPa and 8500 MPa, respectively. The optimal 7.5:7.5 hybrid offered balanced mechanical and thermal performance with enhanced elasticity and reduced energy consumption during processing, demonstrating the potential of these hybrids as renewable, sustainable materials for automotive, construction, and sports applications.
KamarudzamanRKalamAAhmadN. Thermal degradation behaviour and tensile properties of OPEFB fiber filled HDPE/clay nanocomposites. Nur Amanina Mohd Fadzil Pos Malaysia. 4 publications 0 citations see profile, 2014. https://www.researchgate.net/publication/263443939
2.
FuQWangG. Polyethylene toughened by CaCO, particles-percolation model of brittle-ductile transition in HDPEICaCO Blends. Polymer International. 1993; 30(3): 309–312.
3.
EssabirHRajiMEssassiEM, et al.Morphological, thermal, mechanical, electrical and magnetic properties of ABS/PA6/SBR blends with Fe3O4 nano-particles. J Mater Sci Mater Electron2017; 28: 17120–17130. DOI: 10.1007/s10854-017-7639-2.
4.
BensalahHGueraouiKEssabirH, et al.Mechanical, thermal, and rheological properties of polypropylene hybrid composites based clay and graphite. J Compos Mater2017; 51: 3563–3576. DOI: 10.1177/0021998317690597.
5.
RajiMEl FoujjiLMekhzoumMEM, et al.pH-indicative films based on chitosan–PVA/sepiolite and anthocyanin from red cabbage: application in milk packaging, J Bionic Eng2022; 19(3): 837–851. DOI: 10.1007/S42235-022-00161-9.
6.
MüllerKBugnicourtELatorreM, et al. Review on the processing and properties of polymer nanocomposites and nanocoatings and their applications in the packaging, automotive and solar energy fields. Nanomaterials. 2017; 7: 74. doi:10.3390/nano7040074.
7.
AmariAAlzahraniFMKatubiKM, et al. Clay-polymer nanocomposites: preparations and utilization for pollutants removal. Materials. 2021; 14: 1365. doi:10.3390/ma14061365.
8.
EssabirHNekhlaouiSBensalahMO, et al.Phosphogypsum waste used as reinforcing fillers in polypropylene based composites: structural, mechanical and thermal properties. J Polym Environ2017; 25: 658–666. DOI: 10.1007/s10924-016-0853-9.
9.
ShahKJShuklaADShahDO, et al.Effect of organic modifiers on dispersion of organoclay in polymer nanocomposites to improve mechanical properties. Polymer (Guildf)2016; 97: 525–532. DOI: 10.1016/j.polymer.2016.05.066.
10.
PatelHAJoshiGVPawarRR, et al.Mechanical and thermal properties of polypropylene nanocomposites using organically modified indian bentonite. Polym Compos2010; 31: 399–404. DOI: 10.1002/pc.20816.
11.
XuPErdemTEiserE. A simple approach to prepare self-assembled, nacre-inspired clay/polymer nanocomposites. Soft Matter2020; 16: 5497–5505. DOI: 10.1039/c9sm01585j.
12.
ChimeniDYToupeJLDuboisC, et al.Effect of hemp surface modification on the morphological and tensile properties of linear medium density polyethylene (LMDPE) composites. Compos Interfaces2016; 23: 405–421. DOI: 10.1080/09276440.2016.1144163.
13.
VermaDGohKLVimalV. Interfacial studies of natural fiber-reinforced particulate thermoplastic composites and their mechanical properties. J Nat Fibers2022; 19: 2299–2326. DOI: 10.1080/15440478.2020.1808147.
14.
FazliAStevanovicTRodrigueD. Recycled HDPE/natural fiber composites modified with waste tire rubber: a comparison between injection and compression molding. Polymers2022; 14: 3197. DOI: 10.3390/polym14153197.
15.
EssabirHBensalahMORodrigueD, et al.Structural, mechanical and thermal properties of bio-based hybrid composites from waste coir residues: fibers and shell particles. Mech Mater2016; 93: 134–144. DOI: 10.1016/j.mechmat.2015.10.018.
16.
Ramezani KakroodiALeducSRodrigueD. Effect of hybridization and compatibilization on the mechanical properties of recycled polypropylene-hemp composites. J Appl Polym Sci2012; 124: 2494–2500. DOI: 10.1002/app.35264.
17.
KazemiHFazliAIraJP, et al.Recycled tire fibers used as reinforcement for recycled polyethylene composites. Fibers2023; 11: 74. DOI: 10.3390/fib11090074.
18.
DolzaCFagesEGongaE, et al.Development and characterization of environmentally friendly wood plastic composites from biobased polyethylene and short natural fibers processed by injection moulding. Polymers2021; 13: 1692. DOI: 10.3390/polym13111692.
19.
NegawoTAPolatYKilicA. Effect of compatibilizer and fiber loading on ensete fiber-reinforced HDPE green composites: physical, mechanical, and morphological properties. Compos Sci Technol2021; 213: 108937. DOI: 10.1016/j.compscitech.2021.108937.
SarasiniFTirillòJSergiC, et al.Effect of basalt fibre hybridisation and sizing removal on mechanical and thermal properties of hemp fibre reinforced HDPE composites. Compos Struct2018; 188: 394–406. DOI: 10.1016/j.compstruct.2018.01.046.
22.
Ez-ZahraouiSSemlaliFZRajiM, et al.Synergistic reinforcing effect of fly ash and powdered wood chips on the properties of polypropylene hybrid composites. J Mater Sci2024; 59: 1417–1432. DOI: 10.1007/s10853-023-09299-1.
23.
YilmazerU. Tensile, flexurai and impact properties of a thermoplastic matrix reinforced by glass fiber and glass bead hybrids. Compos. Sci. Technol.1992; 44(2): 119–125.
24.
YunJHJeonYJKangMS. Prediction of elastic properties using micromechanics of polypropylene composites mixed with ultrahigh-molecular-weight polyethylene fibers. Molecules2022; 27: 5752. DOI: 10.3390/molecules27185752.
25.
NekhlaouiSEssabirHKunalD, et al.Comparative study for the talc and two kinds of moroccan clay as reinforcements in polypropylene-SEBS-g-MA matrix. Polym Compos2015; 36: 675–684. DOI: 10.1002/pc.22986.
26.
ThomasonJLOwensEFiberglasC. The influence of fibre length and concentration on the properties of glass fibre reinforced polypropylene: 5. Injection moulded long and short fibre PP. https://www.elsevier.com/locate/compositesa
27.
VilasecaFValadez-GonzalezAHerrera-FrancoPJ, et al.Biocomposites from abaca strands and polypropylene. Part I: evaluation of the tensile properties. Bioresour Technol2010; 101: 387–395. DOI: 10.1016/j.biortech.2009.07.066.
28.
DghoughiANazihFEHalloubA, et al.Development of shelf life-extending packaging for vitamin C syrup based on high-density polyethylene and extracted lignin argan shells. Int J Biol Macromol2023; 242: 125077. DOI: 10.1016/j.ijbiomac.2023.125077.
29.
RajiMEssabirHEssassiEM, et al.Morphological, thermal, mechanical, and rheological properties of high density polyethylene reinforced with illite clay. Polym Compos2018; 39: 1522–1533. DOI: 10.1002/pc.24096.
BalanESaittaAMMauriF, et al.First-principles modeling of the infrared spectrum of kaolinite. Am Mineral2001; 86: 1321–1330. DOI: 10.2138/am-2001-11-1201.
35.
BougeardDSmirnovKSGeidelE. Vibrational spectra and structure of kaolinite: a computer simulation study. J Phys Chem B2000; 104: 9210–9217. DOI: 10.1021/jp0013255.
36.
ZulfiqarSSarwarMIRasheedN, et al.Influence of interlayer functionalization of kaolinite on property profile of copolymer nanocomposites. Appl Clay Sci2015; 112–113: 25–31. DOI: 10.1016/j.clay.2015.04.010.
37.
NathDCDBandyopadhyaySYuA, et al.Structure-property interface correlation of fly ash-isotactic polypropylene composites. J Mater Sci2009; 44: 6078–6089. DOI: 10.1007/s10853-009-3839-3.
38.
NekhlaouiSEssabirHBensalahMO, et al.Fracture study of the composite using essential work of fracture method: PP-SEBS-g-MA/E1 clay. Mater Des2014; 53: 741–748. DOI: 10.1016/j.matdes.2013.07.089.
39.
Ramezani KakroodiAKazemiYRodrigueD. Mechanical, rheological, morphological and water absorption properties of maleated polyethylene/hemp composites: effect of ground tire rubber addition. Compos B Eng2013; 51: 337–344. DOI: 10.1016/j.compositesb.2013.03.032.
40.
EssabirHElkhaoulaniABenmoussaK, et al.Dynamic mechanical thermal behavior analysis of doum fibers reinforced polypropylene composites. Mater Des2013; 51: 780–788. DOI: 10.1016/j.matdes.2013.04.092.
41.
EvanovichJKingL, Hardcore twenty-four: a stephanie plum novel.
42.
BoujmalRKakouCANekhlaouiS, et al.Alfa fibers/clay hybrid composites based on polypropylene: mechanical, thermal, and structural properties. J Thermoplast Compos Mater2017; 31: 974–991. DOI: 10.1177/0892705717729197.
43.
EssabirHHilaliEElgharadA, et al.Mechanical and thermal properties of bio-composites based on polypropylene reinforced with Nut-shells of Argan particles. Mater Des2013; 49: 442–448. DOI: 10.1016/j.matdes.2013.01.025.
44.
YuMHuangRHeC, et al.Hybrid composites from wheat straw, inorganic filler, and recycled polypropylene: morphology and mechanical and thermal expansion performance. Int J Polym Sci2016; 2016: 1–12. DOI: 10.1155/2016/2520670.
45.
EssabirHBoujmalRBensalahMO, et al.Mechanical and thermal properties of hybrid composites: oil-palm fiber/clay reinforced high density polyethylene. Mech Mater2016; 98: 36–43. DOI: 10.1016/j.mechmat.2016.04.008.
46.
WattEAbdelwahabMASnowdonMR, et al.Hybrid biocomposites from polypropylene, sustainable biocarbon and graphene nanoplatelets. Sci Rep2020; 10: 10714. DOI: 10.1038/s41598-020-66855-4.
47.
AlzebdehKINassarMMA. An integrated approach to evaluate mechanical performance of date palm filler reinforced polypropylene. Mater Today Commun2023; 35: 105583. DOI: 10.1016/j.mtcomm.2023.105583.
48.
WangHLiCPengZ, et al.Characterization and thermal behavior of kaolin. J Therm Anal Calorim2011; 105: 157–160. DOI: 10.1007/s10973-011-1385-0.
49.
AjouguimSAbdelouahdiKWaqifM, et al.Modifications of Alfa fibers by alkali and hydrothermal treatment. Cellulose2019; 26: 1503–1516. DOI: 10.1007/s10570-018-2181-9.
50.
WeiJMeyerC. Improving degradation resistance of sisal fiber in concrete through fiber surface treatment. Appl Surf Sci2014; 289: 511–523. DOI: 10.1016/j.apsusc.2013.11.024.
51.
PallmannJRenYLMahltigB, et al.Phosphorylated sodium alginate/APP/DPER intumescent flame retardant used for polypropylene. J Appl Polym Sci2019; 136. DOI: 10.1002/app.47794.
52.
FazliARodrigueD. Phase morphology, mechanical, and thermal properties of fiber-reinforced thermoplastic elastomer: effects of blend composition and compatibilization. J Reinforc Plast Compos2022; 41: 267–283. DOI: 10.1177/07316844211051749.
53.
GuessoumMNekkaaSFenouillot-RimlingerF, et al.Effects of kaolin surface treatments on the thermomechanical properties and on the degradation of polypropylene. Int J Polym Sci2012; 2012: 1–9. DOI: 10.1155/2012/549154.
54.
WangYChengLCuiX, et al. Crystallization behavior and properties of glass fiber reinforced polypropylene composites. Polymers. 2019; 11: 1198. doi:10.3390/polym11071198.
55.
AtiqahAJawaidMSapuanSM, et al.Physical and thermal properties of treated sugar palm/glass fibre reinforced thermoplastic polyurethane hybrid composites. J Mater Res Technol2019; 8: 3726–3732. DOI: 10.1016/j.jmrt.2019.06.032.
56.
HarisNINIlyasRAHassanMZ, et al.Dynamic mechanical properties and thermal properties of longitudinal basalt/woven glass fiber reinforced unsaturated polyester hybrid composites. Polymers2021; 13: 3343. DOI: 10.3390/polym13193343.
57.
BoparaiKSSinghR. Thermoplastic composites for fused deposition modeling filament: challenges and applications. In: Encyclopedia of Materials: Composites. Amsterdam, The Netherlands: Elsevier, 2021, pp. 774–784. DOI: 10.1016/B978-0-12-803581-8.11409-2.
58.
Vinu KumarSMSenthil KumarKLSiddhi JailaniH, et al.Mechanical, DMA and sound acoustic behaviour of flax woven fabric reinforced epoxy composites. Mater Res Express2020; 7: 085302. DOI: 10.1088/2053-1591/abaea5.
59.
NegawoTAPolatYBuyuknalcaciFN, et al.Mechanical, morphological, structural and dynamic mechanical properties of alkali treated Ensete stem fibers reinforced unsaturated polyester composites. Compos Struct2019; 207: 589–597. DOI: 10.1016/j.compstruct.2018.09.043.
60.
CheeSSJawaidMSultanMTH, et al.Thermomechanical and dynamic mechanical properties of bamboo/woven kenaf mat reinforced epoxy hybrid composites. Compos B Eng2019; 163: 165–174. DOI: 10.1016/j.compositesb.2018.11.039.
JawaidMAbdul KhalilHPSAlattasOS. Woven hybrid biocomposites: dynamic mechanical and thermal properties. Compos Part A Appl Sci Manuf2012; 43: 288–293. DOI: 10.1016/j.compositesa.2011.11.001.
63.
SenturkOSenturkAEPalabiyikM. Evaluation of hybrid effect on the thermomechanical and mechanical properties of calcite/SGF/PP hybrid composites. Compos B Eng2018; 140: 68–77. DOI: 10.1016/j.compositesb.2017.12.021.
64.
AsimMParidahMTSabaN, et al.Thermal, physical properties and flammability of silane treated kenaf/pineapple leaf fibres phenolic hybrid composites. Compos Struct2018; 202: 1330–1338. DOI: 10.1016/j.compstruct.2018.06.068.
65.
HarperCA. Handbook of plastics, elastomers, and composites. New York, NY: McGraw-Hill, 2002.
66.
ShaikhHM. Thermal, rheological, and mechanical properties of polypropylene/phosphate ore composites. Constr Build Mater2020; 263: 120151. DOI: 10.1016/j.conbuildmat.2020.120151.
