The present work discusses the development and characterization of microwave-processed hybrid composite laminates consisting of linear low-density polyethylene (LLDPE) as a matrix and sisal (S) and banana (B) fibers as reinforcements. Comprehensive evaluations were conducted on mechanical, physical, thermal, and tribological properties. The hybrid laminate SB exhibited superior properties compared with single-fiber and neat polymer systems. The SB composite demonstrated the highest fracture toughness of 1.4171 MPa·√m and fracture energy of 7.39 kJ/m2, supported by scanning electron microscopy, which revealed strong fiber-matrix bonding. The compressive strength of the SB laminate reached 20.81 MPa, corresponding to a 73% increase over LLDPE (12.01 MPa). The hardness of the SB laminate was measured at 52 ± 1.41, and the HDT was significantly improved to 81.6 ± 3.43°C, showcasing the superior thermal stability provided by the banana fibers. The SB composite also showed the highest crystallinity (9.42%) with a melting point of 122.21°C, compared with the lower crystallinity (5.56%) and higher thermal hysteresis of neat LLDPE. All studied laminates retained stability up to 300°C, with no evidence of degradation. The banana/banana (BB) composites demonstrated exceptional tribological properties, achieving the lowest specific wear rate (SWR) of 2.31 × 10-6 mm3/N-m and coefficient of friction (COF) of 0.210 at load 30 N and sliding velocity 2 m/s, outperforming SWR compared to SS and SB composites by 89.8% and 77.8%, respectively. These findings highlight the effectiveness of microwave curing and surface modification in producing sustainable, high-performance fiber composites for automotive, construction, and engineering.
GuptaHSPalsuleS. Oil palm and nettle fibers reinforced functionalized HDPE hybrid composites and their comparative performance. Polym Eng Sci2025; 65: 4977–4989.
2.
Maruthi PrashanthBHGoudaPSSManjunathaTS, et al.Prominence of quantitative fiber loading on free vibration, damping behavior, inter-laminar shear strength, fracture toughness, thermal conductivity, and flammability properties of jute–banana hybrid fiber phenol-formaldehyde composites. Polym Compos2022; 43: 3313–3325.
3.
ArzondoLMVazquezACarellaJM, et al.A low-cost, low-fiber-breakage, injection molding process for long sisal fiber reinforced polypropylene. Polym Eng Sci2004; 44: 1766–1772.
4.
NathanVBSoundararajanRGandhiBS, et al.Mechanical, wear, fatigue, and water absorption behavior of epoxy biocomposite toughened using marine waste Sepioteuthis sepioidea pen chitosan biopolymer and pineapple plain-weaved fiber. Biomass Convers Biorefin2025; 15: 6699–6712.
5.
PrashanthMGoudaPSSManjunathaTS, et al.Understanding the impact of fiber orientation on mechanical, interlaminar shear strength, and fracture properties of jute–banana hybrid composite laminates. Polym Compos2021; 42: 5475–5489.
6.
MylsamyBShanmugamSKMAruchamyK, et al.A review on natural fiber composites: polymer matrices, fiber surface treatments, fabrication methods, properties, and applications. Polym Eng Sci2024; 64: 2345–2373.
7.
SivakumarNSThangarasuVSSoundararajanR, et al.Mechanical and machining behavior of betel nut fiber/leather/chitin-toughened epoxy hybrid composite. Biomass Convers Biorefin2023; 13: 4365–4372.
8.
SinghJIPSinghSDhawanV. Effect of alkali treatment on mechanical properties of jute fiber-reinforced partially biodegradable green composites using epoxy resin matrix. Polym Polym Compos2020; 28: 388–397.
9.
RayDSarkarBKRanaAK, et al.Effect of alkali treated jute fibres on composite properties. Bull Mater Sci2001; 24: 129–135.
10.
KaliaSKaithBSKaurI. Pretreatments of natural fibers and their application as reinforcing material in polymer composites-a review. Polym Eng Sci2009; 49: 1253–1272.
11.
NagarjunJKanchanaJRajesh KumarG. Improvement of mechanical properties of coir/epoxy composites through hybridization with sisal and palmyra palm fibers. J Nat Fibers2022; 19: 475–484.
12.
MauryaHOKumarGPrasadL, et al.Development and characterization of microwave-processed linear low-density polyethylene based sisal/jute hybrid laminates. Polym Compos2024; 45: 8306–8320.
13.
NaikTPGairolaSSinghI, et al.Microwave-assisted molding of sisal/HDPE composites: water absorption, diffusion kinetics and tribological behavior. Polym Compos2023; 44: 6194–6211.
14.
VermaNSinghMKZafarS, et al.Comparative study of in-situ temperature measurement during microwave-assisted compression-molding and conventionally compression-molding process. CIRP J Manuf Sci Technol2021; 35: 336–345.
15.
MishraRRSharmaAK. Microwave–material interaction phenomena: heating mechanisms, challenges and opportunities in material processing. Compos Part A Appl Sci Manuf2016; 81: 78–97.
16.
SinghMKZafarS. Influence of microwave power on mechanical properties of microwave-cured polyethylene/coir composites. J Nat Fibers2020; 17: 845–860.
17.
López De VergaraUSarrionandiaMGondraK, et al.Impact behaviour of basalt fibre reinforced furan composites cured under microwave and thermal conditions. Compos Part B Eng2014; 66: 156–161.
18.
NaikTPGairolaSSinghI, et al.Microwave-assisted alkali treatment of sisal fiber for fabricating composite as non-structural building materials. Constr Build Mater2024; 411: 134651.
19.
NaikTPGairolaSSinghI, et al.Microwave hybrid heating for moulding of sisal/jute/HDPE composites. J Nat Fibers2022; 19: 13524–13538.
20.
SinghMKZafarS. Effect of layering sequence on mechanical properties of woven kenaf/jute fabric hybrid laminated microwave-processed composites. J Ind Text2022; 51: 2731S–2752S.
21.
Dharani KumarSAravindhMManojVK, et al.Fracture toughness of bio-fiber reinforced polymer composites-A review. Mater Today Proc2023. doi:10.1016/j.matpr.2023.01.334
22.
ShahapurkarKRameshSNik-GhazaliNN, et al.Tensile, compressive, and fracture behavior of habeshian chopped banana/epoxy core sandwich woven banana composite. Biomass Convers Biorefin2024; 14: 21553–21564.
23.
MuflikhunMAYokozekiT. Systematic analysis of fractured specimens of composite laminates: different perspectives between tensile, flexural, mode I, and mode II test. Int J Lightweight Mater Manuf2023; 6: 329–343.
24.
AroraGPathakHZafarS. Fabrication and characterization of microwave cured high-density polyethylene/carbon nanotube and polypropylene/carbon nanotube composites. J Compos Mater2019; 53: 2091–2104.
25.
XuXWangXCaiQ, et al.Improvement of the compressive strength of carbon fiber/epoxy composites via microwave curing. J Mater Sci Technol2016; 32: 226–232.
26.
HangXLiYHaoX, et al.Effects of temperature profiles of microwave curing processes on mechanical properties of carbon fibre-reinforced composites. Proc Inst Mech Eng, Part B: J Eng Manuf2017; 231: 1332–1340.
27.
NabilaSJuwonoALRosenoS. Effect of weight fractions of jute fiber on tensile strength and deflection temperature of jute fiber/polypropylene composites. IOP Conf Ser Mater Sci Eng2017; 196: 012029.
28.
VinayagamoorthyR. Friction and wear characteristics of fibre-reinforced plastic composites. J Thermoplast Compos Mater2020; 33: 828–850.
MauryaHOJhaKTyagiYK. Tribological behavior of short sisal fiber reinforced epoxy composite. Polym Polym Compos2017; 25: 215–220.
31.
ChaudharyVBajpaiPKMaheshwariS. An investigation on wear and dynamic mechanical behavior of jute/hemp/flax reinforced composites and its hybrids for tribological applications. Fibers Polym2018; 19: 403–415.
32.
PradhanSAcharyaSKPrakashV. Mechanical, morphological, and tribological behavior of Eulaliopsis binata fiber epoxy composites. J Appl Polym Sci2021; 138(12): 50077.
33.
MuthalaguRSrinivasanVKumarSS, et al.Tribological and viscoelastic behaviour of jute, Prosopis juliflora bark, and kenaf fibers reinforced polyester hybrid composites for engineering applications. Mater Res2022; 25: e20220310.
34.
BabuTNShyamSKaulS, et al.Natural fibre composites – an alternative to plastics in the automotive industry: a review. Proc Inst Mech Eng, Part L: J Mater Des Appl2022; 236: 237–266.
35.
OjhaSBisariaHMohantyS, et al.Mechanical performance of e-glass reinforced polyester resins (isophthalic and orthophthalic) laminate composites used in marine applications. Proc Inst Mech Eng, Part L: J Mater Des Appl2024; 238: 615–626.
36.
SahuPGuptaMK. Water absorption behavior of cellulosic fibres polymer composites: a review on its effects and remedies. J Ind Text2022; 51: 7480S–7512S.
37.
RajaAKAGeethanKAVKumarSS, et al.Influence of mechanical attributes, water absorption, heat deflection features and characterization of natural fibers reinforced epoxy hybrid composites for an engineering application. Fibers Polym2021; 22: 3444–3455.
38.
SaxenaPShuklaPGaurMS. Thermal analysis of polymer blends and double layer by DSC. Polym Polym Compos2021; 29: S11–S18.
39.
RamkumarPLGuptaNSanganiV. Experimental investigation on underlying mechanism of LLDPE based rotationally molded biocomposites. J Nat Fibers2023; 20: 2156022.
40.
LuDXuXZhangX, et al.Study on influencing factors of phase transition hysteresis in the phase change energy storage. Materials (Basel)2022; 15: 2775.
41.
SharmaNKumarSSinghKK. Taguchi’s DOE and artificial neural network analysis for the prediction of tribological performance of graphene nano-platelets filled glass fiber reinforced epoxy composites under the dry sliding condition. Tribol Int2022; 172: 107580.
PrajapatiPKKumarSSinghKK. Optimization of tribological behavior of CFRP composites under dry sliding condition using taguchi method. Mater Today Proc2020; 21: 1320–1329.
44.
PrajapatiPKKumarSSinghKK. Taguchi approach for comparative optimization of tribological behavior of glass fabric reinforced epoxy composite with and without graphene-nano platelets filler. Mater Today Proc2023; 72: 1605–1612.
MauryaHOKumarGPrasadL, et al.Thermo-mechanical and viscoelastic behavior of microwave-processed sisal and banana hybrid composite laminates. J Mater Sci2024; 59: 20283–20303.
47.
BirdJOChiversPJ. FrictionNewnes eng. Phys. Sci. Pocket book. London: Butterworth and Co (Publishers) Ltd, 1993, pp.235–237.
48.
KhuntiaTBiswasS. An investigation on the flammability and dynamic mechanical behavior of coir fibers reinforced polymer composites. J Ind Text2022; 51: 1616–1640.
49.
TripathyPBiswasS. Mechanical and thermal properties of basalt fiber reinforced epoxy composites modified with CaCO3 nanoparticles. Polym Compos2022; 43: 7789–7803.
50.
IrezABBayraktarEMiskiogluI. Fracture toughness analysis of epoxy-recycled rubber-based composite reinforced with graphene nanoplatelets for structural applications in automotive and aeronautics. Polymers (Basel)2020; 12: 48.
51.
OjhaSBisariaHMohantyS, et al.Fractographic analysis of fiber-reinforced polymer laminate composites for marine applications: a comprehensive review. Polym Compos2024; 45: 6771–6787.
52.
ArulMSasikumarKSKSambathkumarM, et al.Enhancement of fracture toughness characteristics of woven jute fabric mat reinforced epoxy composites with SiC fillers. J Nat Fibers2023; 20(1): 2144979.
53.
JamesDJDManoharanSSaikrishnanG, et al.Influence of bagasse/sisal fibre stacking sequence on the mechanical characteristics of hybrid-epoxy composites. J Nat Fibers2020; 17: 1497–1507.
54.
KarthiSSoundararajanRArunkumarS, et al.Compendious Characterization Studies on the Physio Mechanical Behaviour of Habara Plant Fiber Fortified Epoxy Composites (No. 2022-28-0538). In: SAE Technical Papers, 2022. SAE International.
55.
RamasubbuRMadasamyS. Fabrication of automobile component using hybrid natural fiber reinforced polymer composite. J Nat Fibers2022; 19: 736–746.
56.
KumarNRSoundararajanRSrinivasanR. Effect of surface-treated paddy straw biosilica additive on PET core–pineapple fiber composite subjected to water and temperature aging: a characterization study. Biomass Convers Biorefin2025; 15: 15985–16001.
57.
KarthikAJeyakumarRSampathPS, et al.Study and fabrication of fan blade using coconut leaf sheath fibre/epoxy-reinforced composite materials. J Inst Eng India Ser D2024; 105: 405–412.
58.
JainNKGuptaMK. Hybrid teak/sal wood flour reinforced composites: mechanical, thermal and water absorption properties. Mater Res Express2018; 5: 125306.
59.
KumarSSVigneshVPrasadVVSH, et al.Static and dynamic mechanical analysis of hybrid natural fibre composites for engineering applications. Biomass Convers Biorefin2024; 14: 14889–14901.
60.
NarendarRPriya DasanKRajendranK. Coir pith/nylon/epoxy hybrid composites and their thermal properties: thermogravimetric analysis, thermal ageing, and heat deflection temperature. J Vinyl Addit Technol2018; 24: 297–303.
61.
HafizhahRJuwonoALRosenoS. Study of tensile properties and deflection temperature of polypropylene/subang pineapple leaf fiber composites. IOP Conf Ser Mater Sci Eng2017; 196: 012031.
62.
Da LuzFSCandidoVSda SilvaACR, et al.Thermal behavior of polyester composites reinforced with green sugarcane bagasse fiber. JOM2018; 70: 1965–1971.
63.
RamkumarPLRupareliyaTJasaniS. Processability investigation on underlying mechanism of LLDPE-based rotationally moulded banana fibre biocomposites. Proc Inst Mech Eng, Part E: J Process Mech Eng2023: 1–9. doi: 10.1177/09544089231221564
64.
Jagadeesh ChandraRBShivamurthyBMVH, et al.Tensile and thermal behaviour of linear low-density polyethylene nanocomposite films. IOP Conf Ser Mater Sci Eng2022; 1272: 012024.
65.
YallewTBKumarPSinghI. Sliding behaviour of woven industrial hemp fabric reinforced thermoplastic polymer composites. Int J Plast Technol2015; 19: 347–362.
66.
ZhangXPeiXWangQ. Friction and wear behavior of basalt-fabric-reinforced/solid-lubricant-filled phenolic composites. J Appl Polym Sci2010; 117: 3428–3433.
KumarRAnandA. Dry sliding friction and wear behavior of ramie fiber reinforced epoxy composites. Mater Res Express2018; 6: 015309.
69.
VishwanathBVermaAPRaoCVSK. Friction and wear of a glass woven roving/modified phenolic composite. Composites1990; 21: 531–536.
70.
RajeshkumarG. Effect of sodium hydroxide treatment on dry sliding wear behavior of Phoenix sp. Fiber reinforced polymer composites. J Ind Text2022; 51: 2819S–2834S.
71.
MariattiMJannahMAbu BakarA, et al.Properties of banana and pandanus woven fabric reinforced unsaturated polyester composites. J Compos Mater2008; 42: 931–941.
72.
RowellRM. Opportunities for lignocellulosic materials and composites. In: 1992:12-27. doi:10.1021/bk-1992-0476.ch002.
73.
KarthikeyanSRajiniNJawaidM, et al.A review on tribological properties of natural fiber based sustainable hybrid composite. Proc Inst Mech Eng, Part J: J Eng Tribol2017; 231: 1616–1634.
74.
ChangBPMd AkilHZamriMH. Tribological characteristics of green biocomposites. In: JawaidMSapuanSAlothmanO, et al. (eds) Green Biocomposites. Green Energy and Technology. Cham: Springer , 2017, pp.149–179.
75.
SubramanianKRamasubramanianSSelvamB, et al.Investigations on effectiveness of transfer layer on specific wear rate and coefficient of friction during dry sliding of hybrid polymer matrix composites. Polym Compos2022; 43: 250–266.
76.
El-TayebNSM. Abrasive wear performance of untreated SCF reinforced polymer composite. J Mater Process Technol2008; 206: 305–314.
77.
RamakrishnanMRamasubramanianSRamanS, et al.Evaluation of the physical, mechanical, water absorption, and tribological behavior of pineapple leaf fiber/roselle fiber reinforced vinyl ester hybrid composites for non-structural applications. Polym Compos2023; 44: 5284–5295.
