EFFECT OF MOISTURE ON TENSILE PROPERTIES OF OIL PALM EMPTY FRUIT BUNCH (EFB) UNSATURATED POLYESTER COMPOSITES SULAIMAN BIN MOHAMAD ALI

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1 EFFECT OF MOISTURE ON TENSILE PROPERTIES OF OIL PALM EMPTY FRUIT BUNCH (EFB) UNSATURATED POLYESTER COMPOSITES SULAIMAN BIN MOHAMAD ALI This report is submitted to Faculty of Engineering University Malaysia Sarawak (UNIMAS) as to fulfil the requirements of Bachelor Degree Program Mechanical Engineering and Manufacturing Systems Faculty of Engineering UNIVERSITI MALAYSIA SARAWAK 2008 i

2 Dedicated to my beloved father and mother ii

3 ACKOWLEDGEMENT I would like to take this opportunity to express my gratitude to the entire individual for their guidance, time and contribution towards the completion of my final year project. First of all, I would like to thank my supervisor, Puan Mahshuri Binti Yusof for giving me the chance to be one of her student in this final year project. Her knowledge and experience had helped and guided me a lot in performing my project. I will never forget the effort and time she sacrificed for me in matter to finish this project. Secondly, I would like to express my appreciation to all the laboratory technical staff of mechanical department especially Mr. Sabariman, Mr. Rhyier and Mr. Masri in assisting me using the laboratory apparatus and facilities. Last but not least, my beloved family for their blessings and support, fellow course mate and friends for giving opinions and shared their wisdom. Thank you very much for those involved directly or indirectly for the completion of this project. iii

4 ABSTRAK Gentian daripada tandan tanpa buah kelapa sawit telah diguna dalam kajian ini sebagai gentian yang berpotensi untuk digunakan dalam menghasilkan bahan komposit berasaskan poliester. Bahan komposit berasaskan poliester daripada gentian dari tandan tanpa buah kelapa sawit telah dihasilkan dalam susunan lapisan yang rambang atau berteraburan. Spesimen-spesimen ini dikelaskan berdasarkan jumlah gentian (10%, 15% dan 20%) yang terdapat di dalam komposit, jenis rawatan (tidak di rawat, larutan Natrium Hidroksida dan larutan Silane) dan kandungan air (1%, 2%, 3% dan 4%). Ujian kadar resapan air dan ujian tegangan berdasarkan piawai ASTM D3039 telah dijalankan ke atas semua spesimen untuk memahami sifat kandungan air tehadap tegangan komposit tersebut. Keputusan ujian menujukkan komposit yang tidak dirawat dengan 20% nisbah gentian dan 1% kandungan air mempunyai sifat mekanikal yang paling baik dari segi kekuatan tegangan, sifat kelenturan dan tenaga apabila putus. Malahan, keputusan ujian juga menunjukkan apabila peningkatan tahap kandungan air dalam semua spesimen yang mempunyai nisbah gentian dan jenis rawatan yang sama berlaku, kekuatan tegangan semakin berkurangan. iv

5 ABSTRACT This research addressed to the oil palm empty fruit bunch fibre as the potential fibre for fibre reinforced polymer composites. An oil palm empty fruit bunch reinforced polyester composites have been fabricated in a random orientation. The specimens are categorized according to its fibre volume fraction (10%, 15% and 20%), the type of surface treatment (untreated, NaOH and Silane), and moisture content (1%, 2%, 3% and 4%). A moisture absorption test and tensile test according to ASTM D3039 standard has been carried out in order to determine the moisture content and understand the moisture effects of the composite under tension. The results showed that the untreated composites with 20% fibre volume fraction and 1% of moisture content had the best mechanical properties in terms of tensile strength, Young s modulus and energy at break. Furthermore, it also verified that the increment of moisture content in specimen with the same fibre volume fraction and surface treatment reduced the tensile strength. v

6 TABLE OF CONTENTS NO. CONTENTS PAGES CONFIRMATION LETTER OF PROJECT REPORT SUBMISSION APPROVAL SHEET TITLE PAGE DEDICATION ACKNOWLEDGEMENT ABSTRAK ABSTRACT TABLE OF CONTENTS LIST OF TABLES LIST OF FIGURES ABBREVIATIONS i ii iii iv v vi x xi xviii 1.0 CHAPTER 1: INTRODUCTION 1.1 Introduction Natural Composites Moisture Scope and Objective 4 vi

7 2.0 CHAPTER 2: LITERATURE REVIEW 2.1 Introduction Composite Materials Fibres Natural Fibres Empty Fruit Bunch (EFB) Fibres Fibre Matrix Bonding (Coupling Agent) Effects Resins Unsaturated Polyester Resins Tensile Test Theory Tensile / Elastic Properties of Random Oriented Short Fibre Composites Moisture Content Behaviour of Polymeric Composite Materials CHAPTER 3: METHODOLOGY 3.1 Introduction Specimen Preparation Raw Material Sources and Handling Empty Fruit Bunch (EFB) Fibre Extraction Fibre Chemical Treatments Silane Treatment Natrium Hydroxide (NaOH) Treatment Fibre Orientation Fibre Volume Fraction. 42 vii

8 3.5 Specimen Fabrications Curing Tabbing on Test Specimen Cutting the Specimen Total Number of Test Specimens Tensile Specimen Specimen Testing Moisture Absorption Parameters Tensile Test Testing Method for Tensile Properties of Polymer Matrix Composites [ASTM D3039] Scanning Electron Microscope (SEM) Analysis CHAPTER 4: RESULTS AND DISSCUSSIONS 4.1 Introduction Moisture Absorption Determination Result and Data of the Tensile Test Tensile Test Results of Untreated Specimens Tensile Test Results for Specimens Treated with NaOH Tensile Test Results for Specimens Treated with Silane Tensile Strength of Untreated and Treated EFB Reinforced Polyester Composites Stiffness of Treated and Untreated EFB Reinforced Polyester Composites Energy at Break of Treated and Untreated EFB Reinforced Polyester Composites Scanning Electron Microscope (SEM) Analysis 77 viii

9 5.0 CHAPTER 5: CONCLUSIONS AND RECOMMENDATIONS 5.1 Introduction Conclusions Recommendations 83 REFERENCES 85 APPENDIX 89 ix

10 LIST OF TABLES TABLE PAGE Table 2.1: Fibres advantages and disadvantages 10 Table 2.2: Physical and mechanical properties of selected natural fibres and synthetic fibres 11 Table 2.3: Comparison of Typical Ranges of Property Values for Thermosets and Thermoplastics 16 Table 2.4: Detail of ASTM Tensile Test Method 19 Table 2.5: Several Polymer Resins Water Absorption Property at Room Temperature 26 Table 3.1: Numbers of Test Specimens Prepared According to the Different Coupling Agent and Volume Fraction 49 Table 5.1: General Results of The Research 82 x

11 LIST OF FIGURES FIGURE PAGES Figure 1.1: Oil Palm Empty Fruit Bunch 2 Figure 2.1: Phases of a composite material 7 Figure 2.2: Oil Palm Empty Fruit Bunch (EFB) 12 Figure 2.3: Polyester: (a) Constitution of the Resin (b) Cured Resin with Cross-Linked Network 17 Figure 2.4: Load Applied on Tensile Test 20 Figure 2.5: Stress-Strain Curve of an Idealized Fibre-Reinforced Composite 22 Figure 2.6: Diagram of Random Oriented Short Fiber-Reinforced Composite 23 Figure 2.7: Effect of Moisture Absorption on The Fatigue Behaviour of Epoxy Composites with (a) E. Glass and (b) Kevlar Figure 2.8: Effects of Internal Stress on The Measured Water Uptake of A Graphite / Thermoplastic 29 Figure 2.9: Hygric Strains In Unidirectional AS4/ Carbon / Epoxy Composite as A Function Of Moisture Concentration 34 xi

12 Figure 3.1: The process flow of the Project 35 Figure 3.2: Empty Fruit Bunch Soak in Water 37 Figure 3.3: Empty Fruit Bunch Fibres 38 Figure 3.4: EFB Fibres after the Surface Treatment with Silane 39 Figure 3.5: EFB Fibres after the Surface Treatment with NaOH 41 Figure 3.6: The Specimen s Fibre Orientation with Random Oriented Chopped Short Fibre 42 Figure 3.7: The Dimension of the Mould 45 Figure 3.8: Cold Press (a) press open loading resin; (b) press closed pressure applied 46 Figure 3.9: The Specimen Water Absorption Process 50 Figure 3.10: The Specimen Weighing Process 51 xii

13 Figure 3.11: Testometric 52 Figure 3.12: The tensile test specimen according to ASTM D3039; (a) plane view (b) side view 53 Figure 3.13: Scanning Electron Microscope (SEM) 54 Figure 4.1: Weight Gain versus Time (10% Fibre Volume Fraction) 56 Figure 4.2: Weight Gain versus Time (15% Fibre Volume Fraction) 57 Figure 4.3: Weight Gain versus Time (20% Fibre Volume Fraction) 58 Figure 4.4: Stress-Strain Curves for Tensile Test of 10% Fibre Volume Fraction with 1%, 2% and 3% Moisture Content (Untreated) 59 Figure 4.5: Stress-Strain Curves for Tensile Test of 15% Fibre Volume Fraction with 1%, 2% and 4% Moisture Content (Untreated) 60 xiii

14 Figure 4.6: Stress-Strain Curves for Tensile Test of 20% Fibre Volume Fraction with 1%, 2% and 4% Moisture Content (Untreated) 61 Figure 4.7: Tensile Strength of Untreated EFB Reinforced Polyester Composites for 10%, 15% and 20% Fibre Volume Fractions 61 Figure 4.8: Stress-Strain Curves for Tensile Test of 10% Fibre Volume Fraction with 1%, 2% and 3% Moisture Content (NaOH) 62 Figure 4.9: Stress-Strain Curves for Tensile Test of 15% Fibre Volume Fraction with 1%, 2% and 4% Moisture Content (NaOH) 63 Figure 4.10: Stress-Strain Curves for Tensile Test of 20% Fibre Volume Fraction with 1%, 2% and 4% Moisture Content (NaOH) 64 Figure 4.11: Tensile Strength of NaOH Treated EFB Polyester Reinforced Composites for 10%, 15% and 20% Fibre Volume Fraction 64 xiv

15 Figure 4.12: Stress-Strain Curves for Tensile Test of 10% Fibre Volume Fraction with 1%, 2% and 3% Moisture Content (Silane) 65 Figure 4.13: Stress-Strain Curves for Tensile Test of 15% Fibre Volume Fraction with 1%, 2% and 4% Moisture Content (Silane) 66 Figure 4.14: Stress-Strain Curves for Tensile Test of 20% Fibre Volume Fraction with 1%, 2% and 4% Moisture Content (Silane) 67 Figure 4.15: Tensile Strength of Silane Treated EFB Reinforced Polyester Composites for 10%, 15% and 20% Fibre Volume Fraction 67 Figure 4.16: Tensile Strength of Untreated and Treated EFB Reinforced Polyester Composites for 10% Fibre Volume Fraction 68 Figure 4.17: Tensile Strength of Untreated and Treated EFB Reinforced Polyester Composites for 15% Fibre Volume Fraction 69 xv

16 Figure 4.18: Tensile Strength of Untreated and Treated EFB Reinforced Polyester Composites for 15% Fibre Volume Fraction 70 Figure 4.19: Stiffness of Untreated and Treated EFB Reinforced Polyester Composites for 10% Fibre Volume Fraction 71 Figure 4.20: Stiffness of Untreated and Treated EFB Reinforced Polyester Composites for 15% Fibre Volume Fraction 72 Figure 4.21: Stiffness of Untreated and Treated EFB Reinforced Polyester Composites for 20% Fibre Volume Fraction 73 Figure 4.22: Energy at Break of Untreated and Treated EFB Polyester Reinforced Composites for 10% Fibre Volume Fraction 75 Figure 4.23: Energy at Break of Untreated and Treated EFB Polyester Reinforced Composites for 15% Fibre Volume Fraction 76 xvi

17 Figure 4.24: Energy at Break of Untreated and Treated EFB Polyester Reinforced Composites for 20% Fibre Volume Fraction 77 Figure 4.25: Scanning Electron Microscope (SEM) Image of (a) Untreated, (b) NaOH treated and (c) Silane Treated Fibre in Dry Condition (100µm) 79 xvii

18 ABBREVIATIONS σ ε Ε t Stress Strain Modulus of Elasticity in tension σ f Stress of fibre σ m Stress of matrix ν f Volume of fibre ν m Volume of matrix σ Ltu c D t M ρ W m Lmin σ c τ t W f Longitudinal tensile strength moisture concentration diffusion coefficient time Moisture uptake Density Weight mass Tab Length Strength of composite Shear strength Thickness Weight of fibres xviii

19 W m W c Weight of matrix Weight of composites ASTM American Society for Testing and Materials Sodium Hydroxide MPa EFB NaOH Mega Pascal Empty Fruit Bunch C Degree Celsius F g M mg min ml mm Force Gram Mass Milligram Minute Milliliter Millimeter xix

20 Chapter 1 Introduction CHAPTER 1 INTRODUCTION 1.1 Background Oil palm, Elaeis guineensis, is originated from western Africa continent, particularly in East Nigeria, where it has been traditionally used as a source of food. It was introduced to Malaysia in 1917 as a decorative plant but was grown commercially since 1980 s as an agricultural crop for its versatility in application of oil and fat. To date, palm oil constitutes about 21% and 47% of global edible oil and fat production and market trade respectively (Basiron et al, 2004). By 2020, it is expected to constitute 40% of the world market and to overtake soy bean as the world largest consumed edible oil (Basiron and Weng, 2004). The palm oil can be commercialized and manufactured to many varieties of product. The nut can be used as foodstuffs and make into cooking oil, margarine, cream and pastry. Besides, it can be used in industrial products such as raw materials for cosmetics, soap, detergent and candles. The commercialization of the oil palm 1

21 Chapter 1 Introduction also contributes to environmental problem especially from its waste. Oil Palm Empty Fruit Bunch (EFB) (Figure 1.1), is the leading solid waste in the palm oil mills industry but it is also can be utilised. Due to its bulky nature, EFB causes high landfill disposal cost and was traditionally burnt in simple incinerators where a tonnes of EFB produces only 4 kg of ash (Prasetsan, 1996). Figure 1.1: Empty Fruit Bunch However, due to the new environmental laws, some countries such as Malaysia have banned this type of removal. Therefore, in some plantations, EFB are left to decompose under oil palm trees but such acts result in very high breeding of Oryctes rhinoceros beetles, which has become the most serious pest for oil palm trees and could cause up to 92 % crop loss (Ooi et al, 2004). This research addressed the oil palm crop waste such as EFB as a potential fibre for particle reinforced composite. This is due mainly to the availability of the waste 2

22 Chapter 1 Introduction which can be massively found all over Malaysia. Moreover, the technology of natural fiber-polymer composite had attracted a lot of interest from the industrial sectors such as construction, aviation and automotive. 1.2 Natural Composites According to Schaffer et. al. (1999), composites are materials formed by uniting two or more basic materials in which one materials, called the reinforcing phase is in form of fibres, sheets or particles, embedded in another material called the matrix. The most common applications for fibre reinforces composites are as structural materials where rigidity, strength, and low density are important. Examples of some current applications of composites include the diesel piston, brake shoes and pad, tires, and the Beechcraft aircraft in which 100% of the structural component are composites (Schaffer et al, 1999). Other form of composites that are very popular nowadays and easily available from the natural resources are natural composite (natural fibres). The examples of natural fibres are cotton, flax, jute, hemp, ramie, wood, straw, hair, wool, palm, coconut, banana and silk. In recent years, the use of natural fibres as reinforces in the fibre thermoplastic composites has been of great interest, particularly to automotive industry. These fibres have many advantages such as low density, high specific 3

23 Chapter 1 Introduction strength and modulus, relative non-abrasiveness, ease of fibre surface modification, wide availability and renewability (Krishnan, 1987). 1.3 Moisture Other than having to withstand with loading extremes, composites materials have also to survive in a range of different environment of moisture and temperature. Most of the polymer matrix composites absorb moisture when exposed to humid air or water environments by instantaneous surface absorption followed by diffusion through the matrix (Mallick, 1993). This is usually limited to the resin matrix, but some fibres also absorb moisture (Matthews and Rawlings, 1999). Moreover from several past study, this environmental effect is believed affecting the mechanical properties of the composites material. 1.4 Scope and Objective The main objective of this study is to investigate the moisture effects of untreated and treated oil palm reinforced polymer composites that was constructed with different volume fraction and random orientation of fibres under tensile test. 4

24 Chapter 1 Introduction In order to achieve the primary objective, the research will be carried out according to ASTM D3039 which is a standard test method for tensile properties of polymer matrix composite material. The fibres are treated with Silane 174 and Sodium Hydroxide (NaOH). The properties of untreated composite, composite treated by silane and treated with NaOH are finally compared. 5

TENSILE PROPERTIES OF ALKALI TREATED SUGAR PALM FIBER MOHAMAD NAZIRUL MUBIN BIN MERZUKI

TENSILE PROPERTIES OF ALKALI TREATED SUGAR PALM FIBER MOHAMAD NAZIRUL MUBIN BIN MERZUKI Report submitted in partial fulfillment of the requirements for the award of Diploma in Mechanical Engineering Faculty