Effect of Fiber Orientation on Mechanical Properties of Kenaf-Reinforced Polymer Composite

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The increase of environmental awareness has led to interest in the use of materials with eco-friendly attributes.In this study, a sandwich composite was developed from polyester and kenaf fiber with various orientation arrangements.Polyester/kenaf sandwich composite was fabricated through the combination of a hand lay-up process and cold compression.The tensile, flexural, and Izod impact tests of the sandwich composites were evaluated by using a universal tensile tester and an impact tester.The thermal stability of polyester/kenaf sandwich composite and plywood were investigated by using a thermogravimetric analyser.Results showed that the polyester/kenaf sandwich composite with kenaf fiber in anisotropy orientation achieved the highest mechanical properties.The kenaf fiber in anisotropic orientation could absorb the impact energy and allow the sandwich composite to withstand greater impact forces compared to composite with fiber in perpendicular or isotropic orientations.The polyester/kenaf sandwich composite also showed higher thermal stability compared to a conventional plywood sheet.Thus, the fabrication of polyester/kenaf sandwich composite with kenaf fiber in an anisotropic orientation design has great potential to replace plywood sheets for beam construction applications.

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## Effect of Fiber Orientation on Mechanical Properties of Kenaf-Reinforced Polymer Composite

Ching Kuan Yong, a, b Yern Chee Ching, a, - Cheng Hock Chuah, c and Nai-Shang Liou d

The increase of environmental awareness has led to interest in the use of
materials with eco-friendly attributes. In this study, a sandwich composite
was developed from polyester and kenaf fiber with various orientation
arrangements. Polyester/kenaf sandwich composite was fabricated
through the combination of a hand lay-up process and cold compression.
The tensile, flexural, and Izod impact tests of the sandwich composites
were evaluated by using a universal tensile tester and an impact tester.
The thermal stability of polyester/kenaf sandwich composite and plywood
were investigated by using a thermogravimetric analyser. Results showed
that the polyester/kenaf sandwich composite with kenaf fiber in anisotropy
orientation achieved the highest mechanical properties. The kenaf fiber in
anisotropic orientation could absorb the impact energy and allow the
sandwich composite to withstand greater impact forces compared to
composite with fiber in perpendicular or isotropic orientations. The
polyester/kenaf sandwich composite also showed higher thermal stability
compared to a conventional plywood sheet. Thus, the fabrication of
polyester/kenaf sandwich composite with kenaf fiber in an anisotropic
orientation design has great potential to replace plywood sheets for beam
construction applications.

_Keywords: Kenaf fiber; Polyester; Tensile; Thermal stability; Impact strength_

_Contact information: a: Department of Mechanical Engineering, Faculty of Engineering, University of_
_Malaya, 50603 Kuala Lumpur, Malaysia; b: Faculty of Engineering and the Environment, University of_
_Southampton, Southampton SO17 1BJ, United Kingom; c: Department of Chemistry, Faculty of Science,_
_University of Malaya, 50603 Kuala Lumpur, Malaysia; d: Department of Mechanical Engineering,_
_Southern Taiwan University of Science and Technology, Yungkang Dist., Tainan City 710, Taiwan R.O.C.;_

_* Corresponding author: chingyc@um.edu.my_

INTRODUCTION

The increases in environmental and health concerns, cost awareness, more
sustainable methods of manufacturing, and increased awareness of energy consumption are
the factors that provide an impetus to drive the growth of new materials and products based
on natural fibers (Fowler _et al._ 2006; Yu _et al_ . 2006; Bakar _et al._ 2014). Nowadays, kenaf
fibers are being applied in various products including bagging, carpet backing, packaging
materials, papers, and fencing. In addition, their use is being extended to structural,
automotive, plastic, and food packaging industries too. This natural-based fiber is widely
used as reinforcing medium for thermoplastic resins such as polyethylene (Chen and Porter
1994), polypropylene (Sanadi _et al._ 1995), as well as thermosetting materials such as
polyester (Aziz _et al._ 2005). Now, efforts have been taken to increase the usage of biobased
fiber components in sandwich composites. Kenaf sandwiches with plastic composite are a
potential substitute to replace wood-based products for use as building materials in
construction industry. A comparison between various insulating materials including stone,
paper, glass, and kenaf fiber has been reported (Ardente _et al_ . 2008). The result shows that

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kenaf fibers experience less impact if various disposal scenarios are adopted in life cycle
impacts (Ardente _et al_ . 2008). Automotive manufacturing has adopted traditional material
such as glass fibers and manufactured foams because of the issue of non-biodegradability
(Davoodi _et al_ . 2010). The use of kenaf fiber can provide lower density than the traditional
materials and has resulted in lightweight and eco-friendly automotive interiors. Not only
that, it has been shown that the cellulosic-based non-woven fiber has better sound
absorption and noise level reduction (Parikh _et al._ 2006). This sandwich layer composite
is a very efficient structural design with the benefit of being lower in cost. The previous
work by Parikh (2002) had reported that the composite containing kenaf fiber showed
lower strength and hardness compared to glass fiber reinforced plastic. However, the
composite with kenaf reinforcement offers the advantages of being biodegradable and more
economical (Parikh 2002).

The main objective of this study is to reduce the existing dependence on synthetic
products or energy intensive materials for numerous composite applications. In this study,
a sandwich composite base on polyester and kenaf fibers has been designed as an
alternative material to replace the conventional plywood sheets in a beam construction
system. This research will present the mechanical properties and thermal stability analysis
of polyester/kenaf sandwich composites. Tested result parameters including tensile,
flexural, and impact strength were compared and recorded based on different fiber
orientation. Factors favoring this development include low cost, user-friendliness,
availability, and productivity.

EXPERIMENTAL

Materials
Unsaturated polyester resin and methyl ethyl ketone peroxide (MEKP) were
supplied from Mostrong Industries Sdn Bhd. Methyl ethyl ketone peroxide was used as a
catalyst in this study. The mechanical properties of polyester resin are given in Table 1. A
random mat of kenaf fiber with the density of 1.4 g/cm 3 was supplied by a local company
named Innovative Pultrusion Sdn Bhd. The Young modulus and tensile strength of
unidirectional kenaf fiber is about 2 to 4 GPa and 18 MPa, respectively. The kenaf fiber
matt has the size of 500 mm x 2000 mm x 4 mm and was delivered without any surface
treatment.

Table 1. Mechanical Properties of Polyester Resin

Properties Value
Density (g/cm 3 ) 1.2 to 1.5
Young modulus (GPa) 1.5 to 3.5
Tensile strength (MPa) 5 to 12

Preparation of Polyester/ Kenaf Sandwich Composite
First, a surface treatment process known as mercerization was employed on kenaf
fiber in order to enhance the interfacial adhesion of fiber-matrix. During the mercerization
process, kenaf fiber was soaked in NaOH solution (6 wt %) for 12 h and subsequently
washed with distilled water and dried at room temperature for 24 h. The mercerized kenaf
fiber was further dried in the oven at 95 ºC for 4 h to remove the excess moisture, which
had been in equilibrium with the air humidity. The treated kenaf fiber was then kept in a

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plastic bag to prevent moisture exposure. Polyester was blended with 1.0 wt% of methyl
ethyl ketone peroxide catalyst. The polyester solution was cast onto the
polytetrafluoroetheylene (PTFE) coated pan. The polyester solution was left to cure under
room temperature conditions into a sheet film. Lastly, the polyester sheets were removed
from the molds for the lamination process.
A liberal coating of lay-up laminating resin was evenly brushed over the base
polyester sheet and then the treated kenaf fiber was laid on top of it. Subsequently, the
second layer of polyester sheet was coated and stacked on top of the kenaf fiber. The same
process was repeated until the last layer of polyester sheet was stacked as shown in Fig. 1.
The composites were prepared by sandwiching a layer of treated kenaf fiber in between
two layers of polyester films. The final sandwich composite was prepared with 5 layers
height. The polyester/kenaf sandwich composite contains 3 layer of polyester resins and 2
layers of kenaf fibers. The volume fraction weights of polyester and kenaf fiber layers were
controlled to maintain composites with the ratio of 70:30. There were 3 different
polyester/kenaf sandwich composite prepared, with the fiber arrangement in perpendicular,
anisotropic, and isotropic orientations. Thereafter, a cold compression method (150 N
loads) was applied to the polyester/kenaf sandwich composite for 2 h at room temperature.
This process is important to release the bubbles between the bonding surfaces and to
achieve homogeneity within the sandwich composite. After 2 h of cold compression, the
sample was then removed from the mould and dried at 95 ºC for 12 h.

Fig. 1. Stacking sequence of kenaf fibers and polyester matrix

Characterization Study
The tensile, flexural, Izod impact tests of the sandwich composites were carried out
according to ASTM D638-03, D790-90, and D256-04, respectively by using a universal
tensile tester and an Izod impact tester. The tensile properties such as tensile stress,
elongation to breakage, and modulus elasticity were performed by using the Universal
tensile tester (Instron 4400). Every specimen was cut into size of 246 mm (L) X 29 mm
(W) X 12.7 mm (T) with gauge length of 30 mm and tested according to D638-03 type III
specimen. Yield stress, elongation at break, and modulus elasticity were recorded. The data
obtained represent an average of 5 specimens. The Izod impact resistance test was
conducted in compliance to ASTM D256-04 by using an Izod pendulum type impact
machine _(_ PST-300-N) with standard pendulum type hammers. The facture energy was

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calculated by dividing the experimentally determined breaking energy by the thickness of
the specimen. The maximum pendulum energy is determined by the weight attached to the
pendulum. Every specimen was cut into size of 63.5 mm X 12.7 mm X 12.7 mm. The
milled notch of the specimen was done by a milling machine with constant feed and cutter
speed throughout the notching operation. The energy loss at no load of the machine is
recorded at 1.62698J. Five individual determinations of impact resistance were made on
each sample and an average of five samples was taken for the final result. Impact strength
of specimen is determined by using the formula,

?

?????? ???????ℎ= ?×? (1)

?

?????? ???????ℎ= ?×? (1)

where _E_ = _E_ r – _E_ o, _E_ r is the energy loss read at the scale, and _E_ - is the energy loss at no
load.

The flexural test was performed by using the Universal testing machine according
to the 3-point bending method (ASTM D790-03). The dimensions of the specimens were
127 mm (L) x 12.7 mm (W) x 3.2 mm (T). The distance between the spans was 100 mm,
and the strain rate was 5 mm/min. Thermal stabilities of polyester, polyester/kenaf
composite, and plywood were carried out by using thermogravimetric analysis (TGA).
Thermogravimetric analysis (TGA) was carried out by using Mettler TGA 851. The weight
loss and temperature of weight change of the specimens were identified throughout the
experiment, and descending TGA thermal curves were plotted.

RESULTS AND DISCUSSION

Tensile Properties
A typical stress-strain plot for the different fiber orientations of polyester/kenaf
sandwich composite and pure polyester resin is shown in Fig. 2. The curve shows linear
deformation behaviour with the stress rising to a maximum value before fracture occurred.
The stress strain curve was plotted during the test for the determination of the ultimate
tensile strength and elastic modulus. The tensile strength and elongation at break for
different fiber orientations of polyester/kenaf sandwich composite and pure polyester are
plotted in Figs. 3 and 4.

Figure 3 indicates that the incorporation of kenaf fiber increased the tensile strength
of polyester/fiber composites. However, the elongation at break of the polyester was
reduced with the introduction of kenaf samples in all the stacking orientations, as shown in
Fig. 3. An anisotropic specimen showed the lowest elongation at break, which was
recorded at 2.81%, while an isotropic specimen was recorded at 3.32%, and a perpendicular
specimen was recorded at 3.71%. This result indicates that the polyester effectively
transferred the tensile force to the kenaf fiber. The reinforcement of kenaf fiber eventually
absorbed the tensile force.

The tensile strength of composite with fibers in anisotropic arrangement achieved
the highest tensile strength. It was 55% higher than the composite sample with fiber
arrangement in perpendicular directions. On the other hand, the composite with kenaf fiber
in isotropic arrangement gave a tensile strength 49% lower than fiber in an anisotropic
arrangement.

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Fig. 2. Stress strain curve of different fiber orientation of Kenaf/polyester sandwich composite

Polyester Perpendicular Anisotropic Isotropic

Sample

Fig. 3. Tensile strength of polyester and polyester/kenaf sandwich composite

Polyester Perpendicular Anisotropic Isotropic

Sample

Fig. 4. Elongation at break of polyester and polyester/kenaf sandwich composite

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This result indicates that the tensile strength was reduced with the increase of fiber
orientation angle. The increase of fiber contents in loaded direction would increase the
strength efficiency. However, the strength efficiency was decreased when the loaded fiber
was in perpendicular direction. A similar observation has been reported by Nishino and coworkers (2003), who indicated that a large mechanical anisotropy will result in high
mechanical performance.

Young’s Modulus
The Young's modulus, _E_, of the polyester/kenaf sandwich composite and neat
polyester was calculated from the slope of the stress-strain curve as shown in Fig. 2. Figure
5 shows results indicating that the arrangement of anisotropic fiber in a polyester/kenaf
sandwich composite successfully improved the Young’s modulus of polyester from 314
MPa to 650 MPa. The figure also illustrates that the fiber stacked in anisotropic
arrangement was stiffer than other fiber orientations. Work by Campbell (2010) also
reported that the materials will become stiffer when the fiber is aligned parallel to the
direction of applied load. On the other hand, Bernasconi _et al._ (2007) reported that the
Young modulus would decrease as the fiber orientation angle increases with a maximum
at 0 degrees and minimum at 90 degrees.

700

600

500

400

300

200

100

Polyester Perpendicular Anisotropic Isotropic

Compound

Fig. 5. Young modulus of polyester and polyester/kenaf sandwich composite

Impact Strength
The Izod impact test was used in this study to measure the impact strength of the
resulting composite materials. The notch impact strength generally reflects the energy
required to propagate an existing notch in the specimen. The fibers play an important role
for the propagation of a crack through a matrix by increasing the volume which can allow
the energy dissipation to take place (Amal 2012). The presence of fibers also led to the
improvement in the number of potential energy absorbing mechanisms in the system
(Sanadi _et al_ . 1995). Figure 6 shows the impact strength of polyester and polyester/kenaf
sandwich composites. Pure polyester exhibited the lowest value of impact strength, which
was 1.42 kJ/m 2 . The composite with an anisotropically oriented fiber arrangement achieved
the highest Izod impact strength of 6.68 kJ/m 2 . The impact strength of polyester/kenaf
composite with anisotropic orientation was at least >50% higher than those composites
with kenaf reinforcement stacked in perpendicular and isotropic orientation. It can be
concluded that the fabrication of polyester/anisotropic kenaf sandwich composite could
effectively transfer the stress from polyester matrix to kenaf fiber.

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Polyester Perpendicular Anisotropic Isotropic

Sample

Fig. 6. Izod impact strength of polyester and polyester/kenaf sandwich composite

The interfacial bond strength between the polymer and fiber has high influence on
the impact response of the sandwich composite. Failure mechanisms such as fiber/matrix
debonding, fiber and/or matrix fracture, and fiber pull-out are able to account for the
dissipation of the impact energy. All of these damage mechanisms were observed in the
post-experiment specimens. Figure 7 shows the failure mechanisms of the polyester/kenaf
sandwich composite with fiber oriented in a perpendicular direction. When the pendulum
strikes on the specimen, the matrix will transfer the force to the fiber. This action has caused
the fiber to split or peel along the interface of the polyester/fiber. As a result, the crack
propagated easily along the fiber axial direction. The interfacial failure was observed along
the fiber axial direction. In this case, the polyester was the main matrix to absorb energy.

Fig. 7. Schematic diagram of perpendicular polyester/kenaf sandwich composite

Figure 8 shows a schematic diagram of polyester/anisotropy kenaf sandwich
composite. When the pendulum strikes the specimen, the pendulum first will contact the
fiber and then forces the bundle of fibers in anisotropic orientation to bend. As the fibers
bend, subsequently fiber pull-out, fiber matrix debonding, and fiber breakage will be
observed (Kim and Sham 2000). For composite with kenaf in anisotropic orientation, the
crack tip normally propagate through the polymer matrix until it reaches the next layer of
fibers and then is arrested there. When the fibers in the first layer are broken, a high shear

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stress will develop in the matrix between these two layers (Broutman and Rotem 1972).
This shear stress will initiate cracks which could run to both sides parallel to the layers.
The impact is continued and when the stress in the second layer is high enough, the fibers
will be broken and again a crack will propagate up to the third layer and branch to the side
(Broutman and Rotem 1972). Those cracks that run to the sides could delaminate the
specimen and absorb the greatest amount of energy during the failure process. In summary,
the mechanism for the sandwich composite with kenaf fiber in anisotropic orientation
involves the steps such as the following: A strong fiber forms bridges over the cracks before
the fiber breakage occurs, and the fiber breakage contributes to the absorbtion of higher
energy, resulting in higher toughness (Marcus and Peter 2014). Thus, the fiber in
anisotropic orientation helps to improve the toughness and impact resistance of the
polyester/kenaf sandwich composite. In other words, the sandwich composite with kenaf
fiber in anisotropic orientation can absorb more energy and experience more than one
fracture mode before failure.

Fig. 8. Schematic diagram of anisotropy polyester/kenaf sandwich composite

A composite with fiber in isotropic orientation showed an intermediate failure
mechanism in between composite with fiber in perpendicular and anisotropic orientation.
When the pendulum strikes the specimen, less fiber pull out, and breakage were observed
as compared to polyester/anisotropy kenaf composite. The presence of fibers arrested the
crack propagation in the test specimen. Thus, the final failure was due to delamination
between layers in the compression zone. In conclusion, the composite with fiber in
isotropic orientation, which experiences more than one fracture mode, will have higher
toughness and higher impact resistance than the sandwich composite with fiber in isotropic
orientation.

Flexural Modulus
Figure 9 show that the incorporation of kenaf fiber in anisotropic and isotropic
arrangements successfully improved the flexural modulus of the neat polyester from 24.6
MPa to 95.9 MPa and 43.8 MPa, respectively. However, the fabrication of a sandwich
composite with kenaf fiber in perpendicular orientation reduced the flexural modulus
significantly to 10.3 MPa. This result indicates that a crack had propagated easily along the
axial direction when the fiber was arranged in perpendicular orientation. The separation

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between the fiber layer and polyester resulted in a significant drop in the flexural modulus
of the polyester/fiber composite with kenaf fiber in a perpendicular orientation.

100

Polyester Perpendicular Anisotropic Isotropic

Sample

Fig. 9. Flexural modulus of polyester and polyester/kenaf sandwich composite

The polyester/kenaf sandwich composite with kenaf fiber in anisotropic orientation
achieved the highest flexural modulus. This is because the flexural modulus decreases with
the increasing of orientation angle (Shenoy and Melo 2007). Thus, the kenaf fiber in
anisotropic orientation exhibits high bending resistance and manages to carry high tensile
and compressive stress. However, kenaf fiber in a perpendicular arrangement does not
carry much stresses since the crack can propagate easily along the fiber-matrix bonding,
resulting in separation between matrix and fiber.
A similar result has been reported by Bernasconi _et al._ (2007), where the modulus
was found to decrease as the fiber orientation angle increased with a maximum at 0 degree
and minimum at 90 degree. The work by Manalo _et al._ (2010) also considered the flexural
behavior and failure mechanism of the sandwich composite in both flatwise and edgewise
directions.

Thermogravimetric Analysis
Thermal stability is important to evaluate the potential use of polyester/kenaf
sandwich composite in a structural beam system. The structural beam must always
maintain good mechanical properties and high structure rigidity. Thermal and
photochemical degradation would jeopardize the mechanical properties of the structural
beam (Chee _et al._ 2013). Thus, an intensive study on thermal stability property is important
and useful during the designing stage of the composites. The thermogravimetry analysis
(TGA) and differential thermogravimetry (DTG) analysis for polyester, polyester/kenaf
sandwich composite, and plywood materials are shown in Figs. 10 and 11, respectively.
Polyester was shown to possess the highest thermal stability among the materials. The
decomposition of polyester occurred in two mass loss steps with the thermal degradation
occurring at around 230 °C.

Plywood exhibited the lowest thermal stability, exhibiting thermal degradation at
120 °C. The upper use temperature of the polyester/fiber composite was at around 180 °C.
The polyester/kenaf sandwich composite degraded at their intermediate temperature. So
the sandwich composite carries the thermal properties of both kenaf fiber and polyester
matrix material. The result indicates that the thermal stability of the kenaf-reinforced
polyester composite is better than plywood. In other words, the used of polyester/kenaf

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sandwich composite for a structural system could enhance the thermal resistance and
prolong the degradation against thermal and photochemical reaction.

Fig. 10. Comparison TGA result of polyester, plywood, and polyester/kenaf sandwich composite

0.010
0.005
0.000

-0.005
-0.010
-0.015
-0.020
-0.025
-0.030
-0.035

Polyester
Composite
Plywood

50 150 250 350 450 550

Temperature (°C)

Fig. 11. Comparison DTG result of polyester, plywood, and polyester/kenaf sandwich composite

CONCLUSIONS

1. Fiber orientation plays a significant role to determine the mechanical properties of a
sandwich composite for structural application. Polyester/kenaf sandwich composites
with various fiber orientations were fabricated successfully by sandwiching a layer of
treated kenaf fiber in between two layers of polyester sheets until 5 layers height by
using hand lay-up and cold press processes. The volume fraction weights of polyester
to kenaf fiber in the composite were controlled at 70:30.

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2. The polyester/kenaf sandwich composite with kenaf fiber in anisotropic orientation
design will form a strong bridge over the cracks, thus increasing the breakage resistance
of the kenaf fiber.

3. Polyester/kenaf composite with kenaf fiber in anisotropic arrangement achieved the
highest tensile, flexural, and impact properties. This was followed by a sandwich
composite with kenaf fiber in isotropic and perpendicular orientations. It can be
concluded that the strength of polyester/kenaf sandwich composite increases with the
decreases of fiber orientation.

4. The polyester/kenaf sandwich composite also showed higher thermal stability and
thermal resistant than plywood. Thus, the design of polyester/kenaf sandwich
composite shows high potential to replace the existing use of plywood in beam
construction systems.

ACKNOWLEDGMENTS

The authors would like to acknowledge the financial support from High Impact
Research MoE Grant UM.C/625/1/HIR/MoE/52 from the Ministry of Education Malaysia,
RU022A-2014, RP011A-13AET, and FP030-2013A for the success of this project.

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Article submitted: December 15, 2014; Peer review completed: February 7, 2015;
Revised versin received and accepted: February 25, 2015; Published: March 10, 2015.
DOI: 10.15376/biores.10.2.2597-2608

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