Ong, Thai Kiat
(2025)
Oil palm fibre filled polymer composites for aircraft interior.
PhD thesis, University of Nottingham.
Abstract
This study aimed to assess the feasibility of using natural fibre reinforced thermoplastic composites for aircraft interior components. Currently, aircraft interior components like seats, interior panels, floor coverings, and linings are primarily made from polymeric materials and composites. Synthetic fibre thermoset composites are commonly used due to their excellent mechanical and thermal properties as well as compliance with airworthiness standards. However, recycling thermoset composites is environmentally challenging compared to thermoplastics.
The study involves investigating the mechanical performance and flammability of natural fibre composites after applying fibre surface treatment, coupling agents, and flame retardants. The goals are to enhance mechanical properties of oil palm fibre (OPF) reinforced acrylonitrile-butadiene-styrene (ABS) composites and ensure compliance with Federal Aviation Regulations (FAR) standards.
First, the optimum process parameters for melt blending used in the fabrication of OPF/ABS composites were justified through visual inspection, tensile test result and melt plastogram analysis. Visual inspection highlighted colour changes at high processing temperatures, while melt plastogram data indicated temperature control challenges at varying rotor speeds and mixing times. Mechanical test result revealed that ultimate tensile strength (UTS) and impact strength of ABS reduced by 20% and 30% respectively. This decline in performance can be attributed to oxidative degradation of ABS, which exposed at high temperatures for extended period.
Second, nanocellulose was extracted from oil palm fibres and used as a reinforcing filler for ABS composites. The material was characterized by Fourier Transform Infrared Spectrometry (FTIR) analysis, Scanning Electron Microscopy (SEM) observation and particle size measurements. FTIR analysis revealed that nanocellulose isolated from OPF and commercial cellulose nanocrystals (Celluforce NCC) have similar FTIR spectra. The Zeta particle size test result showed that average particle size of nanocellulose isolated from OPF and Celluforce NCC are 175.19 nm and 125.42 nm respectively. Tensile tests demonstrated that, with suitable coupling agents (silane and maleic anhydride) and 3 wt. % Celluforce NCC, ultimate tensile strength of ABS composites improved by up to 18.61%. The SEM images also verified the reinforcing mechanism of NCC.
In the third phase, chemically treated oil palm fibres were introduced into ABS composites to study their effects on mechanical properties of ABS composites. The research indicated that fibre surface treatment and coupling agents significantly improved mechanical properties of OPF/ABS composites. Maleic-treated and silane-treated oil palm fibres increased ultimate tensile strength of raw OPF/ABS composites by up to 35.59%, while chemically treated oil palm fibre/ABS composites also marginally enhanced the tensile properties of neat ABS by 2.38%. The SEM images showed reduced gaps at the interface between chemically treated OPF and ABS.
In the fourth phase, ammonium polyphosphate (APP), alumina trihydrate (ATH), Zinc borate (ZB) and expandable graphite (EG) were added to investigate their effects on mechanical properties and flammability of OPF/ABS composites. Expandable graphite is proven as the most effective flame retardant in OPF/ABS composites. 25 wt. % EG filler able to help OPF/ABS composite to achieve V-0 rating in the vertical burning test. Other flame retardants (APP, ATH and ZB) are unable to help OPF/ABS composites achieve self-extinguish properties. 15 wt.% of APP, ATH and ZB only able to slow down the burning rate of OPF/ABS composites in horizontal burning test. Limiting Oxygen Index (LOI) test result revealed that LOI values increased with addition of flame retardants and APP is the most effective flame retardants. Furthermore. no synergistic effects among flame retardants were observed in the burn test and LOI test. In addition, the tensile properties of OPF/ABS composites were compromised after incorporating of 15 wt. % flame retardants.
Overall, this study explored the potential of natural fibre-reinforced thermoplastic composites for aerospace interior components. The investigation encompassed various aspects including the determination of optimal processing parameters. mechanical properties and flammability. It is feasible to utilize OPF/ABS composites with an appropriate amount of flame retardants for use as aircraft interior materials. However, it is crucial that OPF/ABS composites also pass the heat release rate test and smoke test which prescribed in FAR Part 25. Compliance with stringent safety and flammability standards are required for aerospace applications.
| Item Type: |
Thesis (University of Nottingham only)
(PhD)
|
| Supervisors: |
Tshai, Kim Yeow
Khiew, Poi Sim |
| Keywords: |
polymer composites; natural fibre composites; thermoplastic composites; aircraft interior components; oil palm fibre (OPF) |
| Subjects: |
T Technology > TA Engineering (General). Civil engineering (General) |
| Faculties/Schools: |
University of Nottingham, Malaysia > Faculty of Science and Engineering — Engineering > Department of Mechanical, Materials and Manufacturing Engineering |
| Item ID: |
78659 |
| Depositing User: |
ONG, Thai
|
| Date Deposited: |
08 Feb 2025 04:40 |
| Last Modified: |
08 Feb 2025 04:40 |
| URI: |
https://eprints.nottingham.ac.uk/id/eprint/78659 |
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