Microstructural Evolution and its Influence on Thermal and Mechanical Performance of HDPE Hybrid Composites

Abstract

With the rising need for sustainable, lightweight, and economically viable ceiling materials, more attention is being paid to hybrid composites made from polymers and wastes derived from agriculture and industries. Nevertheless, typical ceiling boards are often limited by their poor thermal stability, insufficient mechanical strength, sensitivity to moisture, and ecological problems related to the disposal of the waste. Specifically, the disposal of sawdust dust and crushed glass fragments is an alarming issue. This research explores the microstructure development and its effect on the thermal and mechanical properties of HDPE-based hybrid composites used for making ceiling boards. The aims of this study were to examine the interface interaction, thermal conductivity, and strength of HDPE reinforced with sawdust and crushed glass fragments. Fabrication process of the composites included melt blending and compression moulding method with different reinforcement blends. Characterization of the microstructure was done with the help of scanning electron microscope (SEM). Thermal and mechanical properties were determined by differential scanning calorimeter (DSC), thermal conductivity test, tensile strength test, flexural strength test, impact test, hardness test, and density test. Improved dispersion of the fillers, better interfacial bonding, and minimized voids in the composite structure were found to be achieved in the optimized composite structure. The study findings indicate that the synergistic blending of sawdust and glass particles significantly improved the microstructure, thermal properties, and mechanical behaviour of HDPE composite for ceiling board applications. It is suggested that future studies should focus on the durability and fire resistance of the composite material under actual service conditions. The research makes a valuable contribution to the body of knowledge through the development of sustainable processes for converting waste to functional composite ceiling boards.