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This study emphasizes the significance of stacking sequence and hybridization of glass, carbon, kevlar and basalt fibers to enhance the mechanical characteristics and the overall wear response of polymer composites. The carbon layer on the outside of the composite exhibited higher ultimate tensile and flexural strengths. The abrasive wear of fabricated hybrid composites is also explored by performing experiments using Box–Behnken design approach. The pin‐on‐disc tester is utilized to do the wear test by varying composite type, sliding distance, and sliding velocity, with specific wear rate (SWR) serving as the response parameter. Regression analysis is performed to predict SWR using control and response parameters derived from experimentation. A novel firefly algorithm technique is adopted to determine the optimal process parameter combination. By utilizing optimized parameters (430 m, 10.5 m/s, and the CKBG4BKC stacking sequence), the SWR is considerably reduced to 16.82 × 10−5 mm3/Nm. Scanning electron microscopy on the worn‐out wear surface reveals enhanced interfacial bonding, fiber breakage and plowing as the fundamental wear mechanism. This work provides insight into hybrid composites for constructing aircraft and automobile body structures, where they provide an optimal blend of strength, sustainability, and structural performance.Highlights Hybrid composite: Stacking sequence impacts on mechanical and abrasive wear. Box–Behnken design: Applied on stacking order, sliding distance and velocity. Utilizing metaheuristic firefly algorithm to enhance specific wear results. Optimal parameters: 430 m, 10.5 m/s, and CKBG4BKC stacking sequence. Lightweight, high‐strength, cost‐effective, and sustainable hybrid composites.
This study emphasizes the significance of stacking sequence and hybridization of glass, carbon, kevlar and basalt fibers to enhance the mechanical characteristics and the overall wear response of polymer composites. The carbon layer on the outside of the composite exhibited higher ultimate tensile and flexural strengths. The abrasive wear of fabricated hybrid composites is also explored by performing experiments using Box–Behnken design approach. The pin‐on‐disc tester is utilized to do the wear test by varying composite type, sliding distance, and sliding velocity, with specific wear rate (SWR) serving as the response parameter. Regression analysis is performed to predict SWR using control and response parameters derived from experimentation. A novel firefly algorithm technique is adopted to determine the optimal process parameter combination. By utilizing optimized parameters (430 m, 10.5 m/s, and the CKBG4BKC stacking sequence), the SWR is considerably reduced to 16.82 × 10−5 mm3/Nm. Scanning electron microscopy on the worn‐out wear surface reveals enhanced interfacial bonding, fiber breakage and plowing as the fundamental wear mechanism. This work provides insight into hybrid composites for constructing aircraft and automobile body structures, where they provide an optimal blend of strength, sustainability, and structural performance.Highlights Hybrid composite: Stacking sequence impacts on mechanical and abrasive wear. Box–Behnken design: Applied on stacking order, sliding distance and velocity. Utilizing metaheuristic firefly algorithm to enhance specific wear results. Optimal parameters: 430 m, 10.5 m/s, and CKBG4BKC stacking sequence. Lightweight, high‐strength, cost‐effective, and sustainable hybrid composites.
In the industry of Kota stone, a significant amount of waste material is produced at the time of manufacturing. This waste is typically discarded on the local site, which is then carried away by rainwater and air, leading to environmental deterioration. The current study focuses on utilizing the waste i.e. Kota stone dust (KSD) as the filler in the polyester resin for the development of a polymeric composite. Various composite sets with different micro-particulate contents through open moulding technique are prepared and its characterization is reported. The density and void percentage of polyester increase with KSD loading. The hardness and compressive strength increased to 83.7 Shore-D number and 102.7 MPa respectively, at 40 wt. % KSD. A tensile and flexural modulus also increases with KSD loading showing an improvement of 72.8 % and 64.1 % respectively. Contrary to that, the highest tensile and flexural strength was recorded at 25 wt. % and 30 wt. % KSD loading respectively, which is 29.2 % and 28.8 % higher than unfilled polyester. Sliding wear tests were conducted following Taguchi's experimental design. The experiments revealed that the filler content had the most significant impact on the specific rate. The study of surface morphology of the worn surfaces provided an insight into the wear mechanisms of the composites such as craters, cracks, wear debris, and wear track formation at different sliding conditions. The composites' wear response prediction for various test conditions within and beyond the experimental boundary was conducted by successfully implementing a model based on artificial neural networks.
The quarrying and utilization of natural stones such as marble and granite are growing rapidly in developing countries. However, the processing, cutting, sizing, and shaping of these stones to render them functional generates huge quantities of waste and dust. These materials are often disposed of openly in the environment, and their potentially hazardous nature has negative repercussions on both the environment and human health. In this study, marble waste (MW) was used as a filler in the unsaturated polyester resin (UPR) matrix to enhance performance and characteristics while adding value to the waste and minimizing manufacturing costs. For this purpose, samples of UPR/MW composites were produced with 0, 5, 10, 15, and 20 wt.% of MW incorporated into the UPR. A full characterization that focused on the microstructure, thermal stability, and physical and mechanical properties was carried out. The results revealed that the use of 10 to 15% of MW improves mechanical performance, with increases from 17 to 26 kJ/m2, 14 to 17 MPa, and 794 to 1522 GPa in impact strength, tensile strength, and elastic modulus, respectively. By introducing a 20% MW filler, the composite loses its performance, particularly Shore D hardness, and becomes very brittle. Thermogravimetric analysis (TGA) indicated significant thermal stabilization, with a delay in the start decomposition temperature of 28 °C for 20 UPR/MW compared to 0 UPR/MW. Additionally, morphological and microstructural tests, namely, FT-IR, XRD, and SEM analysis, show a microstructural change, including the formation of crystalline phases, enhancing matrix-filler interactions due to the creation of Mg-O and Ca-O chemical bonds and the forming of filler agglomeration at high introduction rates that lead to defects in the microstructure. These results confirmed the mechanical results of the UPR/MW composites.
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