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FABRICATION AND ANALYSIS OF KEVLAR AND FLAX FIBER REINFORCED HYBRID

COMPOSITE MATERIALS ABSTRACT Many of our modern technologies need materials
with combined properties like high strength to weight ratio, high stiffness, high
corrosion resistance, high fatigue strength, high dimensional stability, etc., these can’t be
met by the traditional metal alloys. Composites Formed by Polymeric materials are
reinforced with natural fibers like flax, jute, bamboo, etc.

and usually with synthetic fibers provide advantages of high stiffness and strength to
weight ratio as compared to traditional construction materials, i.e., wood, concrete, and
steel. In this work, a trial has been made to examine the potential utilization of woven
kevlar29 laminate and woven flax laminate reinforced with epoxy and formed a new
hybrid composites with and without Aluminium (Al) filler material by varying with
different proportions such as weight percentage of 2.7%, 5.4%, and 8%.

Specimens are prepared by using hand lay-up technique as per ASTM standards and
also investigated the mechanical properties such as tensile, compression, flexural, charpy
impact, and Brinell’s hardness tests. Results obatined from above tests are very
encouraging due to addition of filler material in natural and synthetic fibre reinforced
hybrid composites.

Properties are increased by increasing aluminium (Al) filler material. INTRODUCTION A

hybrid composite is a material which consists of two or more different types of fibers in
which one type of fiber balance the glitch of another type of fiber. A composite material
is fabricated by combining two or more materials among them one material is the
binding material i.e.,

matrix and the other is the reinforcement material (fiber, Kevlar and whiskers). Natural
fibers (like hemp, sisal, jute, kenaf, flax, etc.) have major advantages, compared to
synthetic fibers, that make them very competitive and highly valuable materials for
composite applications. Availability, mechanical properties, minimum cost, thermal and
acoustical properties, new environmental regulations and sustainability concepts,
together with the high cost of petroleum resources make them an attractive substitute
to synthetic fibers.

Many researchers draw a particular interest to flax fibers because they studied and
noticed their competitiveness and appropriateness for polymeric matrix reinforcement.
Flax fibers can be used in various forms and configurations (such as mats, roving’s,
fabrics, etc.) with a wide variety of fabricating techniques such as film stacking, vacuum
infusion, compression molding, resin transfer molding (RTM) etc. to manufacture
composites.

Most researches mainly focused on flax fiber composites due to its superior mechanical
properties and chemical modifications. It has low density when compared with glass
fiber composites, they have a higher longitudinal stiffness and high specific stiffness. At
present, in recent times, the protection of military and law enforcement personnel from
injury by high-velocity-object impact has given new and tough challenges for
fundamental scientific research since World War II to recent time.

It becomes more important to develop an impact-energy-absorbing material for the

scientific research community. Aramid Fibers(Kevlar), have high tensile strength, high
tensile modulus, toughness and high thermal stability as compared to other organic
fibers. Kevlar fibers were made for reaching the demand for industrial and improved-
technology applications, such as ballistic protection armor, helicopter blades and
sporting goods. The main advantage of composite materials over other traditional
materials are their superior properties, which makes structural designs more versatile.

Shahirul et al. [1] Fabricated a homogenous and hybrid composites by using two
sequences like sandwich-like (SL) and intercalation (IC) sequences. The materials like
woven E-glass with flax, jute and basalt are used for preparation of these composites. By
considering the fiber weight fraction, hybrid laminates are prepared with same ratios
between synthetic and natural fibers in both sequences.
Indentation and impact tests are conducted on those composites which are formed with
two sequences. The obtained results show that compared with IC sequence, SL
sequence of E-glass/basalt and E-glass/flax showed more impact peak force and E-
glass/jute exhibit less impact force. In terms of impact energy, compared with SL
sequence of E-glass/basalt, the IC sequence of E-glass/jute and E-glass/flax showed high
values.

Maheswaran et al. [2] prepared Kevlar/Glass-Epoxy Hybrid Composite and studied the
fracture behaviour both experimentally and also in finite element analysis method. The
tensile test was conducted and also Fracture Toughness was determined experimentally
for along specimen’s fiber direction and across the specimen’s fiber direction. Result
shows that compared with across the fiber direction the cracked specimen is tougher
along the fiber direction.

The same fracture test can be done using FEA software and calculated the Critical Stress
Intensity Factor (KIC) at fracture or failure using displacement extrapolation method for
both directions. The ANSYS result denote that magnitude of the Critical Stress Intensity
Factor (KIC) is effective in along the fiber orientation of the Compact Tension (CT)
specimen.

It has to be found error in estimation of KIC. The magnitude of elastic modulus along
the fiber orientation is 417 Mpa more compared with across the fiber orientation. Ou et
al. [3] used kevlar fibers as reinforcements in Wood-Flour/High-Density-Polyethylene
composites to improve the mechanical properties. For further improvement of these
mechanical properties, kevlar fibers are grafted by small amount (2-3%) of Functional
silane and allyl and used as reinforcements.

Results showed that compared to normal kevlar fibers used as reinforcements in Wood-
Flour/High-Density-Polyethylene composites, Grafted Kevlar Fiber Wood Polymer
Composite (GKFWPC) improve the strength and toughness and also increases the
interfacial compatibility between kevlar fibers and High-Density-Polyethylene which is
evidenced by scanning electron microscopy (SEM), X-ray photoelectron spectroscopy
(XPS) and Fourier transform infrared spectroscopy (FTIR). Foruzanmehr et al.

[4] used modified TiO2 grafted flax fibers to reinforce polylactic acid (PLA) composites.
The oxidation of fibers was carried out to improve the interfacial adhesion of the fibers
to TiO2 film. The TiO2 film is established on the flax fiber by using sol-gel dip-coating
method.
Using microscopy technique, the inter-laminar shear strength was determined to study
quantitatively the interfacial adhesion of fibers to the matrix. The mechanical properties
of the modified TiO2 grafted flax fiber reinforced composites are determined by
performing tensile and impact tests. The results show that there is a significant increase
in the adhesion bonding of the modified fibers to the matrix.

The impact resistance of pure PLA is increased by three times using modified TiO2
grafted flax fibers. Murali et al [5]. In this project, for manufacturing construction helmet,
the natural fibers such as Sisal, Banana and jute reinforced polymer composite material
with epoxy resin were been used. The values of impact strength and compression
strength are identified for further use.

After calculating the material properties of natural fiber reinforced composite using
compressive test and impact test, the hybrid composites showed comparatively superior
performance. Then from the experimental method, the three fibers such as Banana, jute
and Sisal makes a hybrid composite, which possess better strength and reduces half of
the original weight. Hence, it is better to replace the As4 polyphenylene sulphide Plastic
in construction of Helmets as hybrid composite materials. Mursalin et al.

[6] In this paper, studied the flexural properties of the composites fabricated by
reinforcing bagasse, coir and banana fiber of different ratio as the new natural fibers
into epoxy resin matrix. The hybridization of the reinforcement in the composite
material shows almost same strength when compared to particle board used in our
industry but the price is much lower than our natural fibers reinforced composites.

By analyzing the results, the composite which contains 70% Bagasse and 30% coir has
almost same strength, higher density, lower water absorption rate and lower price which
are economically and environmentally very friendly. METHOD OF FABRICATION
Composite components are fabricated by various methods. Many methods were
developed to meet specific design or manufacturing challenges faced with fiber-
reinforced polymers.

Selection of a method for a particular part will depend on the materials, the part design
and end-use or application. The method used to fabricate this hybrid composite
material is hand lay-up method. HAND LAYUP METHOD The earliest and easy method
used for generating reinforced plastic laminates is Hand lay-up technique.
This type technique need few processing steps and also minimum infrastructures.
woven, knitted, stitched or bonded fabrics are the types of fibers used in preparation of
composites. The fibers are placed in the prepared mold and the resin is permeated.
Rollers or brushes are used for impregnation of resin.

Due to this impregnation, the resin is allowed inside the fabrics. This is the simplest
method of laying down fabrics and impregnating with the resin layer by layer until the
desired thickness is obtained. The composites fabricated by this technique are then
allowed for curing under the standard atmospheric conditions(STP).

Usually normal curing time for epoxy based system at room temperature is 24-48 hours.
It requires more time and labor for manufacturing of composite materials but most of
the aerospace composite products are fabricated by this technique in combination with
the autoclave method. Fig.1. hand layup method Advantages: This technique is easy to
use and less tooling cost with the use of resins which are cured at room-temperature.

Different combination of fibers and matrix materials are utilized. Greater fiber contents
and longer fibers are used as compared to other fabrication processes. Applications:
Hand layup technique used for many applications like automotive parts, aircraft
components, boat hulls, deck etc. Generally, materials used for fabrication of the
composite materials through hand layup method are tabulated below.

Materials used _ _Matrix _Epoxy, polyester, polyvinyl ester, phenolic resin, unsaturated
polyester, polyurethane resin _ _Reinforcement _Glass fiber, carbon fiber, aramid fiber
(Kevlar), natural plant fibers (sisal, banana, flax etc.) (the fibers in the form of
unidirectional mat, bidirectional (woven) mat, fabrics, mat of randomly oriented fibers) _
_ Table no. 1.

Type of materials used in hand layup method. TYPES OF MATERIALS USED Matrix used
in this hybrid composite is Epoxy LY556 (Araldite) with combination of Hardener HY951
(Aradur) in 10:1 (E:H) ratio. Two Reinforcements are used in this hybrid composite with
different proportions of filler material. 1.Synthetic Material as woven Kevlar 29 fiber.
2.Natural Plant Fiber as woven Flax fiber. Filler material used in this hybrid composite is
Aluminium powder (al) with various proportions as 1.Al 5 gms 2.Al 10 gms 3.Al 15
gms / / Fig. 2. woven Kevlar 29 fiber Fig. 3. woven flax fiber / / Fig. 4. epoxy ly556 with
hy951 hardener Fig. 5.

aluminium powder (al) Relative Weights of fiber and resin: Resin weight is taken by
considering fiber manufacturing properties. For woven flax fiber, the weight ratio of
fiber and resin is 1:3.5 (fiber: resin). For woven kevlar29 fiber, the weight ratio of fiber
and resin is 1:1 (fiber: resin). Table no. 2. No of layers and weight of each fiber.

Fibers _No of layers of fibers _Weight of the fibers in gms _Weight of the resin in gms
_Desired thickness mm _ _Flax _4 _36 _126 _3 _ _Kevlar _9 _80 _80 _3 _
_Hybrid(flax+kevlar) _3+3 _53 _121 _3 _ _ / Fig. 6. Fabricated hybrid composite materials
with varying different proportions of filler material (Al) Table no. 3. Details and
composition of prepared composites. S.No _Specimen name _Composition of composite
by (wt%) _ _1 _Flax _Flax (22.2%) + Epoxy (77.7%) _ _2 _Kevlar _Kevlar (50%) + Epoxy
(50%) _ _3 _Hybrid(flax+kevlar) _Flax (15.5%) + Kevlar (14.9%) + Epoxy (69.5%) _ _4
_Hybrid with Al 5 gms _Flax (15%) + Kevlar (14.5%) + Epoxy (67.5%) + Al (2.7%) _ _5
_Hybrid with Al 10 gms _Flax (14.6%) + Kevlar (14.1%) + Epoxy (65.7%) + Al (5.4%) _ _6
_Hybrid with Al 15 gms _Flax (14.2%) + Kevlar (13.7%) + Epoxy (64%) + Al (8%) _ _
MECHANICAL TESTING The following tests are to be performed on fabricated hybrid
composite material. 1. Tensile test 2.

Compression test 3. Flexural test 4. Charpy impact test 5. Brinell’s hardness test TENSILE
TEST The dog-bone-shaped tensile specimens with a size of 250×25×3 mm, were
measured using a INSTRON 8801 testing machine according to ASTM D3039 standard
using strain rate 3mm/min and gauge length of mm were used for the test. / Fig. 7.
specimen for tensile test. Table no. 4.

Results from tensile test. S.NO _Specimen label _Maximum load(KN) _Load at break(KN)
_Modulus (E-modulus)(MPa) _Ultimate tensile strength(MPa) _ _1 _Flax _1.73 _1.73 _--
_38.45 _ _2 _Kevlar _18.12 _11.00 _5203.40 _402.65 _ _3 _Hybrid _5.06 _3.11 _4272.16
_112.35 _ _4 _Hybrid with Al 5 gms _4.12 _3.66 _4555.52 _91.58 _ _5 _Hybrid with Al 10
gms _5.02 _3.12 _4749.50 _111.45 _ _6 _Hybrid with Al 15 gms _6.38 _4.74 _4732.09
_141.71 _ _COMPRESSION TEST Rectangular shaped compression specimens with a size
of 140×25×3 mm were measured using a same testing machine in accordance with
ASTM D3410.

/ Fig. 8. Specimen for compression test. Table no. 5. Results from compression test. S.NO
_Specimen label _Maximum load(N) _Modulus(MPa) _compressive strength(MPa) _ _1
_Flax _548.44 _5240.53 _7.31 _ _2 _Kevlar _467.63 _6160.98 _6.24 _ _3 _Hybrid _568.63
_5518.84 _7.58 _ _4 _Hybrid with Al 5 gms _619.69 _5548.60 _8.26 _ _5 _Hybrid with Al 10
gms _735.93 _5719.98 _9.81 _ _6 _Hybrid with Al 15 gms _935.53 _7076.02 _12.47 _
_FLEXURAL TEST Specimens measuring with 125×20×3 mm were measured under three-
point bending using the same mechanical testing machine according to the standard
ASTM D709. / Fig. 9. Specimen for flexural test. Table no. 6. Results from flexural test.
S.NO _Specimen label _Maximum load(N) _Flexural stress at maximum flexural
load(MPa) _Modulus(MPa) _ _1 _Flax _101.01 _70.88 _4483.87 _ _2 _Kevlar _82.49 _57.89
_4816.98 _ _3 _Hybrid _219.97 _154.36 _6465.14 _ _4 _Hybrid with Al 5 gms _200.51
_140.71 _7412.22 _ _5 _Hybrid with Al 10 gms _274.07 _192.33 _7754.62 _ _6 _Hybrid with
Al 15 gms _275.41 _193.27 _7730.81 _ _BRINELL’S HARDNESS TEST Hardness specimens
are measured with Brinell’s hardness testing machine by applying 500 kgf load and
using indenter of 5mm diameter.

/ Fig. 10. Specimen for hardness test. Table no. 7. Results from hardness test. S.NO
_Specimen label _Load applied(N) _Diameter of indenter D=5mm _Average diameter of
indentation d (mm) _Brinelles Hardness Number (BHN) Kg/mm2 _ _1 _Flax _4905 _5 _3.9
_34.04 _ _2 _Kevlar _4905 _5 _3.36 _49.09 _ _3 _Hybrid _4905 _5 _3.73 _38.13 _ _4 _Hybrid
with Al 5 gms _4905 _5 _4 _31.84 _ _5 _Hybrid with Al 10 gms _4905 _5 _3.93 _33.36 _ _6
_Hybrid with Al 15 gms _4905 _5 _3.7 _38.90 _ _ CHARPY IMPACT TEST Impact strength
was determined from specimens measuring 63.5×12.7×3 mm using a notched impact
testing instrument according to ASTM D256.

/ Fig. 11. Specimen for impact test. Table no. 8. Results from impact test. S.NO
_Specimen label _Cross sectional area below the notch (mm2) _Initial energy (J)
_Reading after impact (J) _Error in reading (J) _Actual energy (J) _Toughness J/mm2 _ _1
_Flax _24 _300 _-10 _-6 _284 _11.83 _ _2 _Kevlar _24 _300 _-14 _-6 _280 _11.66 _ _3
_Hybrid _18 _300 _-12 _-6 _282 _15.66 _ _4 _Hybrid with Al 5 gms _18 _300 _-11 _-6 _283
_15.72 _ _5 _Hybrid with Al 10 gms _24 _300 _-13 _-6 _281 _11.70 _ _6 _Hybrid with Al 15
gms _21 _300 _-10 _-6 _284 _11.83 _ _ RESULTS AND DISCUSSION A plot is made
between specimen types and ultimate tensile strength as shown below. / Fig. 12.

Plot between specimen label and Tensile strength. Initially comparing with synthetic
fibers like Kevlar, natural fibers like flax has low tensile strength but combining natural
fibers with synthetic fibers the strength of material increases also the strength is further
increased by adding filler material with different proportions.

A plot is made between specimen types and young’s modulus. It shows that young’s
modulus also increases when both natural and synthetic fibers are reinforced with epoxy
along with filler material. / Fig. 13. Plot between specimen label and young’s modulus. A
plot is made between specimen types and compressive strength as shown below. / Fig.
14.
Plot between specimen label and compressive strength. Initially kevlar has low
compression strength and natural fiber flax has high compression strength compared
with kevlar, by reinforcing these two materials alternatively into epoxy matrix with and
without filler material increases the compression strength of the material.

A plot is made between specimen types and flexural stress shown that bending stress
increases by two times when combining these two natural and synthetic fibers. / Fig. 15.
Plot between specimen label and flexural stress. A plot is made between specimen types
and Brinell’s hardness number. / Fig. 16. Plot between specimen label and hardness
number. From the plot it is evident that Kevlar has high brinell’s hardness number
compared to other composite materials.

A plot is made between specimen types and Toughness. / Fig. 17. Plot between
specimen label and toughness. From the plot it is concluded that hybrid composite
material with 5 gms aluminium filler material has high toughness compared to other
materials. CONCLUSIONS From the above results following conclusions are made: From
this work it is evident that, hybrid composite materials have higher strength as
compared to the natural composite materials. Hybrid composite materials are more
economical as compared to the synthetic fiber reinforced composite materials.

The properties of the natural fibers can be improved by combining with synthetic fibers.
It also reduces the cost. The properties of these hybrid composite materials are further
improved by addition of optimal proportion of filler material. REFERENCES Muhamad
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