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of multi-layered jute fabric-reinforced DOI: 10.1177/0021998319885440
journals.sagepub.com/home/jcm
HDPE composites

Abu Sadat Muhammad Sayem1,2 , Julfikar Haider2,3


and MM Alamgir Sayeed4

Abstract
The bast fibres, a subgroup of natural fibre family, have emerged as a strong competitor of widely used man-made glass
fibre for use as fillers or reinforcing materials in certain types of composite materials, which do not require very high
mechanical resistance. This paper investigates the manufacturing of multi-layered jute fabric-reinforced thermoplastic
composite and its mechanical performance. Hessian jute fabrics in two, four and six layers without any pre-treatment
were sandwiched in 0 orientation into seven layers of high-density polyethylene sheets and pressed at high temperature
and pressure to form composite laminates having three different structural designs. The laminates with two, four and six
layers contain approximately 6.70 wt%, 12.90 wt% and 18.50 wt% of jute fibres, respectively. Mechanical performance of
the composite laminates having four and six layers of jute fabric was found to have improved significantly when compared
to the pure high-density polyethylene laminates. Within a given sample thickness of 6.5 mm, the laminate with six layers
of jute fabric exhibited the best mechanical performance. Optical microscopic analysis revealed that the yarn orientation
of the fabrics within the composites remained stable, and there was no visible void in the laminate structure. Fracture
morphology of the composite investigated by a scanning electron microscope showed good adhesion of the jute fabrics
with the high-density polyethylene matrix.

Keywords
Natural fibre, jute, woven fabric, high-density polyethylene, composite, laminate, tensile strength, flexural strength

approximately 0.5–0.7 tonnes of CO2-equiv, whereas


Introduction it is 1.7–2.2 tonnes CO2-eq per 1 tonne of glass
Natural bast fibre in composites and associated fibres.3 Plant-based natural fibres can be classified as
seed, bast and leaf fibres according to the locations of
environmental benefits their availability in plants.4 Those come from the stem
Fibre-reinforced polymer composite materials have of plants are known as bast fibres. Jute, flax, hemp,
found extensive industrial and household applications kenaf and rammie are the common bast fibres grown
in the areas where monolithic materials were employed and processed for different textile applications. Jute is
traditionally.1 This is now a multimillion-dollar market the most grown bast fibre in the world and considered
globally and around 95% of it is shared by the glass
fibre-reinforced composite (GFRC).2 However, some 1
Fashion Institute, Manchester Metropolitan University, UK
natural fibres, due to their advantages over glass fibre 2
Advanced Materials and Surface Engineering Research Centre,
such as low price, low environmental impact and low Manchester Metropolitan University, UK
3
embodied energy, have emerged as an alternative to the Department of Engineering, Manchester Metropolitan University, UK
4
glass fibre in polymer composite. Fibre bearing plants Textile Physics Division, Bangladesh Jute Research Institute, Bangladesh
release oxygen to the atmosphere and absorb carbon
Corresponding author:
dioxide in contrast to the glass fibre, which therefore Abu Sadat Muhammad Sayem, Manchester Metropolitan University,
has a relatively high carbon footprint. For example, Cavendish Street, Manchester M15 6BG, UK.
carbon footprint of 1 tonne of natural fibres is Email: asm.sayem@mmu.ac.uk
2 Journal of Composite Materials 0(0)

as the second most important natural fibre after head rest, door trim panel and sub-floor covering,
cotton.5 Jute is cultivated and processed as fibre at etc.10 NFRC applications in construction include deck-
large scale in Bangladesh, India and China mainly ing, railing, outdoor furniture, picnic table, garden
during the monsoon season, as it is a rain fed crop benches, pallet, boards, NFRC rods, panels, tubes and
and grows in standing water. Two species of jute I-beams; in sport and leisure sector, these include snow-
plants are commonly cultivated: Corchorus capsularis boards, canoe, surfboard, bike frames, etc.; in consumer
(white jute) and Corchorus olitorius (tossa or dark products, they include indoor furniture components,
jute).6,7 Like many other natural fibres such as flax, tableware, handles, electric goods, rigid packaging,
hemp, ramie, sisal and cotton, the chemical constitution plant pots and mobile phone components, etc.2,5
of jute fibre is dominated by cellulose (over Jute-reinforced composite has potential applications
61%–71.5%).8 However, its chemical composition is in window and doorframes, indoor furniture panels,
specially characterised by the presence of hemicellulose automotive panels and upholstery, parcel shelves and
(13.6%–20.4%) and exceptionally high content of noise insulating panels, etc.11 An example of the appli-
lignin (12%–13%). Therefore, jute is also identified as cation jute-based thermoplastic composite is the auto-
a lignocellulosic fibre. Although tensile strength of the motive door panels produced and commercialised by
jute fibre is lower than that of glass fibre, their density is German automaker Mercedes-Benz in the 1990s.7,11
approximately the half, therefore the specific modulus A very interesting finding by Monteiro et al.12 shows
is higher and tensile modulus is roughly similar to the that the use of jute fabrics-reinforced polyester compos-
glass fibre.5,8 From the sustainability point of view, jute ites (see Table 1) an inner layer between ceramic and alu-
production through plantation can bring a number minium alloy in a multi-layered armour system exhibited
of environment benefits. One hectare of jute plants similar ballistic performance to that of much stronger
consumes about 15 metric tonnes of CO2 and liberates Kevlar (an aramid fabric) laminate. This opens up the
11 metric tonnes of O2 in only 120 days.9 Greenhouse application of jute composite in the construction of mili-
gas emission from cultivation, harvesting and process- tary vehicle and protective warfare structures.
ing of jute fibre is lower than that of flax and hemp
fibres.3 Jute is a naturally adapted and well-resistant Comparative analysis of contemporary research
plant; usually use of any chemical fertiliser and pesti-
works on jute fabric-reinforced composites
cide is also very low in comparison to flax and hemp
cultivation, and most of the times no such chemicals are Textile materials are available in different forms, such
required at all. Moreover, jute plants contribute around as short fibre, long fibre, sliver (a untwisted linier struc-
5.43 million tons of dry leaves per year to the soil ture of fibres before converting into yarn), yarn, woven
during defoliation process prior to retting in water. and knitted fabrics and non-woven sheet.4 In contem-
This leaves through natural decomposition enrich soil porary research works, jute has been utilised in all the
quality by an equivalent amount of fertiliser providing forms of fibre,13,14 sliver,15 yarn,16,17 woven fabric,18,19
nutrients of 168,750 tonnes of nitrogen, 56,250 tonnes knitted fabric19 and non-woven sheets20,21 to fabricate
of phosphorous and 150,000 tonnes of potassium.9 This jute-reinforced composite materials using either
is a tremendous contribution for the next crop (usually thermoplastic21 or thermoset polymeric matrices.13,15,17
food grains rice or wheat) grown during immediate next However, a very limited number of works focussed on
dry season. Furthermore, jute sticks are used as struc- jute fabric-reinforced layered composite materials (see
tural material and an important biomass for clean Table 1). Haydaruzzaman Khan et al.22 treated
energy production through burning in the rural areas. bleached fabric of tossa jute (C. olitorius) with a solu-
tion of 50%–90% oligomer urethane acrylate and 2%
photo initiator in methanol and irradiated under ultra-
Natural fibre-reinforced composites
violet (UV) light for 24 h before heat pressing five layers
Natural fibre-reinforced composite (NFRC) materials of treated fabrics to form composite laminate. They
are gaining popularity for different applications in identified the best mechanical properties from the com-
automotive, construction, sports and leisure and con- posite that was made from jute fabrics treated with
sumer products, particularly where stiffness and low 70% of oligomer, 28% methanol and 2% photo initi-
weight are more important than mechanical strength.5 ator followed by UV radiation. Kafi et al.23 prepared
NFRC has 20%–50% lower carbon footprint compared multi-layered jute–polyester composite after atmos-
to GFRC.3 Thermoplastic NFRC panels used in auto- pheric plasma treatment of jute fabrics and found
motive components include wheel arch, bumper, engine improvements in flexural strength and modulus and
shield, bonnet insulation, centre console trim, various inter-laminar shear stress. Khan et al.24 prepared com-
damping and insulation parts, roof liner, C-pillar trim, posite by compression moulding of four layers of hes-
rear parcel shelf, rear hatch, boot base, seat support, sian fabrics within five layers of polyvinyl chloride and
Table 1. Contemporary research on jute fabric-reinforced composite fabrication.

Jute fabric
Sayem et al.

Number of
Fibre Fabric Fabric Raw fabric jute fabric Composite
type design structure quality Pre-treatment Matrix layer type Method Reference

Tossa Likely wovena nm Bleached Monomer methyl Urethane acrylate oligomer 5 Thermoset UV curing Haydaruzzaman
methacrylate þ 2% photo initiator þ heat press Khan et al.22
in methanol
nm Woven nm Unbleached Atmospheric Polyester resin 12 Thermoset Vacuum Kafi et al.23
plasma (He/Ac/N) bagging þ curing
nm Woven Hessian Bleached Hexanediol diacrylate Urethane acrylate oligomer 5 Thermoset UV curing Zaman et al.26
(plain weave) þ heat press
nm Woven Plain weave nm Alkali Vinylester resin, 4 Thermoset Compression Sudha and
catalyst and accelerator moulding Thilagavathi18
þ curing
Tossa Likely wovena nm Bleached 2-hydroxyethyl Polypropylene 4 Thermoplastic Heat press Haydaruzzaman
methacrylate Khan et al.30
and starch
Tossa Woven Hessian Unbleached n/a Polyvinyl chloride 4 Thermoplastic Heat press Khan et al.24
(plain weave)
nm nm nm nm Alkali and High-density polyethylene 1 Thermoplastic Heat press Seki et al.25
oligomer siloxane
nm Woven nm nm n/a Polypropylene 2 Thermoplastic Heat press Berhanu et al.27
nm Woven Plain weave nm n/a Poly (L-lactic acid) 1 Thermoplastic Heat press Khan et al.28
(52  44)
nm Woven and Plain, twill, nm n/a Polypropylene 1 Thermoplastic Heat press Arju et al.19
knitted single jersey
and rib
nm Woven Plain nm n/a Bisphenol A epoxy 1 Thermoset Pultrusion El Messiry
þ polyamide triethylene and El Deeb29
tetramine
nm Woven Plain nm n/a Orthophthalic polyester 3,6,9 Thermoset Curing Monteiro et al.11
resin þ 1 wt% methyl þ heat press
ethyl ketone
Note: nm: not mentioned; n/a: not applicable; UV: ultraviolet.
a
Although not mentioned, it appeared to be woven fabric from discussion.
3
4 Journal of Composite Materials 0(0)

found the composite containing 40 wt% fibre showed the jute fabrics and HDPE. However, it offers economic
best performance. An increase in tensile, flexural and advantages due to lower price than polypropylene.
inter-laminar shearing strength was observed by Seki As HDPE is mechanically less strong than the com-
et al.25 in composite made from alkali and oligomer monly used other polymers such as polypropylene,
siloxane-treated single layer of jute fabric compression any improvement of HDPE by reinforcing with natural
moulded into two layers of high-density polyethylene fibres will be significantly advantageous from structural
(HDPE). Zaman et al.26 varied the concentration of application point of view. This paper aims to develop
urethane acrylate oligomer including photo initiator for multi-layered HDPE composite laminates reinforced
pre-treating bleached hessian fabric and UV radiated for with hessian jute fabrics and to investigate its mechan-
24 h for preparing thermoset laminate from five layers of ical properties and interfacial characteristics. Laminate
treated jute fabrics through compression moulding. They composites were prepared by varying the number of
found best results from 70% oligomer-treated fabrics. jute fabric layers within a nominal laminate thickness
Berhanu et al.27 sandwiched two layers of jute fabrics of 6.5 mm.
between three layers of polypropylene sheets and made
thermoplastic composites by hot pressing. They reported
significant enhancement of mechanical properties of jute- Materials and experimental method
reinforced composites with the increase of fibre content
up to 40% (in weight). Sudha and Thilagavathi18
Raw materials
reported a jute–vinylester composite material by com- Figure 1 presents a general flowchart of jute fabric
pression moulding of four layers of alkali-treated jute manufacturing. A 100% hessian fabric (Figure 1(d))
fabrics (16 ends per inch (EPI) and 13 picks per inch made of tossa jute collected from Janata Jute Mills
(PPI); 430 gram per square metre (GSM)) impregnated Ltd. in Bangladesh was used as a filler material
with a solution of vinylester resin, catalyst and acceler- for manufacturing laminated polymer composites.
ator. Arju et al.19 prepared jute-reinforced polypropylene The specification of the jute fabric has been evaluated
composites from single layer of plain (1/1, EPI 10-12 and through visual inspection and relevant tests presented
PPI 10-12) and twill (2/1, EPI 18-20 and PPI 9-10) fabric in Table 2. Structure of the jute fabric (number of yarns
structures separately sandwiched between two layers of in 100 mm) and weight (GSM) were determined follow-
polypropylene sheets and found that the composites ing the standards BS EN 1049-2:199431 and BS
having twill structured fabric displayed higher tensile 2471:200532, respectively. The breaking force and
strength than the composites with the plain fabrics. elongation of the fabric (three specimens in warp and
Khan et al.28 discussed an ecofriendly bio-composite three specimens in weft direction having 50 mm width
made by compression moulding of single layer of jute in each case) were analysed following the test standard
fabrics sandwiched between poly (L-lactic acid) films. BS EN ISO 13934-1:199933 and using ‘Testometric
El Messiry and El Deeb29 prepared single layers compos- Micro 500’ (UK) testing machine. Fibre orientation
ite laminate from jute fabric pultruded with different within the jute fabric was investigated using an optical
combination of resin/solvent ratios. They found that microscope. HDPE sheets with a thickness of 1 mm
mechanical properties of composite can be engineered were purchased from Direct Plastics Ltd, Sheffield,
with the variation of resin/solvent blend ratio without UK and the general specification of the sheet is given
changing fibre volume fraction. It should be noted in Table 3.
that quality and performance of jute-based substance
may significantly vary between the species (i.e. tossa
and white), raw fabric condition (i.e. bleached and
Composite fabrication
unbleached) and fabric construction (i.e. weave design Jute fabrics were cut into square pieces of
and yarn density). Table 1 shows that the reproducibility 175 mm  175 mm dimension and then placed in an
of these works is very much limited as all of them except oven at 105  C35 for 40 min to remove moisture.
Khan et al.,24 did not mention any of the vital informa- HDPE sheets were also cut into the same dimensions
tion about fibre type, fabric structure and raw fabric to form the laminate plate with alternate layer of jute
condition. Therefore, it is challenging to compare the and HDPE. Three different types of composite lamin-
results of various studies available in the literature. ates were fabricated using two, three and six jute layers
along with one laminate of pure HDPE. Figure 2 shows
Statement of research gap, research rationale and the layup sequence of multi-layered jute fabrics stacked
at 0  orientation along the warp (i.e. lengthwise) direc-
aim of this paper
tion between a total seven layers of HDPE sheets in
Current literature shows that no work was previously order to maintain a constant thickness in all compos-
carried out on developing multi-layered laminate with ites. For two-layer design, three HDPE sheets were
Sayem et al. 5

Figure 1. (a) Jute plant, (b) jute fibre after retting and drying, (c) jute yarns after spinning and (d) jute fabric – hessian structure (inset
plain weave design) used in this research.

Table 2. Specification of jute fabrics.


HDPE sheet
L2
Parameters Value Unit Test standards Composite Jute Fabric

Weave 1/1 – BS EN 1049-2:199431


design (plain)
HDPE sheet
Warp 39 Ends per
100 mm L4
Composite Jute Fabric
Weft 35 Picks per
100 mm
Weight 209 g/m2 (GSM) BS 2471:200532
HDPE sheet
GSM: gram per square metre.
L6
Composite Jute Fabric

34
Table 3. Specification of high-density polyethylene sheet.

Parameters Value Unit


Figure 2. Schematic diagrams of the layup sequence of multi-
Colour Natural – layered HDPE–jute composites. HDPE: high-density
Density 0.947 g/cm3 polyethylene.
Tensile strength at yield 25 MPa
Hardness 64 Shore D
 four jute fabrics were in the middle separated by three
Crystalline melting point 130 C
HDPE sheets. For six-layer design, fabrics and HDPE
sheets are placed alternately having HDPE at the both
placed at both top and bottom and two jute fabrics outer ends.
were positioned in the middle separated by one Dry jute fabrics taken out from the oven were first
HDPE sheet. Similarly, for the four-layer design, two weighed, immediately stacked in between the HDPE
HDPE sheets were placed at both top and bottom and layers according to the designs by hand layup technique
6 Journal of Composite Materials 0(0)

(see Figure 2) and placed in a steel die of 177 mm 


Mechanical testing
177 mm  6.5 mm to minimise absorption of moisture Tensile tests of HDPE-jute and HDPE-only specimens
by the jute fabrics from the laboratory environment. were carried out on Hounsfield H10 KS Tensometer,
The jute fabrics were carefully stacked with the same UK testing machine equipped with a 10,000 N load cell,
orientation. Furthermore, the stacked materials in the according to ASTM D3039.36 The cross-head speed used
die were placed between two steel plates and compres- for the tensile specimens was 50 mm/min. System control
sion moulded in a hot press (Bradley & Turton Ltd., and data analysis were performed using Qmat 5 software
Kidderminster, UK) as shown in Figure 3(a) at 195  C system. Specimens with a nominal dimension of 177 mm 
for 20 min under a pressure of 12.4 MPa. Heat-resistant 20 mm  6.5 mm (length  width  thickness) for each
Teflon sheets were placed between the staked structure type of composite laminates were tested. However, the
and steel plates for easy release after hot pressing. Then dimensions of individual test samples were measured
the composite laminate with the die was cooled to room during every test and entered into the software for the
temperature using another water-cooled press under a accurate measurement of strength. The tensile tests of
pressure of 3.10 MPa for 10 min (Francis Shaw & Co., the composite samples were conducted along the warp
Manchester, UK). Finally, the laminate was taken out direction of the jute fabric as tensile loading in that direc-
from the die (Figure 3(b)), weighed for weight fraction tion generally shows higher strength owing to the higher
calculation and cut in warp direction by a vertical yarn density resulting in higher resistance to crack propa-
bandsaw machine for preparing specimen for mechan- gation.28,37 Tensile stress (s) and strain () were calculated
ical testing. The specimens were deburred and polished from the test data using equation (2) and equation (3).
in a grinding machine to remove any stress rising
points. Pure HDPE laminate of same dimensions was F
¼ ð2Þ
also prepared following the same procedure for the pur- bd
pose of comparison. Jute fabric weight fractions in the
laminates were calculated from difference between the L
¼ ð3Þ
laminate and fabric weights using the following for- Lo
mula (equation (1)).28
where F is the applied tensile load (N), b is the specimen
wj width (mm), d is the specimen thickness (mm), Lo is the
Wf ¼ ð1Þ
wp þ wj specimen length (mm) and L is amount of extension.
Young’s modulus was calculated from the initial slope
where Wf, wj and wp are the weight fractions of jute of the stress–strain curve using equation (4).
fabric in the polymer composite, weight of jute fabric
and weight of HDPE polymer matrix, respectively. It 
E¼ ð4Þ
was found that the laminates with two (L2 composite), 
four (L4 composite) and six (L6 composite) jute layers
contain approximately 6.70 wt%, 12.90 wt% and The flexural strength and tangent modulus of
18.50 wt% of jute fibres, respectively. elasticity of the HDPE–jute composites and HDPE

(a) (b)

Die
Composite
plate

HDPE
plate

Figure 3. (a) Hot press for compression moulding and (b) prepared composite and HDPE plates with die. HDPE: high-density
polyethylene.
Sayem et al. 7

plate were measured using a three-point bending test Results and discussions
according to ASTM D790-0238 in the same machine
(Hounsfield H10 KS Tensometer, UK). The tests were
Characteristics of jute fabric
carried out with a span-to-depth ratio of 16:1 and at a From the specification of the jute fabric used in this
cross-head speed of 5 mm/min. The flexural strength work, it was clear that the number of yarns in warp
( f) and modulus (Ef) were calculated using equation direction was more than that in the weft direction.
(5) and equation (6), respectively. Although the weave design (1/1 – plain) was visible in
the naked eye, the optical microscopic view clearly
3Ff L shows the fibre bundles in individual yarns (Figure 5).
f ¼ ð5Þ
2bd2 Some degree of non-uniformity in the diameter of the
yarn and gap between the yarns were also observed.
mL3 It is clear from the breaking force test results presented
Ef ¼ ð6Þ
4bd3 in Table 4 that average breaking force is approximately
31% higher in the warp direction compared to the
where Ff is the applied flexural load (N), L is the span strength in the weft direction. The results agree with
length (mm) and m is the slope of the initial straight- the values mentioned in the literature.39 On the other
line portion of the load-deflection curve. The number of hand, average breaking extension exceeds by 13 mm in
samples tested for each type of specimen ranges the warp direction. Therefore, the tensile strength tests
between three and four. Figure 4 presents the tensile of the composites were confined to mainly in the warp
and flexural test set-ups. direction. Even though jute fibre has high strength, its
failure mode was observed as brittle fracture.39
Furthermore, the fibres broke only by small extension
Microscopic observation ranging from 5.9% to 6.7% indicating low elastic
The top view and side view of the composite sam- property.
ples were observed in an optical microscope to check
the jute yarn orientation and layer positions within the
composites. The cut and fracture surfaces of the
Physical characteristics of composite
HDPE–jute composites were also observed under a Figure 6 presents the top view of jute-reinforced HDPE
scanning electron microscope (SEM) to analyse adhe- composite laminate. Yarn orientation of the jute fabrics
sion and interfacial characteristics between the jute and space between yarns remained unchanged in the
fabric and HDPE matrix. An SEM of model JSM- prepared composite as compared to the jute fabric.
5600LV from JEOL Ltd was used at an accelerating However, in some cases, the fabric in the bottom side
voltage equal to 20 kV in secondary electron mode. of the laminate was slightly stretched in the middle and

(a) (b)

Loading head

Specimen

Specimen

Figure 4. Experimental arrangements for (a) tensile and (b) flexural tests.
8 Journal of Composite Materials 0(0)

Figure 5. Magnified views of (a) jute fabric and (b) jute fibres.

Table 4. Tensile properties of jute fabric.

Parameters Value Unit Test standard

Average breaking force (warp) 432.9  72.52 Newton BS EN ISO 13934-1:199933


Average breaking force (weft) 330.9  15.21 Newton
Average breaking extension (warp) 13.31  2.59 mm
Average breaking extension (weft) 11.81  1.83 mm
%Average breaking extension (warp) 6.7  1.29 %
%Average breaking extension (weft) 5.9  0.91 %

Figure 6. Top surface views of HDPE–jute composite under an optical microscope.

compressed near the edge possibly due to small move- present in the matrix or at the interface between yarn
ment between the die and compression plates while and matrix across the thickness of the samples even at
applying the pressure in the moulding machine. high magnification and the layers were completely
The polished cross-sectional view of the specimen immersed within the matrix, which are an indication
revealed that the layers of the jute fabrics were of good quality composite. The magnified view of a
also evenly spaced in the HDPE matrix even after yarn (Figure 7(b)) shows that it was flattened in the
high-compression moulding process (Figure 7(a)). matrix due to the high moulding pressure and the poly-
This ensured complete wetting between the layers by mer material flowed into the yarn. At this magnifica-
the matrix material in order to reduce the chances of tion, the extent of polymer flown around the fibres in
interfacial adhesive failure might occur particularly the yarn was not very clear. However, further higher
under tensile loading condition. No visible voids were magnified view revealed that even at this higher
Sayem et al. 9

(a) (b)

F
Fabric layer 1
F
Fabric layer 2
Fabric layer 3
F
Fabric layer 4
F
Fabric layer 5

F
Fabric layer 6 Yarn Fibres

Figure 7. Cross-sectional view of jute–HDPE composite: (a) individual fabric layers in the matrix under an optical microscope and
(b) a yarn with fibres under an SEM.

Therefore, six layers in the laminate have been con-


sidered as the optimum number of layers for the die
HDPE
E used in this work. The measurement of sample thick-
No Gap ness clearly indicated that they were thinner than the
Fibre
Gap die thickness by approximately 0.3 mm. This could be
due to shrinkage of HDPE material during cooling
phase. Periodic waviness was also found on the surface
of the laminate plate possibly due to the same reason.

Mechanical properties of composite


Table 5 presents the results from the mechanical
tests and corresponding improvements. They will be
discussed in the following sub-sections.

Tensile strength tests. Figure 9 presents typical tensile


Figure 8. Cross-sectional view of jute yarn in HDPE matrix stress–strain curves for pure HDPE and jute fabric-
showing gaps between fibres and matrix. HDPE: high-density reinforced layered composites. There was a clear
polyethylene. pattern of step change in slopes of the curves for the
composites indicating a transition from linear (initial
pressure the melt polymer could not wet all fibres uni- portion of the curves) to non-linear material behaviour
formly in the yarn, which left some degree of voids before the maximum load as a result of initial crack
between the fibres as shown in Figure 8. These voids development within the matrix followed by progressive
could act as sites for crack propagation under the appli- fibre pull-out or fibre failure.28,37 As the fibre content
cation of load on the composites. was increased in the composites, the tensile strength
Through this study, it has been established that with increased. This could be explained by the fact that
the current die thickness, maximum six layers can be woven jute fabrics in the HDPE matrix increased
accommodated in order to maintain a layered struc- load-carrying capacity of the composites.40 However,
ture with clear separation between the jute layers by not much difference in the strengths between L2 and
HDPE material. Initial tests showed that beyond six L4 composites was noticed. This could be due to struc-
layers within the given die thickness, it was difficult to tural distortion of the fabric or non-uniform arrange-
maintain the jute layer separation within the matrix. ment within the composite thickness. The failure of the
The separation jute layers within the matrix could composites with increasing fibre content in comparison
create strong interfacial bonding through matrix fibre to the pure HDPE can be characterised as ductile to
interpenetration and mechanical interlocking,39 which progressively brittle with lower strain rate. This behav-
could be a critical factor for the mechanical perform- iour is also demonstrated in Figure 10, where the exten-
ance of the composites particularly under tensile load- sions at peak forces are gradually decreasing with the
ing condition. Furthermore, with more than six jute increase of the jute fibre content in the composites.
layers in the composite an uncontrolled relative move- In fibre-reinforced polymer matrix, the tensile
ment distorted the layered structure leading to an strength is dependent on the interfacial bonding
inconsistent and poor quality of layered composite. between the matrix and the fibres. Therefore, a strong
10 Journal of Composite Materials 0(0)

Table 5. Results from the mechanical tests and corresponding relative improvements in the composites with respect to the pure
polymer material.

Tensile Improvement Young’s Improvement Flexural Improvement Flexural Improvement


strength in tensile modulus in Young’s strength in flexural modulus in flexural
Specimens (MPa) strength (%) (GPa) modulus (%) (MPa) strength (%) (GPa) modulus (%)

HDPE 22.39 – 1.538 – 24.84 – 1164.67 –


L2 composites 26.64 19.01 1.591 3.48 24.64 – 1177.50 1.10
L4 composites 26.71 19.30 2.141 39.20 29.21 17.58 1499.00 28.71
L6 composites 36.37 62.47 2.659 72.93 38.73 55.88 2503.67 114.97
HDPE: high-density polyethylene.

40 40 Avg. Samplee size: 177.0 mm × 19.19 mm × 5.75 mm


Avg. Sample size: 177.0 mm × 19.19 mm × 5.75 mm
Materials: Pure HDPE and jute + HDPE layered Materials: Pu
ure HDPE and Laayered jute + HDP
PE composite
35 composites Load range: 10,000 N
Load range: 10,000 N
35 Extension ran
nge: 500 mm
L6 Composite

Tensile Strength (MPa)


Extension range: 500 mm Load rate: 50
0 mm/min
30
Tensile strength (MPa)

Load rate: 50 mm/min


30
25
25
20
20
15
15
10
10
5 L2 Composite HDPE
L4 Composite 5
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0
Strain HDPE L2 Compositee L4 Com
mposite L6
6 Composite

Figure 9. Tensile stress–strain curves for HDPE and different Figure 11. Tensile strength of pure HDPE and layered HDPE–
HDPE–jute composites. HDPE: high-density polyethylene. jute composites in warp direction. HDPE: high-density
polyethylene.

higher fibre concentration and better fibre wetting in


18
Ex
xtension Peak Fo
orce
4.5
the matrix.41 Figures 11 and 12 present the tensile prop-
16
erties of pure HDPE and the composite materials. The
4.0
results clearly indicated that in general all layered com-
Extension at peak force (mm)

14 3.5
posites possessed higher tensile strengths than the pure
12
Peak force (kN)

3.0 HDPE sample.


10 2.5 The tensile strength of the HDPE laminate with
8 2.0 similar dimension of HDPE–jute composite was
6 1.5 tested as 22.23 MPa, whereas the tensile strengths of
4 1.0
four-layer jute-HDPE (with 12.9 wt% of jute) and six-
2
layer HDPE-jute (with 18.50 wt% of jute) were found
0.5
as 26.71 MPa and 36.37 MPa, respectively, which was
0 0.0
HDPE
E L2 com
mposite L4
4 compositee L6 composite
much higher than the findings of Arju et al.19 and Seki
et al.25 A maximum strength improvement by approxi-
Figure 10. Extensions at peak forces for HDPE and HDPE–jute mately 62% was achieved with the composite contain-
composites during tensile testing. HDPE: high-density ing six layers of jute fabrics (L6 composite). A tensile
polyethylene. strength improvement of 19% was realised with two-
layer composite. An improvement in Young’s modulus
interface, minimum stress concentration and appropri- by approximately 39% and 73% was achieved with the
ate fibre orientation are essential to obtain the required composite containing four layers (L4 composite) and
strength. On the other hand, stiffness defined by the six layers of jute fabrics (L6 composite). In addition,
Young’s modulus can be obtained with favourable no significant improvement in Young’s modulus was
fibre characteristics such as high fibre aspect ratio, seen in L2 composite from pure HDPE laminate.
Sayem et al. 11

3.000 45
Avg. Samplle size: 177.0 mm
m × 19.19 mm × 5.75
5 mm
Materials: Pure
P HDPE and Layered
L jute + HD
DPE composite
Load range:: 10,000 N 40
Extension range: 500 mm L6 Composite
2.500 Load rate: 50
5 mm/min
35

Flexural stress (MPa)


Young's Modulus (GPa)

30 L4 Composite
2.000
25
1.500
20 HDPE
Avg. Sample size: 117.0 mm×19.30 mm×5.71 mm
15 Materials: Pure HDPE and Layered jute + HDPE
1.000 composite
Test: Three point flexural
10 Load range: 500 N
Extension range: 50 mm
0.500 5 L2 Composite Load rate: 5 mm/min
Pre-load: 0.05 N
Span length: 96 mm
0
0.000 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
HD
DPE L2
2 Compositte L4 Com
mposite L6 Composiite
Flexural strain

Figure 12. Comparison of Young’s moduli of pure HDPE and Figure 13. Flexural stress–strain curves for HDPE and differ-
layered HDPE–jute composites. HDPE: high-density ent HDPE–jute composites. HDPE: high-density polyethylene.
polyethylene.

This could be due to several reasons such as non-uni-


45
form jute layer distribution in the matrix and uneven Avg. Sample sizze: 177.0 mm×19.30 mm×5.71 mm
Materials: Pure HDPE and Layerred jute + HDPE
m

yarn density in fabric structures, which is quite 40 composite


Test: Three poinnt flexural
Load range: 5000N
common as the hessian fabric primarily made for low 35 Extension rangee: 50 mm
Flexural strength (MPa)

Load rate: 5 mmm/min


end bag and sacking application, where strict quality 30
Pre-load: 0.05 N
Span length: 96 mm
control process is not followed to keep the price as low
25
as possible. Furthermore, a minimum critical weight
fraction of jute is required to realise obvious improve- 20
ment in the composite stiffness. In this case, it seemed 15
that four jute fabric layers or 12.90 wt% would be the 10
critical fibre weight fraction in the composite.
5
Arju et al.19 reported tensile strength and modulus of
20.30 MPa and 1.25 GPa, respectively, for single layer 0
HDPE
E L2 C
Composite L4 Composite L6
6 Compositte
jute fabric-reinforced polypropylene composite having
55% weight fraction of jute fibre, whereas Seki et al.25 Figure 14. Comparison of flexural strength of pure HDPE and
identified tensile strength and modulus of 21.2 MPa and layered HDPE–jute composites. HDPE: high-density
1.21 GPa, respectively, in untreated single layer jute polyethylene.
fabric-reinforced HDPE composite having 20%
weight fraction of jute fibre without specifying the In general, all the specimens showed a non-linear
details of the fabric structure used. After treating jute stress–strain behaviour typical of layered composite
fabric with oligomeric siloxane solution, the tensile material. The crack started to form on the outer side
strength of the HDPE–jute composite could be of the sample subjected to tensile stress and slowly
improved up to 29.1 MPa and the modulus up to propagates across the sample thickness. It is very
1.47 GPa due to the increased adhesion between jute clear from the figure that flexural strengths of the com-
fibre and HDPE matrix. The findings from the current posites are higher than that of pure HDPE and with the
work show that layered jute fabrics within HDPE increase of fibre weight content, the flexural strength
matrix can provide higher tensile strength (36.37 MPa) increases as indicated by the rising change in slope of
and Young’s modulus (3.60 GPa) without any chemical the curves. At the peak compressive loading, no break-
treatment on jute fabrics. It should be noted that the ing of the composite samples was observed. Flexural
results cannot be directly compared with the literature properties of HDPE laminate and HDPE–jute compos-
even though the matrix and fibre content are similar as ites are compared in Figures 14 and 15. Average flex-
the composite construction and fabric processing/treat- ural strength and modulus of pure HDPE laminate
ment are different. were tested as 24.84 MPa and 1.165 GPa, respectively,
whereas the values of four-layer HDPE–jute composite
Flexural strength tests. Flexural stress–strain curves for were found as 29.21 MPa and 1.49 GPa, respectively.
different layered composites with varying weight per- This means that an increase in flexural strength
centages of jute fibre are presented in Figure 13. and modulus by 17.58% and 28.71%, respectively,
12 Journal of Composite Materials 0(0)

is achieved with four-layer composite when compared no significant difference in flexural modulus was found
to the pure HDPE laminate. Further increase in flexural between two-layer composites and pure HDPE. This
strength and modulus by 55.88% and 114.97%, could indicate that in order to achieve a noticeable
respectively, was found in six-layer HDPE–jute com- improvement of flexural strength with a force applied
posite in comparison to the pure HDPE laminate. in the lateral direction, a minimum critical weight frac-
Seki et al.25 achieved flexural strength of 31.4 MPa tion of jute is essential. On the other hand, a small
and modulus of 0.84 GPa with single layer untreated weight percentage jute can make noticeable improve-
jute fabric-reinforced HDPE composite having 20% ment in the tensile properties under a force in the lon-
weight fraction of jute fibre; and with oligomeric silox- gitudinal direction.
ane treatment of jute, the values went up to around
46.8 MPa and 1.67 GPa, respectively. In this case, for
Interfacial surface morphology
six-layer HDPE–jute composites with 18.5 wt% jute,
the values of flexural strength and modulus were In general, three parameters are responsible for the per-
38.73 MPa and 2.504 GPa, respectively. This indicated formance and properties of fibre-reinforced polymer
that even without any fibre treatment, a significant composites: properties of fibre, properties of matrix
improvement in flexural strength and modulus can be and the interfacial characteristics between the matrix
achieved with more fabric layers in HDPE. However, and the fibre. Good interfacial adhesion through chem-
ical and mechanical interlocking between the matrix
and the fibre with high degree of fibre wetting is the
determining factor to achieve improved strength in the
30000 Avg. Samplle size: 177.0 mm
Materials: P
m×19.30 mm×5.71 mm
Pure HDPE and Layered
L jute + HD
DPE
composite.39 This has been explained by the fact that
composite
Test: Three point flexural
higher bonding strength has the ability to transfer the
25000 Load range: 500 N
stress from the matrix to the fibre.42 The magnified
Flexural Modulus (MPa)

Extension range: 50 mm
Load rate: 5 mm/min
20000 Pre-load: 0..05 N views of the cut surfaces (Figure 16(a)) showed no
Span lengthh: 96 mm
void or air gap across the thickness of the composite
15000 laminates with good wetting of the yarns. HDPE
material was well bonded with the yarn of the jute
10000 fabric. On a macroscopic level, the good bonding at
the interface between jute yarn and HDPE matrix
500
0 could be the major contributing factor for improved
tensile and flexural strengths found in the composites.
0 However, there was little evidence of HDPE polymer
HDP
PE L2
2 Compositte L4 Com
mposite L6 Composite
around the fibres within the yarn (Figure 16(b)). This
Figure 15. Comparison of flexural moduli of pure HDPE and indicated that the polymer matrix could not reach
layered HDPE–jute composites. HDPE: high-density inside the yarn fully even at high pressure and tempera-
polyethylene. ture during compression moulding.

Figure 16. SEM pictures of cut surfaces from HDPE–jute composite.


Sayem et al. 13

Figure 17. SEM pictures of tensile fractured surfaces from HDPE–jute composite.

Under tensile loading condition, the composite to the improvement in mechanical properties of the
material started failing from the interface, followed by composite.
extensive fibre pull-out from the matrix and finally tear-
ing of the fibres in individual yarns as evidenced in
Figure 17(a). In most of the cases, the broken fibre sur-
Conclusions
faces during tensile failure are free from any adhering Composites with layered woven jute fabric and HDPE
polymer. This could be explained by the fact that the matrix have been successfully fabricated in a hot
matrix material did not firmly adhered onto the indi- press (compression moulding machine). Three different
vidual fibre surfaces within the yarns owing to lack of types of laminates have been prepared with two, four
fibre wetting similar to what was observed in Pozzi and and six layers of jute fabrics within a die thickness of
Sepe.43 Relatively clean fibre surfaces also indicated approximately 6.5 mm. The tests on the jute fabric
extensive interfacial failure under tensile force owing showed higher strength in the warp direction due to
to the poor fibre/matrix adhesion (Figure 17(b)). higher number of yarns compared to the weft direction.
At high magnification, a clear gap could be seen in The visual inspection showed that the jute fabrics at the
some places between the matrix and a yarn. However, top surface of the laminate maintained its structure
there were also strong evidences of polymer material while at the bottom surface, the structure was slightly
adhering with the outer fibres of a yarn in tensile frac- elongated in the middle and compressed near the edge.
tured surfaces (Figure 17(c) and (d)). In summary, The cross-sectional image of the laminate showed the
it can be said that even without any fabric treatment, layers were clearly separated in the HDPE matrix with
enough bonding at the fibre matrix interface helped no voids and good adhesion. It was found that higher
to share part of the stress by the fibres and contributed content of jute fabric (in wt%) in the composite
14 Journal of Composite Materials 0(0)

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Declaration of Conflicting Interests 12. Monteiro S, Pereira A, Ferreira C, et al. Performance of
The author(s) declared no potential conflicts of interest with plain woven jute fabric-reinforced polyester matrix com-
respect to the research, authorship, and/or publication of this posite in multilayered ballistic system. Polymers 2018; 10:
article. 230.
13. Bisaria H, Gupta MK, Shandilya PA, et al. Effect of fibre
length on mechanical properties of randomly oriented
Funding
short jute fibre reinforced epoxy composite. Mater
The author(s) received no financial support for the research, Today Proc 2015; 2: 1193–1199.
authorship, and/or publication of this article. 14. Gopinath A, Kumar MS and Elayaperumal A.
Experimental investigations on mechanical properties of
ORCID iDs jute fiber reinforced composites with polyester and epoxy
Abu Sadat Muhammad Sayem https://orcid.org/0000- resin matrices. Procedia Eng 2014; 97: 2052–2063.
0003-3034-7892 15. Das S and Bhowmick M. Mechanical properties of uni-
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MM Alamgir Sayeed https://orcid.org/0000-0001-7746- 5: 1–6.
0329 16. Memon A and Nakai A. Fabrication and mechanical
properties of jute spun yarn/PLA unidirection composite
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