Original article

Journal of Reinforced Plastics and

V
R Composites
Fabrication of Kevlar -reinforced 0(0) 1–14
! The Author(s) 2020
ultra-high molecular weight polyethylene Article reuse guidelines:
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composite through microwave-assisted DOI: 10.1177/0731684420959449
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compression molding for body

armor applications

Taresh Guleria1, Nishant Verma2 , Sunny Zafar2 and

Vivek Jain1

Abstract
KevlarVR -reinforced composites are used in high energy absorption applications. In the present work, KevlarVR -reinforced
ultra-high molecular weight polyethylene composites were fabricated through microwave-assisted compression molding.
The microwave-assisted compression molding parameters were optimized through trial and error method. Analysis of
mechanical behavior of composites was accessed through uniaxial tensile testing, flexural testing, impact testing, and
nano-indentation. The fractured specimens were observed using scanning electron microscopy. An increment of 92.2%
was observed in the ultimate tensile strength of the ultra-high molecular weight polyethylene/KevlarVR composite com-
pared to neat ultra-high molecular weight polyethylene. Flexural properties, impact energy absorption rate, and hard-
ness property of the composite were increased by 27.1%, 91.6%, and 4.77%, respectively, compared to pure ultra-high
molecular weight polyethylene. Enhanced mechanical properties may be attributed to unique microwave heating
phenomena during microwave-assisted compression molding.

Keywords
Ultra-high molecular weight polyethylene, KevlarVR , microwave, composites

Introduction
Nowadays, Kevlar-reinforced ultra-high molecular
weight polyethylene (UHMWPE) composite is finding
its potential in body armor and stab resistance appli-
cations due to their unique properties such as flexibil-
ity, high strength to weight ratio, and excellent fracture
toughness.1–4 Kevlar-reinforced UHMWPE is better
alternative for traditional materials such as cast iron,
steel, wrought steel, hardened steel for body armor,
and stab resistance applications. The limitations of
traditional materials were heavy weight, challenging
manufacturing, rigidity, etc.5–7 Contemporary body
armor materials are ceramics, metal matrix composites,
and fiber-reinforced composites.8–12 Literature reveals
the suitability of KevlarVR -reinforced composite for
body armor applications using a 9 mm bullet.13Ultra-
high molecular weight polyethylene is also a light-
weight polymer material, which plays a vital role in
the energy absorption mechanism.14,15 Ballistic and
tensile behavior of UHMWPE was observed by
researchers.16,17 Use of KevlarVR fiber as a reinforce-
ment in UHMWPE, increased the tensile and frictional
properties of fiber-reinforced composite.18 Cheeseman
et al.19 studied the mechanical behavior of KevlarVR 29
and discussed their role and use in ballistic applica-
tions. Bandaru et al.20 fabricated and tested a
KevlarVR -reinforced polypropylene thermoplastic
1
Department of Mechanical Engineering, Thapar Institute of Engineering
and Technology, Patiala, Punjab, India
2
Composite Design and Manufacturing Research Group, School of
Engineering, Indian Institute of Technology Mandi, Mandi, Himachal
Pradesh, India
Corresponding author:
Sunny Zafar, Composite Design and Manufacturing Research Group,
School of Engineering, Indian Institute of Technology Mandi, Kamand,
Mandi 175075, India.
Email: sunnyzafar@iitmandi.ac.in
2 Journal of Reinforced Plastics and Composites 0(0)
composite. The author also varied the architecture to
observe the impact performance variability. Studies
performed by Liu et al.21 and van der Werff,22
convey the use of UHMWPE as a hybrid panel for
soft body armor. The UHMWPE reinforced with
carbon fiber, shows good hardness and tribological
properties.23 Major findings in the different properties
of composite materials were investigated by Chukov
et al.24 by fabricating a composite with carbon fiber
and UHMWPE. Li et al.25 studied the ballistic appli-
cation of UHMWPE fiber and composites for terminal
and stab resistance. Studies conducted by Fang et al.26
also proved that the addition of reinforcement in
UHMWPE leads to an increase in the Young’s modu-
lus of the composite.
Mechanical properties and performance of fiber-
reinforced composites are largely influenced by their
manufacturing route. Traditional manufacturing tech-
niques to fabricate such fiber-reinforced composites are
injection molding, blow molding, transforming, extru-
sion, film blowing, freeform fabrication, pultrusion,
resin transfer molding, hand layup, injection molding,
film-stacking, vacuum pumping, etc.27–34 The limita-
tions of such manufacturing techniques are formation
of temperature gradient, poor mechanical properties,
high cycle time, etc. On the other hand, additive
manufacturing processes pose several limitations
owing to inherent anisotropy during the process.35
Advantages associated with the fabrication of fiber-
reinforced composites by microwave processing route
include uniform and volumetric heating, reduced cycle
time, fast processing speed, selective heating, and
improved properties.36–42 Rao et al.43 compared the
mechanical properties of thermally cured and micro-
wave cured epoxy-reinforced composite. It was
observed that microwave cured epoxy composite has
better mechanical properties than thermally cured com-
posite. The tensile strength for microwave cured com-
posites was increased by 15.5%, relative to thermal
cured composite. Zhou et al.37 observed the two-third
decrease in curing time during curing of maleic
anhydride-reinforced epoxy composite through
microwave curing route. Agrawal et al.44 performed
adhesion tests by tensile tests of the composite fabri-
cated by microwave curing and observed an increase in
adhesion between fiber and matrix material. Optimal
power and temperature in microwave processing
were also studied, and it was observed that better
mechanical and physical properties were inherited by
composite.45
Literature indicates fabrication of KevlarVR -rein-
forced UHMWE composites has not been attempted
using novel microwave processing route. Motivated
by the advantages of microwave processing, it is antic-
ipated that properties of the processed composites
should be improved. Therefore, in the present work,
KevlarVR -reinforced UHMWE composites were fabri-
cated using microwave-assisted compression molding
(MACM) technique. The composites were prepared
with various reinforcement weight fractions (0%–
10%). The composites were characterized for their
mechanical properties using various techniques.
Multi-layered samples of the composite were prepared
comprising with KevlarVR (0%–10%) and UHMWPE.
Mechanical and micro-structural tests were conducted
on the fabricated specimens.
Material and methods
Matrix and reinforcement
The matrix UHMWPE (Polystone 7000, Molecular
weight: 7.5 million AMU) powder was sourced from
Macro Chemie Polymers, Ahmedabad, India. The rein-
forcement, KevlarVR fiber, was purchased from “Go
Green Products,” Chennai, India. The properties of
KevlarVR fiber as provided by the supplier are present
in Table 1.
Composite fabrication
For composite fabrication, KevlarVR fabric was stacked
between UHMWPE with different weight percentages
fraction, i.e. 5% and 10%. Weight measurements of
UHMWPE and KevlarVR were performed on electronic
weighing balance having 0.1 mg resolution (Make:
Mettler Toledo; Model: ML-220). An alumina mold
was filled with UHMWPE and layers of KevlarVR
fabric (180 GSM). Alumina pressure plate was used
during the fabrication to apply the pressure on the
material. The reason to use an alumina mold and alu-
mina pressure plate is that it allows the microwaves to
pass through it and interact with the material inside the
mold.46 The dimension of alumina mold was
150 mm
25 mm
10 mm, and the alumina compres-
sion plates were of 148 mm
23 mm
8 mm. The pres-
sure during the fabrication process was applied
through the dead weights as shown in Figure 1.
Microwave interaction depends on the dielectric prop-
erties of the material. Mishra et al.47 studied the effect
of the interaction phenomenon of microwaves with dif-
ferent materials. The physics behind the microwave
Table 1. Physical properties of KevlarVR fabric mat.
S. No Property Values
1 Elongation at break (%) 3%–3.7%
2 Diameter of fiber 10–15 mm
3 Density 1.8 gm/cm3
4 Yarn size 200 mm
Guleria et al. 3

Figure 1. Schematic of UHMWPE/KevlarVR (K1) composite fabrication.

interaction of the material suggests that the molecules energy to heat energy, which is shown in equations
inside the material tend to orient in the direction of the (1) and (2)48
microwave-induced electric field but inertial, frictional,
and molecular forces tend to oppose it which results in e ¼ e0  ie00 (1)
the heat generation inside the material. The heating
mechanism in any material by microwave depends on e00
its loss factor and dielectric consistency. The dielectric tan d ¼ (2)
e0
loss factor is the ability of conversion of microwave
4 Journal of Reinforced Plastics and Composites 0(0)

where, e* is complex permittivity with units as [Fm1],
e00 is the dielectric constant of material having units as
[Fm1] that is an ability of the material to allow the
microwave entry in mold, e0 is the dielectric loss factor
with units as [Fm1] that is the tendency of conversion
of microwaves into heat energy, and tan d is loss tan-
gent that denotes the conversion of electromagnetic
waves energy into heat energy. In the case of KevlarVR
and UHMWPE, both of them respond differently to
frequency-based microwaves. An industrial microwave
multimode applicator having a frequency range of
2.45 GHz (Make: VB ceramics; Model: 700 C). A sche-
matic of the manufacturing process is illustrated in
Figure 1. As the UHMWPE particles and KevlarVR
fabric are subjected to microwaves, the heating in
KevlarVR takes place first. Heating of KevlarVR fabric is
due to a relative high dielectric constant of 4.5,49
whereas UHMWPE possesses a dielectric constant of
2.26.48 KevlarVR fabric upon heating transfers the heat
to the polymer matrix, i.e. UHMWPE, as seen in
Figure 1. Due to the expansion of UHMWPE particles,
high porosity, and the necking phenomenon is seen in
the samples prepared without pressure. The application
of pressure on the composite removes the porosity and
provides better adhesion between UHMWPE and
KevlarVR . The fabricated composite was removed from
the mold after cooling.
Optimization of pressure for molding process
The selection of pressure in the case of molding
process is an important parameter, and it decided
by the thermal and rheological properties of the
polymer material.50 The MACM is low-pressure
molding process as compared to conventional compres-
sion molding due to their rapid heating property.
While the heat rate in conventional molding is low,
which requires high pressure of order 6.5 MPa.26
Depending on the temperature inside the mold,
(80 C, as observed in IR Pyrometer) for microwave
heating, the requirement of pressure is significantly
less. However, lower pressure of order 0.02 MPa is
used for proper adhesion between UHMWPE and
KevlarVR fiber. The steps of optimal pressure selection
are present in Table 4.
The above table represents the observations after the
fabrication process of composite at different pressure
levels. Results from the observation proved that a pres-
sure of 0.02 MPa is optimal for the fabrication of
UHMWPE/KevlarVR composite by microwave process-
ing route.
Table 2. Optimized parameters for molding of neat UHMWPE.
Power
S No (W) Time (s) Observations

1 360 60–900 Insufficient microwave

Selection of microwave power and time interaction and no melting
The optimized power input (W) and processing 2 540 60–900 Insufficient microwave
interaction
time (s) for MACM was decided by the trial and
3 720 720–900 Partial microwave interaction
error method. It was observed that the processing and partial melting
time and microwave power plays a very crucial 4 720 1100–1500 UHMWPE particles have
role in the fabrication of composite. Optimal process- higher intermolecular
ing time was set hierarchically for an increase in interaction and melting
weight percentage and KevlarVR layer. Table 2 shows takes place
the fabrication results and observations of pure 5 900 1800 UHMWPE particles reach
at their flow transition
UHMWPE.
temperature, and sample
The above parameters were optimized for neat sticking with surface of
UHMWPE, and the same parameters were used to fab- mold and alumina plate
ricate the UHMWPE/KevlarVR composite. Experiments was observed.
were performed, and it was noted that processing or
fabrication time is inversely proportional to wt.% of
KevlarVR . High microwave power leads to a low proc-
essing time of the composite; however, it also decreases Table 3. Optimized process parameters for fabrication of
its surface quality and leads to defects. The optimized KevlarVR -reinforced UHMWPE composite.
process parameters are formulated in Table 3. It was
Microwave Weight % Processing
concluded from the table that based on reinforcement
S No Specimen power (W) of KevlarVR time (s)
weight percentage, the power was increased, and hence,
an optimized spot for power and time was dedicated. 1 Pure UHMWPE 720 0 1310
An image of the sample prepared at 720 W and 1104 s is 2 UHMWPE/K-1 720 5% 1228
3 UHMWPE/K-2 720 10% 1104
shown in Figure 1.
Guleria et al.
Table 4. Optimization of pressure for MACM.
S No Power (W) Pressure (MPa)
1 720 0.01
2 720 0.02
3 720 0.03–0.05
Characterization of composites
Tensile and flexural testing. The Uniaxial tensile test and
the flexural test were performed on specimen by uni-
versal testing machine (Make: mode: H50KS; Tinius
Olsen, UK). ASTMD3039 and ASTMD7264 standards
were followed during the uniaxial tensile tests and flex-
ural tests, respectively. The sample size for UHMWPE/
KevlarVR composite was 64 mm
16 mm
4 mm. A
total of five specimens were tested for each test to
ensure accurate results. A fixed strain rate of 1 mm/
min was set for all the samples in tensile as well as
flexural test. Scanning electron microscopy (SEM)
images of fractured samples were taken to observe
the failure mechanism in the samples. The flexural
strength and flexural modulus were calculated based
on equations (3) and (4)51
3PL
r¼
2Wt2
where r is flexural strength (MPa), P is the maximum
load (N), L is span length (mm), W is the width of the
5
Observations
The fabricated specimen was not found suitable as no bonding
between UHMWPE matrix and KevlarVR was observed.
The specimen had adhesion and better bonding between the
matrix material and the reinforcement.
High pressure on the material by pressure plate leads to excess
leakage of matrix material after its molten state, which causes
material wastage.
composite specimen (mm), and t is the thickness of
composites specimen (mm).
FL3
FM ¼ (4)
4dbh3
where, F is the maximum load (N), L is span length
(mm), b is the width of the composite specimen (mm),
h is the thickness of composites specimen (mm), and d
is the displacement at maximum force (mm).
Izod impact test
A notched composite was placed under the hammer
to check the impact energy absorption capacity
of KevlarVR -reinforced UHMWPE composite.
ASTMD256 was followed for the Izod impact test.
A total of 15 samples were tested in the impact test
which comprised of pure UHMWPE, UHMWPE/K1,
(3)
and UHMWPE/K2. Izod impact tester (Make: model:
AE-ICIT; Izod/Charpy Tester, Advance Equipment,
Mumbai, India.) was used to test the impact energy
absorption of the composite.
6 Journal of Reinforced Plastics and Composites 0(0)
Microstructural characterization
Surface of the as-fabricated and fractured samples
obtained after mechanical tests were studied using elec-
tron microscopy. A scanning electron microscope
(Make: FEI, USA, Model: NOVA, NANOSEM) was
used to study samples of pure UHMWPE and
UHMWPE/KevlarVR composite. Specimens were gold-
coated with a layer of 5 nm on the surface by a sputter-
ing equipment (Make: Quorum Technologies; Model:
Q150R).
Nano-indentation tests
The nano-indentation tests were performed on nano
Triboindenter (Make: HYSITRON, Minneapolis
USA, Model: TI 950 Triboindenter) to find out the
hardness and plasticity index of UHMWPE/KevlarVR
composite. Each sample was subjected to five indents
and three different types of samples, i.e. pure
UHMWPE, UHMWPE/K1, and UHMWPE/K2 were
used in the test. The machine was equipped with a 2D
transducer and a Berkovich indenter. A maximum of
200 mN load was used for loading and unloading func-
tions. A duration of 30s was considered for loading and
unloading. The holding time was 10s for the indent.
The plasticity index of the composite is a function
that provides the elastic or plastic behavior of the mate-
rial under high stress or strain. To calculate the plas-
ticity index of UHMWPE/KevlarVR composite, the
following equation (5)52 was used
S1  S2
w¼ (5)
S1
where w is the plasticity index, S1 is the area under the
loading curve, and S2 is the area under the unloading
curve.
Results and discussion
Role of pressure in composite fabrication
SEM images of manufactured samples reveal the pores
present in the UHMWPE and KevlarVR composite in
Figure 2. The SEM images of UHMWPE particles
shown in Figure 2(a) and (b) show the presence of
voids on the surface of the UHMWPE matrix. The
voids, as observed on the surface of UHMWPE,
resulted due to the absence of pressure on the
UHMWPE powder particles. The micro-particles of
UHMWPE matrix, when heated during the microwave
process tend to melt, which induces expansion and
joins with their surrounding particles. This leads to
the formation of voids and pores and consequently
resulting in necking. This phenomenon is due to the
heating of matrix material and the fusion of two par-
ticles since the surface energy of the particles is directly
proportional to the surface area.48 So, it can be
revealed form the study that, to completely eliminate
the porosity and necking phenomenon, the specimen
has to be processed for longer time duration and high
temperatures. To optimize this increase in processing
time and power consumption, pressure was applied on
the material through an alumina pressure plate to
remove porosity and necking as in Figure 1. A pore
having a hexagonal shape along with the dimension is
observed in the SEM image shown in Figure 2(c) has
resulted due to the absence of pressure applied to the
mold for KevlarVR -reinforced UHMWPE composite.
Figure 2(d) shows the SEM image of the sample man-
ufactured with the application of 0.02 MPa pressure. It
can be observed that, with the application of pressure
by dead weight, no necking between the particles and
voids were observed on the surface of the composite.
Uniaxial tensile testing
The stress–strain curve for microwave processed
UHMWPE/KevlarVR composite is shown in Figure 3
(a). From the tensile graph, it was visible that there is
an increase in the ultimate tensile strength of the com-
posite with the addition of reinforcement in the matrix.
The tensile strength for neat UHMWPE was observed
as 16.8 MPa. The ultimate tensile strength UHMWPE/
K1 was observed approximately as 24.6 MPa, whereas,
UHMWPE/K2 had an ultimate tensile strength of
32.36 MPa. An increase of 46% in the tensile strength
was observed in the UHMWPE/K1, while the
UHMWPE/K2 exhibited an increase of 92% in the
tensile strength. Microwave processing of composite
helps in uniform heating and better internal adhesion
of fiber and matrix.44 The stronger bond between the
matrix and fiber is the most dominating factor in
increasing the tensile strength of the composite.53
Tensile strength in the composite was increased in the
addition of KevlarVR as the transfer of load is taking
place from matrix material to the reinforcement in
UHMWPE/K1. In the case of UHMWPE/K2, the pro-
cess of crack transfer takes place from the external
matrix to fiber, and then from the internal matrix to
fiber, increasing the tensile strength property of the
composite. Further, the addition of such reinforcement
will increase the tensile strength property of the com-
posite material. This transfer of crack can be visible in
the SEM micrographs in Figure 4(a). Similar results for
tensile property were observed by Li et al.18 The tensile
modulus is shown in Figure 3(c). The tensile modulus
values for neat UHMWPE, UHMWPE/K1, and
UHMWPE/K2 are 0.995 GPa, 1.34 GPa, and
Guleria et al.
Figure 2. Microstructural characterization (a) SEM of UHMWPE particles, (b) SEM micrographs of specimen without the effect of
pressure, (c) inset of pore and (d) SEM of the fabricated specimen after the effect of pressure.
1.8 GPa, respectively. An increase of 34% in tensile
modulus was observed from pure UHMWPE to
UHMWPE/K1, and an increase of 80% was noted
from neat to UHMWPE/K2. Previous works reported
tensile tests on a composite fabricated by fused depo-
sition modelling process with KevlarVR as a reinforce-
ment and similar results were obtained.10 Figure 4
shows the graph for the tensile failure mechanism
along with the sample schematics of microwave proc-
essed UHMWPE/KevlarVR composite. The composite is
seen elongating in the elastic region of the graph, and
the crack initiation in the matrix material takes place at
the ultimate tensile point in the graph as visible in
Figure 4. The magnified image from the graph on the
ultimate tensile strength shows the SEM fractography
images consisting of the UHMWPE matrix and
KevlarVR fiber reinforcements. The transfer of crack
from matrix to reinforcement can be easily seen in
Figure 4(a) where the broken UHMWPE matrix trans-
ferred the load on the aligned reinforcement fibers. The
matrix material on the KevlarVR bears the load and pre-
vents the load transfer at this point in the graph. The
7
fiber strands with UHMWPE show a ruptured behav-
ior when subjected to tensile force leading to fracture in
the composite. This can be easily seen in Figure 4(b)
where fibers with UHMWPE are elongated and then
fractured. The transfer of the load on the fiber suggests
a good adhesion between the matrix and reinforcement
in the case of different samples. The adhesion of
UHMWPE and KevlarVR , with a broken end of the
fiber is visible in Figure 4(c). The fiber ends in the
image are visible with the UHMWPE matrix elongated
along with fibers that are broken at the fracture stage in
the graph. The size of KevlarVR fiber was observed to be
in range of 10 mm to 13 mm. UHMWPE is visible on the
fiber strand where the ruptured matrix and fiber are
attached evenly and orderly. This indicates improved
interfacial adhesion between the matrix and reinforce-
ment in the microwave processed composites.
Flexural test
The flexural test was conducted to determine the flex-
ural strength and flexural modulus of the UHMWPE/
KevlarVR composite. The flexural strength for
8 Journal of Reinforced Plastics and Composites 0(0)

Figure 3. Stress–strain graphs for uniaxial tensile testing. (a) Ultimate tensile strength of UHMWPE/KevlarVR composite. (b) Tensile
modulus curve for UHMWPE/KevlarVR composite. (c) Tensile strength of UHMWPE/KevlarVR composite as function of number of
KevlarVR layers. (d) Tensile modulus of UHMWPE/KevlarVR composite as function of number of KevlarVR layers.

UHMWPE, UHMWPE/K1, and UHMWPE/K2 is
17.4 MPa, 20.8 MPa, and 22.1 MPa, respectively. An
increase of 19.5% was observed in the flexural strength
when the sample was reinforced with one layer of
KevlarVR fabric, i.e. from pure UHMWPE to
UHMWPE/K1. In the case of UHMWPE/K2, the
increase in the flexural strength was 27.01%. An
increase in the load-bearing capacity of microwave-
processed composite can be seen in the graph which
increases on the addition of the reinforcement in
UHMWPE. There is an increase in the flexural strength
of the composite as the presence of KevlarVR fiber
increases the stiffness in the composite. This increase
is due to the adhesion between UHMWPE particles
and KevlarVR which makes the composite stiff and
allows it to bear more load; hence increasing the flex-
ural strength of composite material. This adhesion
between the particles of UHMWPE and KevlarVR resists
the molecular movement and hence making it a stiffer
phase together. There was a specific increase of flexural
modulus in the UHMWPE/KevlarVR composite by
varying the fiber reinforcement in the composite.
The flexural modulus for UHMWPE with no rein-
forcement was calculated as 803 MPa, whereas,
UHMWPE/K1 and UHMWPE/K2 possess a flexural
modulus of 886 MPa and 1246 MPa, respectively. An
increase in the flexural modulus from pure UHMWPE
to UHMWPE/K1 can be seen. This increase in the
flexural modulus can be seen due to the increase in
the maximum load-bearing capacity of the composite,
as it is directly proportional to the flexural modulus.
The reason for the increase in the load-bearing capacity
is due to a stronger phase between the matrix and the
reinforcement which further increases the stiffness and
modulus value of the composite.54 A sudden increment
of flexural modulus can be seen from UHMWPE/K1
Guleria et al. 9

Figure 4. Tensile fractured composite specimen (a) SEM micrograph of the aligned fibers and UHMWPE matrix. (b) SEM
fractography of fractured fiber ends that are elongated and then broken after failure. (c) SEM micrograph of matrix adhesive on
the reinforcement and a fractured KevlarVR fiber.

Figure 5. Flexural strength. (a) Flexural strength of UHMWPE/KevlarVR composite as function of number of KevlarVR layers.
(b) Flexural modulus of UHMWPE/KevlarVR composite as function of number of KevlarVR layers.
10
and UHMWPE/K2. This is due to the presence of
stacked UHMWPE between two KevlarVR layers that
acts as a KevlarVR –KevlarVR adhesive material providing
an increase in the Van der Waals forces between the
Figure 6. Impact energy absorption rate as function of KevlarVR
content from 0%–10%.
Figure 7. Izod impact testing. (a) Hammer striking on the UHMWPE/KevlarVR composite. (b) A fractured UHMWPE/K1 specimen
after Izod impact testing. (c) Transfer of crack from matrix to reinforcement. (d) Broken fibers and matrix inside UHMWPE/K2
composite.
Journal of Reinforced Plastics and Composites 0(0)
layers of KevlarVR and UHMWPE bonded inside them.
The matrix outside the KevlarVR layers also provides a
stiffness factor to the complete composite. An increase
of 10.3% was noted from pure UHMWPE to
UHMWPE/K1 containing a 5% weight percentage in
the composite. An increase in the flexural modulus
from pure UHMWPE to UHMWPE/K2 with a 10%
weight percentage is 55.16%. A reduction in the duc-
tility can be seen in UHMWPE/KevlarVR -based com-
posite, as we increase the fiber concentration.
Previous works proved that the flexural strength of
Kevlar-based composite is relatively less.55Figure 5(a)
and (b) shows the comparative graphs of flexural
strength and flexural modulus with variable KevlarVR
content in the composite, respectively.
Izod impact test
Figure 6 reveals the results after Izod impact testing of
the composite. The composite samples tested in the
Izod impact testing machine comprised of pure
UHMWPE, UHMWPE/K1, and UHMWPE/K2, and
Guleria et al. 11

the results for the energy absorption rate were
observed. The composites were subjected to a
hammer strike with 2.71 J of energy. It can be observed
from the graph that the energy absorbed by pure
UHMWPE is 112 KJ/m2. Energy absorbed by
UHMWPE/K1 and UHMWPE/K2 is 168 KJ/m2 and
215 KJ/m2, respectively. An increase in the energy
absorption rate of 50% was noted down from pure
UHMWPE to UHMWPE/K1. Similarly, an increase
of 91.6% was observed from pure UHMWPE to
UHMWPE/K2. The rate of energy absorption
increases as the reinforcement in the composite is
added up to a certain extent. This is mainly due to
the impact energy absorption rate that KevlarVR has a
characteristic trait. KevlarVR is mostly used as a ballistic
material in most of the applications where impact
energy absorption is highly considered. The impact
energy absorption increases because during the crack
propagation from matrix material to the reinforcement
is hindered due to the phase change. As the addition of
reinforcement in the composite increase the hardness
and stiffness, the ability to bear an impact by the com-
posite hence further increases. A crack is visible in
Figure 7(c) and (d), where this phase change is
observed. As the crack propagates from matrix mate-
rial towards the reinforcement, the arrested crack finds
a change in the phase, which resists the crack from
propagation. Hence, addition of KevlarVR reinforce-
ment significantly increases the impact energy absorp-
tion rate of microwave-assisted UHMWPE/KevlarVR
composite. Similar results for an increase in the
impact strength were observed by Roy et al.56, in

Figure 8. Nano-indentation of UHMWPE/KevlarVR composite. (a) Loading and unloading curve for different composite specimens.
(b) Load–time graph for the nano-indentation process. (c) Plasticity index for UHMWPE/KevlarVR composite as function of KevlarVR
content. (d) Hardness (GPa) of UHMWPE/KevlarVR composite as function of KevlarVR content.
12
which the author used Aramid fabric or KevlarVR
coated with natural rubber along with UHMWPE
fabric and investigated impact as well as some other
properties of this composite. As visible in Figure 7(a),
the Izod testing hammer is striking the composite
placed in the fixture. After the impact, the removed
specimen was placed and observed as seen in Figure 7
(b). Here, we can see in Figure 7(b) that some fibers are
still left as a reinforcement inside the composite which
proves a higher impact toughness of KevlarVR fabric as
a reinforcement. Figure 7(c) and (d) shows the SEM
observations of crack arrest where the transfer of crack
can be seen.
Nano-indentation test
From the nano-indentation test, the hardness and the
plasticity index of multi-layered UHMWPE/KevlarVR
composites were calculated. A maximum load of
200 mN was applied as per the loading and unloading
curve as shown in Figure 8(a). The load-depth graph is
visible in the Figure 8(b) for pure UHMWPE,
UHMWPE/K1, and UHMWPE/K2. The trend of
graph started shifting towards the left as a function
of KevlarVR layers. The hardness values obtained were
as 0.1112  0.005 GPa, 0.1325  0.006 GPa, and
0.1731  0.008 GPa for pure UHMWPE, UHMWPE/
K1, and UHMWPE/K2, respectively. An increase of
19.04% was observed from pure UHMWPE to
UHMWPE/K1, and an increment of 55.64% was
observed in pure UHMWPE and UHMWPE/K2.
The increase in the hardness is because of the addition
of reinforcement in the matrix material which makes
the composite stiff and hence increases the hardness.
Further, KevlarVR in adhesion with UHMWPE also
provides a stiffer phase of stacked layers, which
offers notable hindrance and resistance to the indent-
er. The results for hardness are formulated in the
Figure 8(d). The area under the loading curve (S1)
and the unloading curve (S2) was calculated by inte-
grating the area under the curves by full width at
half maximum method. In Figure 8(c), the plasticity
index for pure UHMWPE, UHMWPE/K1, and
UHMWPE/K2 are 0.777, 0.72, and 0.67, respectively.
A decrease in the plasticity index defines the increase
in the hardness and surface roughness of the compos-
ite. A decrease of 7.40% was observed from pure
UHMWPE to UHMWPE/K1, and a decrease of
13.8% was observed from pure UHMWPE to
UHMWPE/K1. This decrease in the plasticity index
of the composite is visible, as the reinforcement in the
composite tends to increase the stiffness and hardness
of the composite.
Journal of Reinforced Plastics and Composites 0(0)
Conclusions
In the present work, UHMWPE/KevlarVR composites
with various weight fractions of reinforcement were
successfully fabricated using MACM technique. The
optimization of the parameters in the manufacturing
of composites depends on the weight percentage of
the matrix and reinforcement. Further, the tensile
strength, Young’s modulus, flexural strength, and flex-
ural modulus of the composite specimen increased with
the weight percentage of reinforcement. The energy
absorption rate of the composite also increased with
the KevlarVR fabric reinforcement. Nano hardness of
the composite increased due to the addition of
reinforcement, and hence the plasticity index of the
composite decreased. With improved mechanical prop-
erties, these composites can find applications in body
armors and ballistic use after high-strain rate tests.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
article.
Funding
The author(s) received no financial support for the research,
authorship, and/or publication of this article.
ORCID iDs
Nishant Verma https://orcid.org/0000-0002-6650-3052
Sunny Zafar https://orcid.org/0000-0002-5511-9418
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