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<p>Biocomposite materials have gained significant attention in recent decades due to their sustainability, lightweight nature, and ability to valorize waste biomass into high-value engineering materials. This study investigates the mechanical, thermal conductivity, and wear behaviour of vinyl ester–based biocomposites reinforced with silane-treated <i>Caryota urens</i> mat fibre and biochar derived from <i>Sterculia foetida</i> fruit shells. Biochar was produced via a slow pyrolysis process, while composite laminates were fabricated using the hand lay-up technique. The composites were evaluated according to ASTM standards to assess tensile, flexural, impact, interlaminar shear strength (ILSS), hardness, wear rate, coefficient of friction, and thermal conductivity. Results indicate that silane-treated fibre reinforcement significantly enhances mechanical performance compared to neat resin, achieving tensile strength of 54&#xa0;MPa, flexural strength of 86&#xa0;MPa, impact strength of 3.4&#xa0;J, ILSS of 18.6&#xa0;MPa, and hardness of 72 Shore-D. Among the hybrid composites, the specimen containing 40 vol% fibre and 2 vol% biochar exhibited the highest overall mechanical performance, with tensile, flexural, impact, and ILSS values of 96&#xa0;MPa, 148&#xa0;MPa, 5.4&#xa0;J, and 28.1&#xa0;MPa, respectively. Higher biochar loading (4 vol%) led to a marginal reduction in mechanical properties but improved wear resistance, frictional behaviour, and thermal conductivity. These results demonstrate the potential of the developed biocomposites for lightweight structural applications in automotive interiors, housing components, and consumer products.</p> Graphical abstract <p></p>

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Valorization and development of Caryota urens mat fiber and sterculia foetida fruit shells biocarbon vinyl ester composite

  • 期刊论文

  • 发表日期：

    2026年1月19日

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  • Sathiyamoorthy Margabandu,
  • Felix Sahayaraj Arockiasamy,
  • R. Sathis Kumar,
  • Raghuram Pradhan,
  • T. Nithyanandhan,
  • T. S. Ajmal

摘要

Biocomposite materials have gained significant attention in recent decades due to their sustainability, lightweight nature, and ability to valorize waste biomass into high-value engineering materials. This study investigates the mechanical, thermal conductivity, and wear behaviour of vinyl ester–based biocomposites reinforced with silane-treated Caryota urens mat fibre and biochar derived from Sterculia foetida fruit shells. Biochar was produced via a slow pyrolysis process, while composite laminates were fabricated using the hand lay-up technique. The composites were evaluated according to ASTM standards to assess tensile, flexural, impact, interlaminar shear strength (ILSS), hardness, wear rate, coefficient of friction, and thermal conductivity. Results indicate that silane-treated fibre reinforcement significantly enhances mechanical performance compared to neat resin, achieving tensile strength of 54 MPa, flexural strength of 86 MPa, impact strength of 3.4 J, ILSS of 18.6 MPa, and hardness of 72 Shore-D. Among the hybrid composites, the specimen containing 40 vol% fibre and 2 vol% biochar exhibited the highest overall mechanical performance, with tensile, flexural, impact, and ILSS values of 96 MPa, 148 MPa, 5.4 J, and 28.1 MPa, respectively. Higher biochar loading (4 vol%) led to a marginal reduction in mechanical properties but improved wear resistance, frictional behaviour, and thermal conductivity. These results demonstrate the potential of the developed biocomposites for lightweight structural applications in automotive interiors, housing components, and consumer products.

Graphical abstract