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<p>The present study investigates the development and characterization of sustainable polyester-based hybrid biocomposites reinforced with hemp–sisal hybrid fiber (60:40) and pigeon pea (Cajanus cajan) waste stalk powder as a bio-filler. The pigeon pea stalk powder was extracted, surface treated with 3-aminopropyltrimethoxysilane (3-APTMS), and incorporated into a polyester matrix along with hemp–sisal hybrid fiber mats. Composite laminates were fabricated using the hand lay-up method with filler contents ranging from 0 to 3 vol%. Mechanical, thermal, tribological, and physical properties were evaluated according to relevant ASTM standards. The results indicate that the incorporation of hybrid fibers significantly enhances the mechanical performance of the polyester matrix. The composite containing 1 vol% pigeon pea filler exhibited the highest tensile strength of 94&#xa0;MPa and flexural strength of 131&#xa0;MPa, corresponding to improvements of 84.3% and 48.9%, respectively, compared with the neat polyester composite. Impact toughness increased from 0.34&#xa0;J to 5.33&#xa0;J, while hardness increased progressively with filler loading, reaching 86 Shore D at 3 vol%. Thermal conductivity improved from 0.21&#xa0;W/mK to 0.38&#xa0;W/mK, and tribological performance showed notable improvement with reductions in both coefficient of friction and wear rate. Although water absorption increased with filler content, the values remained moderate within the tested range. Overall, the results demonstrate that the combined use of pigeon pea stalk powder and hemp–sisal hybrid fibers can enhance the multifunctional performance of polyester composites, indicating their potential for semi-structural and general engineering applications, subject to further validation of long-term durability and microstructural characteristics.</p> Graphical abstract <p></p>

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Development and characterization of sustainable polyester biocomposites using pigeon pea waste stalk powder and hybrid fiber

  • 期刊论文

  • 发表日期：

    2026年5月22日

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  • S. Divya,
  • Ayilam Viswanathan Rajalakshmi,
  • D. Moses Raja Cecil,
  • R. Baskaran,
  • V. T. Vijayaraj,
  • R. Manikandan

摘要

The present study investigates the development and characterization of sustainable polyester-based hybrid biocomposites reinforced with hemp–sisal hybrid fiber (60:40) and pigeon pea (Cajanus cajan) waste stalk powder as a bio-filler. The pigeon pea stalk powder was extracted, surface treated with 3-aminopropyltrimethoxysilane (3-APTMS), and incorporated into a polyester matrix along with hemp–sisal hybrid fiber mats. Composite laminates were fabricated using the hand lay-up method with filler contents ranging from 0 to 3 vol%. Mechanical, thermal, tribological, and physical properties were evaluated according to relevant ASTM standards. The results indicate that the incorporation of hybrid fibers significantly enhances the mechanical performance of the polyester matrix. The composite containing 1 vol% pigeon pea filler exhibited the highest tensile strength of 94 MPa and flexural strength of 131 MPa, corresponding to improvements of 84.3% and 48.9%, respectively, compared with the neat polyester composite. Impact toughness increased from 0.34 J to 5.33 J, while hardness increased progressively with filler loading, reaching 86 Shore D at 3 vol%. Thermal conductivity improved from 0.21 W/mK to 0.38 W/mK, and tribological performance showed notable improvement with reductions in both coefficient of friction and wear rate. Although water absorption increased with filler content, the values remained moderate within the tested range. Overall, the results demonstrate that the combined use of pigeon pea stalk powder and hemp–sisal hybrid fibers can enhance the multifunctional performance of polyester composites, indicating their potential for semi-structural and general engineering applications, subject to further validation of long-term durability and microstructural characteristics.

Graphical abstract