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<p>Bamboo powder-reinforced Nylon 66 composites were successfully fabricated through friction stir processing (FSP) and evaluated for their structural, mechanical, thermal, electrochemical, and electrical performance. The optimum condition (500&#xa0;rpm, 25&#xa0;mm min⁻¹) produced a defect-free stir zone under solid-state conditions, with a peak processing temperature of 198.2&#xa0;°C. SEM and EDS analyses confirmed enhanced bamboo particle distribution and successful reinforcement incorporation, while XRD verified the retention of α-phase crystalline structure without secondary phase formation. The developed composite exhibited improved hardness (69 Shore D) compared with pristine Nylon 66 (63 Shore D), higher modulus retention, enhanced damping behaviour, and greater deformation capability. Thermal analyses revealed improved stability, with degradation temperatures increasing from 330 to 350&#xa0;°C to 425–440&#xa0;°C and biochar yield rising from 0.55 to 0.72&#xa0;mg. Electrochemical testing demonstrated excellent environmental stability, evidenced by a high polarization resistance of 1.55 × 10⁹ Ω and an extremely low corrosion rate of 7.01 × 10⁻⁸ mm y⁻¹. Furthermore, the composite maintained stable electrical insulation under 1–5&#xa0;A loading for 30&#xa0;min, exhibiting negligible Joule heating and a limited surface temperature rise of only 25.2–27.6&#xa0;°C. These results demonstrate that FSP provides a sustainable route for producing lightweight bamboo-reinforced Nylon 66 composites with enhanced multifunctional properties for structural and low-voltage electrical applications.</p> Graphical Abstract <p></p>

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Friction Stir Processed Eco-Friendly Bamboo-Reinforced Nylon-66 Composites for Sustainable Structural and Low-Voltage Electrical Applications

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • M. S. Krishnalal,
  • Sunilkumar Dhasan,
  • Vivekanandan Subburaj

摘要

Bamboo powder-reinforced Nylon 66 composites were successfully fabricated through friction stir processing (FSP) and evaluated for their structural, mechanical, thermal, electrochemical, and electrical performance. The optimum condition (500 rpm, 25 mm min⁻¹) produced a defect-free stir zone under solid-state conditions, with a peak processing temperature of 198.2 °C. SEM and EDS analyses confirmed enhanced bamboo particle distribution and successful reinforcement incorporation, while XRD verified the retention of α-phase crystalline structure without secondary phase formation. The developed composite exhibited improved hardness (69 Shore D) compared with pristine Nylon 66 (63 Shore D), higher modulus retention, enhanced damping behaviour, and greater deformation capability. Thermal analyses revealed improved stability, with degradation temperatures increasing from 330 to 350 °C to 425–440 °C and biochar yield rising from 0.55 to 0.72 mg. Electrochemical testing demonstrated excellent environmental stability, evidenced by a high polarization resistance of 1.55 × 10⁹ Ω and an extremely low corrosion rate of 7.01 × 10⁻⁸ mm y⁻¹. Furthermore, the composite maintained stable electrical insulation under 1–5 A loading for 30 min, exhibiting negligible Joule heating and a limited surface temperature rise of only 25.2–27.6 °C. These results demonstrate that FSP provides a sustainable route for producing lightweight bamboo-reinforced Nylon 66 composites with enhanced multifunctional properties for structural and low-voltage electrical applications.

Graphical Abstract