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<p>Natural fiber-reinforced sandwich composites have attracted considerable attention for lightweight structural applications; however, limited studies have explored the combined use of hybrid natural fibers and agro-waste-derived fillers in PU foam-core vinyl ester composites. In this work, a sustainable sandwich composite was developed using a closed-cell polyurethane (PU) foam core, silane-treated Hennep fiber (40% hemp and 60% areca) face sheets, and silane-treated hazelnut shell particles (HSP) as reinforcement within a vinyl ester matrix. The composites were fabricated using the hand lay-up technique and characterized according to ASTM International standards for tensile, flexural, impact, hardness, fatigue, drop-weight impact, and morphological properties. The results showed that the composite containing 3&#xa0;vol.% HSP (V4) exhibited the optimum mechanical performance, achieving a tensile strength of 152 ± 4.2&#xa0;MPa, flexural strength of 172 ± 4.9&#xa0;MPa, impact strength of 4.9 ± 0.18&#xa0;J, and fatigue lives of 22,842, 22,106, and 21,477 cycles at 25%, 50%, and 75% of ultimate tensile strength, respectively. The specimen containing 5&#xa0;vol.% HSP (V5) exhibited the highest Shore-D hardness of 99 ± 2.2 and drop-weight impact energy absorption of 29 ± 1.1&#xa0;J with a maximum deflection of 3.5 ± 0.15&#xa0;mm. SEM analysis revealed improved fiber–matrix adhesion and filler dispersion at lower filler loadings, while localized agglomeration was observed at higher filler contents. The enhanced performance was attributed to the synergistic effects of silane treatment, efficient stress transfer, and the energy-absorbing characteristics of the PU foam core. The developed composites demonstrate potential for lightweight engineering applications such as automotive interior components, protective panels, packaging structures, and building materials.</p> Graphical abstract <p></p>

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Mechanical, fatigue, and drop-weight impact performance of silane-treated hennep fiber/hazelnut shell powder reinforced vinyl ester–PU foam hybrid composites

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • N. Vinayaka,
  • Anil Kumar Bodukuri,
  • Akhilesh Kumar Singh,
  • Donti Ratnam Srinivasan,
  • Kuldeep Kumar,
  • Prashant Dnyaneshwar Kamble,
  • Tadikonda Vijaya Kumar,
  • Y. Sujatha,
  • A. Joseph Arockiam

摘要

Natural fiber-reinforced sandwich composites have attracted considerable attention for lightweight structural applications; however, limited studies have explored the combined use of hybrid natural fibers and agro-waste-derived fillers in PU foam-core vinyl ester composites. In this work, a sustainable sandwich composite was developed using a closed-cell polyurethane (PU) foam core, silane-treated Hennep fiber (40% hemp and 60% areca) face sheets, and silane-treated hazelnut shell particles (HSP) as reinforcement within a vinyl ester matrix. The composites were fabricated using the hand lay-up technique and characterized according to ASTM International standards for tensile, flexural, impact, hardness, fatigue, drop-weight impact, and morphological properties. The results showed that the composite containing 3 vol.% HSP (V4) exhibited the optimum mechanical performance, achieving a tensile strength of 152 ± 4.2 MPa, flexural strength of 172 ± 4.9 MPa, impact strength of 4.9 ± 0.18 J, and fatigue lives of 22,842, 22,106, and 21,477 cycles at 25%, 50%, and 75% of ultimate tensile strength, respectively. The specimen containing 5 vol.% HSP (V5) exhibited the highest Shore-D hardness of 99 ± 2.2 and drop-weight impact energy absorption of 29 ± 1.1 J with a maximum deflection of 3.5 ± 0.15 mm. SEM analysis revealed improved fiber–matrix adhesion and filler dispersion at lower filler loadings, while localized agglomeration was observed at higher filler contents. The enhanced performance was attributed to the synergistic effects of silane treatment, efficient stress transfer, and the energy-absorbing characteristics of the PU foam core. The developed composites demonstrate potential for lightweight engineering applications such as automotive interior components, protective panels, packaging structures, and building materials.

Graphical abstract