Preparation of ABS/Mica Composites by Melt Mixing Method: A Critical Study of Mechanical and Thermal Properties

This study explores the development of composites by homogeneously blending ABS (Acrylonitrile Butadiene Styrene) with natural calcined mica powder at varying mixing ratios. The melt mixing method in a twin-screw extruder was employed to prepare a mixture of virgin ABS granules and natural calcined mica powder, and the resulting compounded pellets were utilized for the fabrication of mechanical test specimens. Tensile, flexural, and impact tests were conducted according to relevant national and international standards, employing an injection molding machine. The investigation delves into the assessment of ABS/MICA composites across different ratios of ABS infusion, with a focus on mechanical, thermal, chemical, and physical characteristics. The interaction between ABS and MICA was confirmed through Fourier Transform Infrared (FTIR) analysis, providing insights into the molecular level bonding within the composite. Thermal stability of the composite was studied through TGA (Thermogravimetric) and DSC (Differential Scanning Calorimetry) analysis. Results revealed that the composite exhibited superior thermal stability compared to virgin ABS. These findings were further correlated with the mechanical properties of the composites, demonstrating a promising relationship between thermal stability and mechanical performance. The study indicates that increasing the loading of mica into ABS materials leads to a rise in brittleness in the resulting composites. Optimal properties were observed when the mica loading reached 15%, suggesting a balance between reinforcement and flexibility. In conclusion, the synergistic effects of ABS/MICA composites have been explored comprehensively, providing valuable insights into the interplay of materials and their resulting properties. This research contributes to the understanding of composite material design for applications that demand a combination of mechanical robustness, thermal stability, and chemical resistance.