1. Introduction
The formation of reinforced thermoplastic composites has allowed the development of advanced polymeric materials with improved damage tolerance, high rigidity, fatigue endurance and environmental resistance. One approach to enhance the resistance, modulus and mechanical properties of thermoplastics is to incorporate high-performance organic and/or inorganic fibres. Glass fibres (GFs) are often chosen in industry [
1] as a reinforcing agent due to their incomparable high strength-to-weight ratio efficacy and stiffness. Additionally, due to the low raw-material cost of GFs compared to other commercial additives such as clays and carbon nanotubes [
2], as well as their high recycling potential [
3], the industrial usage and mass production of the GF composites is feasible. However, the efficiency of reinforcement and the final performance of glass fibre composites is strongly affected by the interfacial adhesion force between the polymer matrix and the surface of the fibres. Poor matrix–fibre bonding, as a result of the high surface energy of the fibres and the low matrix wettability/hydrophobicity, leads to highly defected composites with low mechanical strength, since stress transferring from the polymeric matrix to the fibrous reinforcing agent cannot be sufficiently achieved. Of all classes of polymers, polyolefins are the hardest to be combined with other materials, even organic substances, due to the lack of functional groups for bonding or even affinity. Organofunctional silane coating, commonly known as sizing, is often applied to the surface of the fibres to promote interfacial adhesion [
4] via the formation of covalent bonds [
5]. Furthermore, it was reported previously that the incorporation of polar functional groups in the polymer chain such as such as grafted maleic anhydride [
6] improves the interfacial adhesion in composites and promotes the homogenous dispersion of the reinforcing agent. The anhydrite groups of the grafted polyolefin compatibilizers chemically react with the amino groups of fibre sizing (coating), which remarkably enhances the fibre/matrix interaction [
7], leading to strengthened composites [
8]. Free-radical grafting of maleic acid onto polymer blends has gained acceptance since maleic-acid-grafted polyolefins were found to exhibit high compatibility,
pe.for combining LDPE and PVA [
9].
Polypropylene (PP) is classified among the most commercially used polyolefins, with applications in industrial fields such as packaging, electrical manufacturing and household appliances, mainly due to its easy processability, good chemical and moisture resistance and high flexural strength. These properties also make PP a candidate matrix material for composites. However, the characteristic low impact resistance, poor dimensional stability and relatively low maximum service temperature often limit its suitability for highly demanding applications. Copolymerization of PP with small volumes of different olefin monomers has been seen to greatly benefit the impact strength [
10,
11] and the thermal properties of polypropylene [
12]. Thus, random polypropylene (PP
R) contains up to 10 wt.% ethylene units randomly dispersed into the PP matrix and exhibits high elasticity, good impact and creep resistance and increased longevity. Furthermore, the embedded ethylene units strongly affect the crystalline/amorphous ratio of the blend, which determines the stiffness of the material [
13]. It was reported previously that incorporation of 10 wt.% short glass fibres in the random polypropylene matrix greatly enhances the strength and modulus of elasticity of the matrix [
14], making PP
R/GF composites suitable for structural engineering applications such as chemical media piping, heating and water supply systems, as PP and PE are the keypolymers in pipe manufacturing of all purposes. It was also shown that further increase in the fibre content significantly lowers the tensile performance. However, not much work has been focused on the effect of compatibilizers on the mechanical and thermal properties of glass-fibre-reinforced PP
R. The novelty of this piece of work is that the role of the compatibilizer is under investigation by applying most of the characterization techniques that concern PP.
In this work, 10 wt.% short-glass-fibre-reinforced PPR composites were obtained by melt-mixing using silane-sized GFs and PP-g-MA as the compatibilizing agent. Different amounts of PP-g-MA were used to demonstrate the effect of compatibilizer loading on the interfacial adhesion and the physical characteristics of the PPR/GF composites. The impact of the compatibilizer on the crystallization behaviour, the adhesion and the mechanical properties of the composites was investigated. It is anticipated that the enhancement of the mechanical and thermal properties of the PP-g-MA modified PP/GF composites will facilitate the design of high-performance and -durability heating pipeline systems.
3. Results and Discussion
The crystalline phase and crystallinity percentage of PP
R, PP-
g-MA and the PP
Rm
x%/GF composites were determined using the wide-scan X-ray diffraction patterns shown in
Figure 1. All patterns demonstrated strong crystalline diffraction peaks at 2
θ angles of approximately 14.1°, 16.8°, 18.4° and 21.2°, which are typical for the monoclinic alpha crystal phase of polypropylene. It is apparent that the modification of the PP
R matrix using PP-
g-MA did not affect the form of the diffraction pattern; however, the crystallinity percentage of the composites is different compared to that of neat PP
R.
Table 1 summarizes the effect of glass fibres and the various content of PP-
g-MA on the crystallinity of PP
R. The crystallinity index I
c of the samples was calculated using the equation [
15]:
where A
cryst. is the integrated area of the crystalline peaks of the diffraction pattern, and A
tot. is the total integrated area, namely the area under the crystalline peaks and the amorphous hallow.
The crystallinity of the PP-
g-MA compatibilizer is slightly lower compared to PP
R due to the lower molecular weight of the grafted polypropylene, as well as due to the branched MA groups. As for the crystallinity index of the composites, the incorporation of 10 wt.% glass fibres in the matrix without the addition of the compatibilizer significantly lowered the crystallinity from 62.1 to 55.5%. This is due to interruption of the linear crystallization of the PP
R chains during cooling as a result of the random distribution of the GFs in the matrix, which leads to an increase in the amorphous content [
16]. The crystallinity of the PP
Rm
x%GF composites is about the same as that of the non-modified material PP
Rm
0%GF, indicating that modifying the PP
R with the addition of up to 2.5 wt.% PP-
g-MA does not significantly decrease the ability of PP
R to crystallize [
17]. The crystallinity values decrease as the modification increases, reaching 53% for PP
Rm
1%/GF and PP
Rm
2.5%/GF.
Following the XRD analysis, it is apparent that the amorphous content in the composites varies from 38 to 47%. It is thus expected that the amorphous fraction is enough to demonstrate a glass transition temperature (T
g). The glass transition of the samples was tested using differential scanning calorimetry.
Figure 2a presents the heat flow curves obtained for the PP
R matrix and the fibre reinforced modified composites on a narrow temperature range around the T
g. The glass transition was calculated using the midpoint temperature method [
18].
Figure 2b shows the glass transition temperature dependence on the addition of glass fibres and different PP-
g-MA content in the PP
R matrix. The addition of glass fibres and the compatibilizer resulted in a drop inT
g temperature, indicating an overall improvement in the polymer chain mobility and the existence of fibre/matrix and/or fibre/fibre slipping and sliding interaction mechanisms [
19,
20]. The addition of up to 2.5 wt.% PP-
g-MA slightly increased T
g from −11.3 °C for composite PP
Rm
0%/GF to −10.2 °C for PP
Rm
2.5%/GF due to the improved interfacial adhesion between the glass fibres and the PP
R matrix, resulting in refined interfaces. However, it is noted that the addition of a small amount of compatibilizer only slightly enhanced the fibre/matrix interaction.
The melting and crystallization properties of the samples were also tested using DSC.
Figure 3 shows the thermograms of neat PP
R and the PP
Rm
x%/GF composites obtained following the thermal history erase procedure. Single melting and crystallization peaks obtained for all samples confirmed the single-phase crystalline state of PP
R prior to and after the PP-
g-MA modification.
Table 2 summarizes the effect of glass fibres and different compatibilizer content on the melting and crystallization behaviour of PP
R.
Incorporation of 10 wt.% glass fibres in the PP
R significantly enhanced the crystallization temperature from 97.1 to 101.6 °C, suggesting the heterogeneous nucleation of PP on the surface of the fibres, leading to faster crystallization rates [
14,
21]. The addition of PP-
g-MA in the PP
R/GF composites also resulted in slightly lower melting and crystallization temperatures, while the effect on the melting enthalpy (ΔH
m) is only marginal. The determined values of the crystallization enthalpy (ΔH
c) are higher compared to that of PP
Rm
0%/GF composite because of the improved compatibility between the fibres and PP
R. It is also noted that with an increment to the compatibilizer content, the melting temperature, the melting enthalpy and the crystallization enthalpy decreased slightly, indicating the limited effect PP-
g-MA on the interaction mechanism of the PP
R/GF interfaces and the nucleation of PP
R [
22]. This confirms the glass transition temperature results discussed earlier. Furthermore, it is expected that with the lowering of the crystallization enthalpy, the crystallinity will also be reduced, and the composites will become less brittle, which is in excellent agreement with the results obtained for the XRD crystallinity index.
Tensile testing stress–strain curves until fracture were obtained for all samples. The recorded stress–strain curves were used to calculate the elongation percentage at break-point, the yield strength and the Young’s modulus (
E), and the results are shown in
Table 3. The use of glass fibres resulted in a considerable increment of the elastic modulus from 194 for neat PP
R to 481 MPa for the PP
Rm
0%/GF composites, as a result of the effective stiffening effect of GFs to the PP
R matrix. The reinforcing effect of the glass fibres becomes more evident when the compatibilizer is incorporated in the composite, confirming once more the improvement of the matrix/fibre interaction with the addition of PP-
g-MA [
23]. Incorporation of up to 2.5 wt.% of PP-
g-MA provided a hardening contribution, and the Young’s modulus increased to 532 MPa. It is no wonder, despite the small ratio, since a satisfactory adhesion facilitates GF to provide mechanical endurance, by transferring the load to the polymeric matrix. The effect of the fibres and compatibilizer content on the Young’s modulus of the PP
R matrix was also analysed using the Halpin–Tsai equation [
24]:
where E
m and E
c are the Young’s modulus of PP
R and the PP
Rm
x%/GF composites, respectively, V
f = 0.037 is the volume fraction of the 10 wt.% glass fibres in the composites and
ζ is the reinforcing parameter. The parameter
η can be calculated using the equation:
where E
f = 80 GPa is the Young’s modulus value of the glass fibres [
25]. The PP
R matrix modulus was found equal to 194 MPa. The reinforcing efficiency can take a large range of values, 0 ≤
ζ ≤ ∞, depending on the matrix, the fillers, the fibre packaging, the isotropy of the system, etc. For very small
ζ values, the composite is considered to be stress-loaded in the direction transverse to that of the fibres’ direction, whereas for large
ζ values, the stress is considered to be applied parallel to the fibres [
24]. Various
ζ parameter values were used to describe the Young’s modulus of the composites, as shown in
Table 3. The PP
Rm
x%/GF demonstrated a reinforcing efficiency varying approximately from 40 to 60, indicating similar fibre spatiality. The small increase in
ζ values with the addition of the compatibilizer can be attributed to the improved fibre/matrix interaction as well as the reduced fibre/fibre interactions due to the PP-
g-MA “lubrication”. This means that the addition of PP-
g-MA in the composites limits the fibre interaction during processing, avoidingfibre breakage and the shrinking of the fibres’ length. As a result, an improved load-bearing capacity and stiffening is achieved due to the sufficient length of the fibres facilitating stress transfer [
26]. The yield point of tensile strength of the composites shows similar behaviour to the modulus as a result of the good stress transfer. A maximum value of 26 MPa was obtained for PP
Rm
1%/GF. However, as the yield strength values and their deviation for the PP
Rm
1%/GF and PP
Rm
2.5%/GF composites are comparable, clear conclusions cannot be obtained for these data. Even though the use of a compatibilizer allows the application of higher stress loads before the irreversible deformation starts, the maximum failure stress and thus the elongation at break significantly decreased for the composites. Tröltzschet al. [
27] observed lowering of the load-bearing capability of the composites, which can be attributed to the formation of intermolecular hydrogen bonds due to the presence of the compatibilizer. H-bonds are weaker than covalent bonds, but they add affinity and “collision” if present in a system.
Figure 4 shows SEM images obtained from the fracture surface of the tensile test specimens of the samples. As shown in
Figure 4a, the fracture surface of pure PP
R is smooth with a granular appearance without any sign of plastic deformation, characteristics of a brittle fracture. The incorporation of glass fibres in the random polypropylene matrix (
Figure 4b,c) led to the breakage and withdrawal of the fibres at the fracture point during the elongation. The GFs appear peeled off the PP
R (
Figure 4c, white arrows) due to the pure fibre/matrix adhesion, while the polymeric matrix demonstrated a fibrillar-like structure (
Figure 4b), possibly related to the local plastic deformation of PP
R. Previous publications suggest that the fibrillation of the matrix is due to the enhancement of plastic deformation around the glass fibres [
28]. Furthermore, the bare glass fibres seem to have a certain degree of orientation possible due to a fibre twist, which occurred in the matrix during the elongation stress loading.
For the PP-
g-MA PP
Rm
2.5%/GF modified composites, the matrix demonstrated an extended plastic deformation and higher fracture surface roughness due to extensive fibrillar formations (yellow arrows in
Figure 4d,e,h–j). Additionally, it is apparent that the addition of the compatibilizer in the composites improved the PP
R matrix adhesion on the fibres. The GFs present at the fracture surface were mostly covered by a polymer layer (red arrows in
Figure 4d,g). Alternatively, PP
R fractions of various dimensions were well attached on the surface of the fibres (red arrows in
Figure 4h–j). The improvement of the bonding capability of the matrix on the glass fibre surface due to formation of chemical bonds promoted by the addition of PP-
g-MA enables transferring of the applied strain load from the matrix to the fibres, leading to higher Young’s modulus and yield strength values as discussed earlier. Furthermore, the improvement of the ductility of the PP
Rm
x%/GF composites is considered the main failure mechanism lowering the maximum stress the composites can withstand during flexural tests before breaking and as a result the lower elongation at break (
Table 3) [
28].
Finally, the effect of the addition of a compatibilizer on the thermomechanical properties of the composites was also tested using dynamic mechanical analysis (DMA).
Figure 5 shows the temperature dependence of the storage modulus,
E′, and the ratio of loss to storage modulus, tan
δ, at a frequency of 1 Hz of all the samples. Up to approximately 60 °C, the storage modulus of all samples demonstrates a sharp decrease due to the relaxation of the amorphous phase that follows the glass transition region. Furthermore, with the addition of the glass fibres and the compatibilizer, the storage modulus increases throughout the temperature range studied. In particular, the PP
Rm
0%/GF composite demonstrated an increase measuring from 10 to 32% in the modulus compared to neat PP
R, while the addition of the compatibilizer resulted in a maximum modulus approximately 1.3 times higher for the PP
Rm
2.5%/GF composite compared to the non-modified composite. Despite seeming a bit inconsistent, tan
δ curves are in accordance with the literature for PP for recordings above RT [
29].
The storage modulus improvement over the experimental temperature range confirms the improved stiffening and reinforcing effect of the fibres due to the addition of the modifier, typical of the enhanced fibre/matrix interaction. Overall, the tanδ decreases with the addition of fibres in the PPR matrix due to the moderate interaction between the polymeric matrix and the fillers. Incorporation of the modifier improved the energy dissipation potential of the composites; however, only PPRm2.5%/GF demonstrated similar vibration damping efficiency to neat PPR. The rest of the composites exhibited a rather elastic character, which is expected to improve the load storage capacity of the PPR matrix. Furthermore, the irregularity in tanδ curves of PPRm1%/GF and PPRm2.5%/GF shown at 55–60 °C is rather attributed to displacement of some rigid parts of the polymeric chains, perhaps because of the preparation mixing process.