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Journal of Polymer & Composites Original Research

Development of Polymer–Micro-Aluminum Composites for Lightweight Engineering Applications

  1. P. Saravana Kumar Department of Mechanical Engineering, University college of Engineering Arni, Thatchur
  2. D. Sudha Department of Physics, R.M.K. Engineering College, Kavaraipettai
  3. Nantha Kumar P Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai
  4. N. Rajesh Department of Mechanical Engineering, Sri Venkateswara college of Engineering, Tirupati
  5. T. Venkatamuni Department of Mechanical Engineering, VSB Engineering College, Karur
  6. Sivakumar A. Department of Mechanical Engineering, Varuvan Vadivelan Institute of Technology, Dharmapuri
  7. J. Sharmila Department of Chemistry, St. Joseph's College of Engineering, OMR, Chennai
  8. Shailendra Kumar Bohidar Department of Mechanical Engineering, School of Engineering & I.T., MATS University, Arang, Raipur
  9. Zakir Hussain Department of Chemical Technology, Loyola Academy, Secunderabad

Abstract

This research focuses on the systematic development of polymer–micro aluminum composites, with polypropylene (PP) and epoxy selected as representative polymer matrices. Micro aluminum fillers in the range of 5–25 wt.% were incorporated through melt blending (PP) and casting (epoxy), and the resulting composites were evaluated in terms of mechanical performance, microstructural integrity, and crystalline characteristics. Tensile strength of the composites increased significantly, from 31 MPa in neat PP to 44 MPa in PP–20 wt.% Al (~42% improvement), and from 62 MPa in neat epoxy to 86 MPa in epoxy–20 wt.% Al (~38% improvement). Flexural strength exhibited similar enhancements, peaking at 70 MPa for PP composites and 125 MPa for epoxy composites, corresponding to ~67% and ~39% improvements, respectively. Hardness of both polymer composites improved progressively up to 20 wt.% filler, followed by marginal decline due to particle clustering and void formation. SEM microstructural characterization confirmed that filler dispersion and polymer–filler adhesion were critical to composite strengthening, with well-bonded particles at intermediate contents and severe agglomeration at 25 wt.%. XRD diffraction patterns revealed the preservation of crystalline aluminum peaks ((111), (200), (220), (311)) within both polymer matrices, with sharper intensities in epoxy composites due to superior interfacial compatibility. The results clearly establish that polymer–micro aluminum composites achieve optimum performance at 20 wt.% filler loading, beyond which agglomeration undermines their advantages. These findings highlight the potential of polymer composites reinforced with micro aluminum for multifunctional lightweight engineering applications.

Keywords

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