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WEB ACCESS 2022: Volumes 905 - 938 (34 Vols.)
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The Journal published as of 1982 - 2021: 904 Vols.
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Materials Science Forum
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Wear Properties of Stainless Steel Lubricated by Cerbera and Rubber Seeds Methyl Estersunder Boundary Lubrication ConditionZ. Fuadi, R. Kurniawan, M. Dirhamsyah, S. Bahri, M. Muhammad, K. Kanda and K. Adachi 1
Adsorption of Iron (II) Ion by Using Magnetite-Bentonite-Based Monolith from WaterI. Nurul, S. Yanna, Adisalamun, A.S. Veneza and Darmadi 10
GTA Welding Dissimilar of AISI 309 to AISI 201 Stainless Steels by Using AISI 308L FillerMetalsSuherman, Ilmi, C.P. Sitompul, H.B. Kurniyanto and Suprapto 17
Mapping Corrosivity Steel Construction at Atmospheric Conditions in Langsa Town Centerand Palm Oil Mill IndustryZ. Muhammad, A. Nurdin, Husaini and M. Sri 25
Immobilization of Silver Nanoparticles on Chitosan-Coated Silica-Gel-Beads and theAntibacterial ActivityM.I. Hidayat, M. Adlim, I. Maulana and M. Zulfajri 36
The Design of Reactive Powder Concrete (RPC) Mixtures Using Aceh Quartzite PowderY.R. Alkhaly, Abdullah, Husaini and M. Hasan 43
Permanent Deformation and Fatigue of Semi Flexible Pavement Incorporating Waste TireRubber and Natural ZeoliteHamzani, Munirwansyah, M. Hasan, Sugiarto and Zulfhazli 51
Experimental Investigation of Making a Composite Material from Plastic (LDPE) WasteM.E. Arsana, I.N. Suamir, Sudirman, I.W. Temaja and I.B.G. Widiantara 59
Influence of Rubber Content on Failure Mode and Resistance Characteristics of PC/ABSBlends and their ABS Constituents under ImpactM.N. Machmud, M. Omiya, H. Inoue and K. Kishimoto 67
Failure Analysis of the Short Drive Shaft in a Screw Press MachineI.B. Muhammad, Husaini, A. Nurdin, A. Rauzatul and E.P. Teuku 74
Comparison of Hardness and Microstructure of Cast Wheel and Spoke Wheel Rims ofMotorcycles Made of Aluminum Alloy AlloyHusaini, A. Nurdin, A. Sofian and N.R. Muhammad 81
Failure Analysis of a Fractured Leaf Spring as the Suspension System Applied on the DumpTruckHusaini, R.H. Liza, A. Nurdin and S. Muammar 89
Flexural Resistance Analysis on Hot Asphalt Mixtures with Wire Mesh Placement Modelingas ReinforcementR. Ismy, Husaini, M.S. Sofyan and M. Isya 99
Failure Analysis on the Fracture Shaft of a Centrifugal Pump Used for Diesel EngineCooling SystemW. Saiful, Husaini and A. Nurdin 107
Chromate and Molybdate Inhibitors Effects on Corrosion Charateristic of API 5L Grade Bin a Brine Water Solution Containing 8 % NaClV. Malau and W. Hakiki 115
Stress Analysis on an Automotive Coil Spring Driven on Flat, Uphill, and Downhill RoadSurfacesH. Jagodang, Husaini, E.P. Teuku and D. Schramm 124
Nanomagnetite Extraction from Iron Sand Prepared by Mechanical Alloying MethodR. Adi, I. Ismail, Akhyar, J. Zulkarnain and H.G. Ariel 129
Bending Strength of Fiber Metal Laminate Based on Abaca Fiber Reinforced Polyester andAluminum Alloy Metal SheetM. Iqbal, M.S. Satrianda, T. Firsa, S.A. Azan and L.B. Abhang 134
Atmospheric Corrosion Analysis on Low Carbon Steel Plate Profile and Elbow in MedanBelawan DistrictAffandi, I. Tanjung, A.R. Nasution, A.G. Harahap, S. Fonna, A.K. Ariffin and S. Huzni 142
Advanced Technologies in Material Processing IIAdvanced Technologies in Material Processing IIAdvanced Technologies in Material Processing IIAdvanced Technologies in Material Processing IIISBN(softcover): 978-3-0357-1853-9 ISBN(eBook): 978-3-0357-3853-7
Numerical Simulation of Physical-Mechanical Properties Based on the Composition ofGTAW Weld Metal Alloys with Dissimilar Base MetalsSugianto, Riswanda, K. Harlian, Akhyar, Aminur and F. Arman 150
The Effect of Tool Rotation Speed on Hardness, Tensile Strength, and Microstructure ofDissimilar Friction Stir Welding of Dissimilar AA5083 and AA6061-T6 AlloysA. Wahyudianto, M.N. Ilman, P.T. Iswanto, Kusmono and Akhyar 159
Bending Strength of Fiber Metal Laminate Based on Abaca Fiber Reinforced Polyester and Aluminum Alloy Metal Sheet
M. Iqbal1,a*, M.S. Satrianda1 b, T. Firsa1,c, S.A. Azan2,d and L.B. Abhang3,e 1Mechanical and Industrial Engineering Dept, Universitas Syiah Kuala, Banda Aceh, Indonesia
2Civil Engineering Dept, Universitas Syiah Kuala, Banda Aceh, Indonesia 3Mechanical Engineering Dept. Pravara Rural Engineering College, Loni, SPPU, Pune,
Abstract. The Fiber Metal Laminate (FML) discussed here was made from Fiber Reinforced Polymer (FRP) composite, laminated by aluminum alloy sheet. The FRP composite panel was made from abaca fiber and polyester resin matrix. The objective was to study the bending strength of the FML with different fiber content. Five panels of abaca FRP were prepared using hand-lay-up methods. The weight content of the fiber in the panels were 0%, 3.56%, 5.18%, 8.94% and 12.22% respectively. The aluminum alloy sheet was laminated to the composite panel using epoxy super glue. The density of the FMLs were measured to confirm the fiber content in the panels. The bending specimen were prepared based on ASTM D-7264. The bending strength that represented by flexural stress of the FML panels were 53.15, 56.44, 46.80, 63.53 61.48 and 49.57 MPa, respectively. The result of the experiment showed that the content of abaca fiber significantly affects the bending strength of the FML. The highest bending strength (63.53 MPa) was produced by the FML with 5.18% fiber content. The result of the study showed that the bending strength of abaca FML was 19.5% higher than commercial FML (53.15 MPa). It was an indication that abaca fiber could be used to substitute the glass fiber in commercial FML.
Introduction Composite material has been considered as new material with excellent properties since it
combines the benefit of its based materials. Research and development have been widely conducted by researcher institutions and industries R&D for a better performance of either metal-based composite [1, 2, 3, 4], fiber-based composite [5, 6, 7] and wood-based composite [8]. Fiber Reinforced Polymer (FRP) composite has been a popular non-metal material due to their benefit such as light weight, high specific strength and stiffness, as well as a superior fatigue resistance. Their application becomes wider from time to time, including engine component, vehicles and sport equipment [5, 9].
However, FRP composite has low impact strength. The impact during application could starts crack on the FRP surface and even worst, it could cause fracture. In the manufacturing stage of the product, FRP composite could not be transformed to other shape, even a simple bending to form a curve surface. To overcome the problems, researchers and industries combined FRP composite with thin metal plates to produce a new material called as Fiber Metal Laminate (FML). Both of FRP surfaces were laminated with thin metal plate (less than 1 mm thickness). The FML took advantage of the properties of the FRP composite and the metal plate, such as, ductility, impact performance, fatigue strength and fracture properties. Compare to its single source material, FML was better in almost all of property parameters.
FML is a though material. When the collusion occurred in the application, the metal plate protects the FRP composite from the impact force and avoid the crack. At the same time the impact energy is absorbed by the FRP composite and protect FML from fracture. In the manufacturing stage, the
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ductility of the metal plate makes the FML could be transformed to other shape, like circular, curve, or even sharp bend. The better properties, make the FML being attractive materials use for aircraft parts, such as in doors, in the nose structure, in wings and empennage leading edges, as well as in wall structures in the cargo hold [10].
FML have been developed from several types of fibers, i.e. glass fiber, carbon fiber, hybrid glass and carbon fiber. Mostly FML was laminated by aluminum alloy sheet because of its lower price, light weight and good mechanical properties [11], but other metal laminates were also available such as titanium and magnesium alloy. The manufacturing method and process treatment have been studied to improve the performance of the FML. Mendibil et al (2016) developed FML from glass fiber and aluminum sheet using liquid molding process, modified by drill holes for flow paths of the resin to enable the impregnation through the aluminum sheets. They investigated the FML’s structure and provided low velocity impact tests. The results showed that the impregnation was successful with a strong bounding between FRP and the aluminum sheet. Furthermore, the presence of the holes has no effect on the performance of the plate during the impact loading [12].
Dhaliwan et al developed FML from carbon fiber and aluminum sheet, and investigated the influence of layer structure and resin layers on the delamination and compression after impact response. They found that the addition of resin rich layers at interfaces of carbon FRP and aluminum layers reduced delamination area by 40-50%, and increased the residual compressive strength by 30-35% [13].
Dadej and Bieniaś developed hybrid FML from glass fiber and carbon fiber to improve the properties of the FML compare to individual type of fiber. Theoretical predictions of static and fatigue strength were performed and validated experimentally in their research. They found that the hybrid glass/ carbon FMLs are featured by lower static but higher fatigue strength than glass fiber FML [14].
Nassir et al [15] developed FML based on a fiber reinforced composite laminated by titanium alloy and applied a laser surface treatment to the metal plies. The evaluated the effect of the treatment and compared the response to the untreated FML. The result showed that applying a laser fluence of 4.54 J/cm2 to the titanium layers in the FML gave a good bond strength between the titanium foil and the glass fiber composite.
Zhang et al [16] developed FML based on magnesium alloys (MgFML) with different surface treatments and different bonding types. They tested and analyzed it by using dynamic contact angle measurement and scanning electron microscopy (SEM). The result showed that phosphating treatment significantly improved the surface energy and wettability of magnesium alloy. The surface energy of phosphated magnesium alloy was approximately 50% higher than that of untreated one. Furthermore, phosphating treatment and modified polypropylene interleaf were observed to improve the tensile strength and interfacial fracture toughness of MgFML.
All of the FML product available on the market were made from synthetic fiber. FML from glass fiber has been the most popular one due to the lower price and sufficient strength for the applications. However, synthetic material has serious environmental problem such as, health issue and degradability process of the waste. The possibility to replace the synthetic material with natural ones has become a priority in research and development of industrial products [17]. Several researches have been conducted regarding FML from natural fiber.
Aminanda and Hamid [18] carried out an experimental study on hybrid aluminum-Palm fiber-aluminum hybrid composite plate subjected to energy impact. The result showed that the energy absorption of the hybrid composite plate increases linearly with the thickness of aluminum plate. They explained that the aluminum skin absorbed impact energy at the beginning of contact, while the remaining energy will be taken by the fiber as the second layer of panel. The methodology of this study could be used for designing the armor to absorb the energy of projectile using palm fiber composite panel.
Zareei et al [19] employed tensile and interlaminar shear tests to investigate the mechanical properties of environmentally-friendly fiber metal laminates with jute - basalt fibers as a hybrid reinforcement and aluminum (Al) 2024-T6 as a skin, as well as an epoxy serving as a matrix. The results showed that the jute fibers sandwiched by the basalt fibers had the high tensile strength
Key Engineering Materials Vol. 892 135
(213 MPa), elastic modulus (39.5 GPa) and interlaminar shear strength (16.67 MPa). Microstructural investigations also revealed that the jute fibers had some weak bonding with the aluminum layers, whereas the basalt fibers had the strong one with them.
The work of Vieira et al [20] describes novel sisal fiber reinforced aluminum laminates (SiRALs) that prepared by cold pressing techniques and tested under tensile, flexural and impact loading. The result showed that the mean specific tensile strength and modulus of the SIRALs reached increased of 132% and 267%, respectively, when compared to the sisal fiber reinforced composites (SFRCs). They concluded that the SiRALs can be considered promising and sustainable composite materials for structural and multifunctional applications.
This research developed natural FML from abaca fiber, polyester matrix and aluminum alloy thin plate. Abaca fiber has been recognized as a potential natural fiber for composite application. It has good mechanical properties and has been produced mainly by Philippines, Ecuador and other tropical countries to supply the world demand [21, 22]. This research aims to study the flexural strength of abaca-aluminum alloy FML. The FML were fabricated with different fiber content to observe its effect to the flexural strength and to find out the fiber content that give the highest flexural strength. The flexural strength of the abaca FML was compared to the commercial FML to observe the possibility of abaca FML to substitute synthetic FML in the market. The result could be used as the reference for composite researcher and related industries to develop natural FML from abaca fiber for non-structural applications.
Method The abaca fiber was from Lhok Nibong, norh part of Aceh province, Indonesia, supplied by PT.
Nangroe Royal Diamond, a company that has been years in the business of abaca fiber. The fiber was rinse and cleaned by pure water, then dried naturally in the open space under the sun light. The dry fiber was then harrowed using metal comb to remove the dirt and to get similar size and orientation. No chemical treatment was applied to the fiber. The average length of the final fiber was 60 cm and the average diameter was 0.4 mm.
The matrix for the composite was commercial polyester resin with 1% hardener. The FRP composite was fabricated using hand-lay-up method in a glass mold with the pocket’s dimension of 200 mm length, 160 mm width and 5 mm depth, as shown in Fig 1 a. The abaca fiber was prepared in random orientation with sufficient size for the mold and stitched using a tinny cotton yarn to horizontal and vertical direction with 5 cm interval to form a fiber mat, as shown in Fig 1 b. In order to study the effect of fiber content, the fiber mats were prepared with 4 level of the weight, which are 5 gr, 10 gr, 15 gr and 20 gr respectively.
(a) (b) Fig. 1. FRP composite fabrication (a) the mould (b) the fiber mat
136 Advanced Technologies in Material Processing II
(a) (b)
Fig. 2. The fabrication of abaca FRP composite (a) molding (b) the composite panel
The fabrication process of abaca FRP was started with applying the wax to the surface of glass mold. Polyester resin and 1% weight of hardener were mixed up in electrical mixer and were stirred for 60 seconds to make sure that the resin and hardener were completely mixed. The mixture matrix then was poured into the mold to fill up approximately 50 % of the mold. The fiber mat was put into the mold and the rest of the matrix was poured until the mold completely full with fiber and matrix, as shown in Fig 2 a. The mold was closed with glass top cover and a 15 kg load was put on the top of the cover to press the composite to 5 mm thickness. The natural curing process started from this point. After 4 hours, the load and the top cover were removed and the curing process continued for the next 4 hours. After 8 hours of curing process, the abaca FRP composite was taken out from the mold and was ready to be laminated with aluminum alloy plate, as shown in Fig 2 b.
The 0.1 mm thickness aluminum alloy plate was laminated to the both surface of the abaca FRP composite panel using epoxy super glue. The plate was press to the composite surface using a hand roll to make sure that both surfaces were completely bounded. The FML panel was shown in Fig 3 a. The specimen for bending test was prepare according to ASTM D-7264, with 165 mm length and 19 mm width, as shown in Fig 3 b [23].
The bending test was conducted using three points method on Universal Testing Machine (UTM) Hung Ta HT-8503 with constant speed of 22 mm/min, and support’s distance of 115 mm, as shown in Fig 4 a and b. The force was applied continuously by the UTM machine until the bottom aluminum plate of the FML specimen was completely broken. The real time bending force and deflection were automatically recorded by the machine’s computer during the test and would be used latter for further analysis.
The fiber content of the abaca FRP was calculated using the following equation
WF = 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤
(1)
Where: WF = mass percentage of fiber content (%) wf = weight ot abaca fiber wc = weight of abaca FRP panel
(a) (b)
Fig. 3. Abaca FML (a) the FML panel (b) FML for bending test specimen
Key Engineering Materials Vol. 892 137
(a) (b) (c)
Fig. 4. The three point bending test (a, b) the testing process (c) the speciment after the test
The density of the abaca FML was calculated using the following equation:
𝜌𝜌 = 𝑚𝑚𝑉𝑉
(2)
Where: 𝑚𝑚 = mass of the FML specimen (gr) 𝑉𝑉 = volume of the FML specimen (cm3) The mass (m) was measured by using weighing scale. The volume (V) was measured by using glass scale where the FML specimen was put into the glass scale with a certain level of water inside. The volume of the FML specimen was the different of the water level before and after the FML specimen was put in the glass scale.
The flexural stress of the abaca FML was calculated using the following equation
𝜎𝜎𝑏𝑏 = 3𝐹𝐹𝑚𝑚𝐿𝐿2𝑏𝑏𝑑𝑑2
(3)
Where: 𝜎𝜎𝑏𝑏 = Flexural stress (MPa) 𝐹𝐹𝑚𝑚 = bending force (N), recorded by the UTM machine during the bending test L = The distance between the two supports = 115 mm b = The width of the FML specimen = 19 mm d = The thickness of FML specimen (mm), measured from each FML specimen
Result and Discussion The bending experiment were conducted to commercial FML, FML without fiber (only polyester
resin) and abaca FML with all fiber content levels. The commercial FML was the FML product that available in the market. The 3 mm thickness FML made by Super Bond brand was chosen because it could be easily found in most of hardware shops in Indonesia. Each of the experiment were repeated 3 times to avoid experimental error or ununiform specimen. The average of the 3 repeated data were considered as the final result of the experiment. After the bending test, the bottom plate of all of the specimen were completely broken. It indicated that the surface of the abaca FRP and aluminum plate has a perfect bounding. There is no slip between the surface when the shear force occurred during the
Table 1. Result of the experiment No Fiber content Weight of
138 Advanced Technologies in Material Processing II
Fig. 5. The flexural strength of commercial FML and abaca FML with different fiber content
bending test. Based on the data obtained by weighing, scale and bending test, the weight percentage of fiber content was calculated using equation 1, density was calculated using equation 2 and flexural stress was calculated using equation 3. The result was shown in Table 1.
Table 1 showed that the density of the FML decreased by increasing the fiber content. It was because the density of the fiber was lower than the density of the polyester resin. Since the volume of the FRP composite was maintained to be constant, increasing the fiber content will decrease the amount of polyester resin and decrease the total weight of panel.
In order to show the effect of fiber content and the comparison between the abaca FML and commercial FML, result of the experiment was shown in a bar chart (Fig 5). It could be seen in Fig 5 that the fiber content gave significant effect to the flexural strength of the abaca FML. The flexural strength of abaca FML with 3.56% of fiber content was 46.80 MPa. It was lower than the flexural strength of FML without fiber (56.44 MPa). When the fiber content increased to 5.18%, the flexural strength increased to 63.53 MPa. However, increasing the fiber content after this level, decreased the flexural strength. It was because abaca fiber and polyester resin have different mechanical properties. Mixing both of these material in a composite panel produced new mechanical properties.
The highest flexural strength was 63.53 MPa, produced by the abaca FML with 5.18% fiber content. It was 19,53% higher than commercial FML (53,15 MPa). It shown that abaca FML could be used to substitute commercial synthetic FML. Furthermore, the flexural strength of abaca FML could be increased by applying chemical treatment to abaca fiber before the fabrication process of the composite panel [24, 25]. However, the commercial FML has lower density compare to abaca FML. Further research was required to improve the mechanical properties of abaca fiber using chemical treatment and to reduce the density of abaca FML as the requirement of light-weight material. Other important future work was the study on machinability of abaca FML. Since the abaca FML will be used as the material for many types of products, it requires machining processes such as drilling and milling. The machining issues, i. e. influence of cutting parameters [26], optimum cutting condition [27], cutting temperature [28], cutting force [29], vibration, tool wear, delamination and surface roughness need to be studied in detail.
Conclusion The natural FML from abaca fiber and polyester resin matrix has been fabricated and its flexural
strength has been studied. The experiment showed that the fiber content gave significant effect to the flexural strength of the abaca FML. The highest flexural strength was 63.53 MPa, achieved by fiber content of 5.18%. Compare to commercial FML, the flexural strength of abaca FML was 19.53% higher. The result of the experiment indicated that the abaca fiber is a potential natural fiber to
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substitute synthetic fiber in commercial FML. Further study needs to be conducted, such as applying chemical treatment, to improve the mechanical properties of abaca fiber.
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