Influence of Fiber Content on Mechanical and Morphological Properties of Woven Kenaf Reinforced PVB Film Produced Using a Hot Press Technique

7/24/2019 Influence of Fiber Content on Mechanical and Morphological Properties of Woven Kenaf Reinforced PVB Film Produ

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Research ArticleInfluence of Fiber Content on Mechanical andMorphological Properties of Woven Kenaf ReinforcedPVB Film Produced Using a Hot Press Technique

Suhad D. Salman,1,2 Z. Leman,1 M. T. H. Sultan,3 M. R. Ishak,3,4 and F. Cardona3

Department of Mechanical and Manufacturing Engineering, Faculty of Engineering, Universiti Putra Malaysia, Serdang, Selangor, Malaysia

Materials Engineering Department, Faculty of Engineering, Al-Mustansiriya University, Baghdad, IraqAerospace Manufacturing Research Centre (AMRC), Level , ower Block, Faculty of Engineering, Universiti Putra Malaysia, Serdang, Selangor, Malaysia

Laboratory of Bio-Composites echnology, Institute of ropical Forestry and Forest Products (INROP),Universiti Putra Malaysia (UPM), Serdang, Selangor, Malaysia

Correspondence should be addressed to Suhad D. Salman; [email protected]

Received December ; Accepted January

Academic Editor: Heitor L. Ornaghi

Copyright Suhad D. Salman et al. Tis is an open access article distributed under the Creative Commons AttributionLicense, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properlycited.

Tis work addresses the results o experimental investigation carried out on mechanical and morphological properties o plainwoven kena ber reinorced PVB lm which was prepared by hot press technique. Te composites were prepared with variousbercontents: %, %, %, %, %, %, and% (by weight), with the processing parameters C, min, and ata pressureo MPa applied on the material. ensile, exural, and Charpy impact properties were studied as well as morphological propertieso impact racture surace. With the increase in kena bers content up to %, the PVB composites have shown lower tensile andexural strength accompanied with reduction in the ultimate strain o the composite. Te results showed that impact propertieswere affected in markedly differentways by using various kena contents and decrease with the increase in kena ber content up to%; however, high impact strength was observed even with % kena ber content. Furthermore, scanning electron microscopyor impact samples was utilised to demonstrate the different ailures in the racture suraces or various kena bers contents.

1. Introduction

Natural ber composites are proposed to replace syntheticmaterials in many engineering applications due to severaladvantages such as renewability, less abrasiveness to equip-ment, biodegradability, and low weight and cost []. Kenaber has been ound to be an important source o ber orcomposites due to its good properties and its contribution toenvironmentalsustainability and eco-riendly products [, ].

In several studies, El-Shekeil et al. [] have concen-trated their efforts on the study o the natural ber contenteffects on the behavior o composites. It was concludedthat the ber content strongly affects the overall propertieso composites; % ber loading displays the best tensile

strength, while the tensile modulus, thermal stability, hard-

ness, and exural strength increased with increase o bercontent, but the strain decreased. In other studies, Josephet al. [] and Ku et al. [] described a remarkable incremento mechanical behaviors in the polymeric composites byincreasing the natural ber content.

Likewise, Ochi [] and Nishino et al. [] indicatedthat unidirectional kena/polylactic acid composite at berloading o % has high tensile and exural strength. It wasconcluded that the decline in tensile strength and Youngsmodulus increased with the increase o ber loading withabove vol.%. Tis means bers might not be ully satu-rated because o insufficient lling o the polymer amount.Similarly, Lee et al. [] investigated the kena/polypropylene

Hindawi Publishing CorporationInternational Journal of Polymer ScienceVolume 2016, Article ID 7828451, 11 pageshttp://dx.doi.org/10.1155/2016/7828451


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International Journal o Polymer Science

composites abricated with different ber content, varyingrom % to % weight raction with % increment. Teresults indicated that the tensile strength and modulus okena/PP composites increased with increasing kena bercontents, reaching a maximum value at %, and thendecreased.

However, Hargitai et al. [] indicatedthat the mechanicalbehaviors o the hemp/PP composites improved when thehemp ber content increased, up to %, and reduced gradu-ally at %. Shibata et al. [] examined the exural behavioro the kena ber reinorced biodegradable resin compositesand observed that exural modulus increases with increasein kena loading irrespective o ber orientation. Tis is inagreement with the ndings o Liew [] who ound similartrends or oil palm ber/polyester composites and concludedthat the presence o % ber content is the best. Rao et al.[] studied experimentally the effect o banana ber loadingand other natural bers reinorced polyester composites onmechanical behaviors o their composites.

More recently, a ew attempts have been made to studythe effect o processing method and polymer type relative tothe physical and mechanical properties o composites basedon kena bers by Sharba et al. [, ]. From the results, itwas concluded that kena bers could be used as a potentialreinorcing material, in order to decrease the use o syntheticbers while taking advantage o natural resources.

However, the experimental results are different due tothe properties o bers and viscosity o matrix; thereore,the effect o ber loading on the mechanical behavioro composites is one o the signicant interests o manyresearchers. Even though many studies in the literatureinvestigate the ber loading effects on mechanical charac-terization, introducing new resin into the eld o naturalber composites gives more alternatives with a broad set oproperties. Kena reinorced PVB lm composites will opena new avenue or use in structural applications due to theirremarkable properties, or example, in the automotive andaircraf industries. Te objective o this research is to studythe effect o ber content on the mechanical perormance oplain woven kena reinorced PVB composite.

2. Materials and Methods

o clariy the effect o ber loading on the mechanicalbehavior o composites, plain woven kena and PVB lm

were utilised to abricate the composites with different kenaber loading. Plain woven kena was supplied by ZKK Sdn.Bhd., Malaysia, with the properties as reported in able and shown in Figure . PVB lm (polyvinyl butyral resin) isnow employed in a wide array o industrial processes andprojected to ascertain a bright uture or the new industry.Te PVB tensile strength is MPa and breaking elongation% (manuacturer data sheet).

.. Fabrication of Composite Samples. Te composite sam-ples were made with %, %, %, %, %, and %kena ber weight content by using a hot hydraulic presstechnique to reinorce PVB lm. A detailed ow chart or

: Properties o woven kena [].

Characterization Woven kena

Tickness,(mm) .

Weight (g/m2)

Density (g/cm3) .

Warp density (warp/inch) Wef density (wef/inch)

Wavelength,(mm) .

Interyarn abric porosity () .

Moisture content (%) .

Water uptake (%) .

Average breaking strength (MPa) .

Average maximum strain (%) .

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F : Kena ber.

processing method is explained in Figure . Six panels withdimension mm by mm were abricated and thencut by using a wheel saw machine, according to the ASMstandard o each test. For each panel, ve layers o wovenkena and six layers o PVB lm are centered betweentwo stainless-steel molds and hot plates o a compressionmoulding press. Te hot press plates are heated to Cand the compression pressure is increased to MPa and heldconstant or min. Ten, the platen temperature is reducedto room temperature (C), under pressure MPa, until the

temperature reaches

C. Te panel was taken out o thecompression molding rame and allowed to complete innercure.

.. Mechanical Properties of Composites. Te effect o bercontent on the tensile and exural properties o wovenkena/PVB composites was investigated in the compositelaboratory o the Mechanical Department, Universiti PutraMalaysia, according to the ASM D/DM- []and ASM D- []. Te composites were categorizedaccording to their ber weight ractions (%, %, %,%, and %). Te test was carried out to determine themaximum tensile strength, maximum tensile strain, tensile


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PVB resin

5 layers ofkenaf

Hot press

Kenaf/PVB composite

Motorised notch

Tensile test specimens

Flexural test specimens

Notched Charpy impactspecimens

Tensile test

Flexural test

Charpy impact

Temperature(C)

Time (s)

0 200 400 600 800 1000 1200 1400

250

200

150

100

50

0

MPa

CoolingP

reh

eati

ng

300 mm

300mm

Pressing, 8

F : Drawing o the plain woven kena/PVB composite laminates by using the hot press technique and the temperature prole.

modulus, and stress-strain graphs, with crosshead speed o mm/min. ensile specimens were cut to mm mmactual thickness or each composite, rectangular sectionalarea at strip (gage length o mm). Four tabs plates witha dimension o mm were attached to the two sides oboth ends o the specimens by an adhesion agent.

Te exural tests were investigated using the three-pointbending xture with rectangular shape three-point bendingspecimens, mm . mm actual thickness or eachcomposite. Te distance between the supports (span length)was calculated as per the standard, with a ratio o : .Te crosshead motion was calculated or each composite,according to

= 2

6 , ()

whereis rate o crosshead motion (mm/min), is supportspan (mm),is depth o composite (mm), and is equal to..

Te exural modulus or bending modulus was calculatedby drawing a tangent to the steepest initial straight-lineportion o the stress-strain curve and using

=

3

4, ()

whereis the modulus o elasticity in bending (MPa),isthe slope o the tangent to the initial straight-line portion o

the load-deection curve, (N/mm) o deection, and

is thewidth o sample tested (mm).Eight samples or each composite were tested and the

average value o ve specimen results was reported by usinga universal testing machine (Instron ) with a capacity o KN (or both tests).

Te impact strength o the samples was measured usingCharpy impact test machine, according to the ASM D[]. Te Charpy impact tests were conducted by using auniversal testing machine, INSRON, MECOMB, in the Lab-oratory o Bio-Composites echnology, Institute o ropicalForestry and Forest Products (INROP), Universiti PutraMalaysia. By using a wheel saw machine, the specimens were

careully cut and nished to the accurate size, mm

. mm actual thickness or different weight raction andstriking hammer energy (., ., ., and . joules). Allimpact test samples were notched withthe radius o curvature.mm to . mm by motorised Notchvis in the middle.Eight specimens or each composite and energy level weretested and the average value o ve specimen results wasreported.

.. Morphological Observation. Te inuence o the kenaber content on the ractured surace o the composites aferCharpy impact test was observed by using the scanning elec-tron microscope (SEM) instrument model Hitachi . kV,


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0

5

10

15

20

25

0 0.01 0.02 0.03 0.04 0.05 0.06

Tensiles

tress(MPa)

Tensile strain (mm/mm)

10%

20%

30%

40% [22]

50%

F : Average values o tensile stress-deormation diagram odifferent ber content o kena/PVB composites.

afer being coated with a thin layer o gold to avoid electroncharge accumulation.

3. Results and Discussions

.. ensile est Results. Figure shows that the stress-straincurve o kena/PVB lm with different ber content is linearand ollows Hookes law. It could be seen that the tensilestrength increased linearly with the increase o the tensilestrain and ber content, reaching a maximum value at %.However, when it reaches certain stress values, nonlinearbehavior is noticed, especially or the % and % bercontent. Te average tensile strength is . MPa, . MPa,. MPa, . Mpa, and . MPa or %, %, %, %[],and % ber content, respectively. Te results indicatedthat ailure takes place at a much lower strain rate at %and % kena ber content. Meanwhile, the highest tensilestrength was enhanced at % kena ber content. Te resultsindicated that the mechanical interlocking was sufficient totranser the load rom the PVB lm to the kena bers andthe reinorcing effect o the kena bers predominated, whileat low kena ber content, less ber amount caused low loadtranser capacity among the bers, which led to accumulation

o stress that occurred in the matrix which led to rapidailure o the composites. Te low stress rate or % bercontent is attributed to two reasons. Te rst reason is thelow tensile properties o PVB lm, and the second one is theact that the spacing between kena bers becomes so smallthat the stress transer between kena ber and PVB resinbecomes inefficient. As a result, a premature ailure occurreddue to increased shear stresses on all planes parallel to theaxes o the bers which led to delamination. It is stated byKim et al. [] that most highly polymeric materials tendto be stress rate dependent. It has been recorded that thestrength o composites is inuenced by several actors suchas ber content, ber/matrix interacial bonding, and ber

0

2

4

6

8

10

12

14

0 0.05 0.1 0.15 0.2

Flexur

estress(MPa)

Flexure strain (mm/mm)

10%

20%

30%

40% [22]

50%

F : Effect o different kena ber content on exural proper-ties o kena/PVB composites.

and matrix strength []. However, the ber works as loadcarriers in the matrix, and high tensile strength dependsmore on effective and uniorm stress distribution. Severalresearches have concluded that there is a practical maximumber content above which composite characteristics deteri-orate [, ] and/or porosity increases highly []. Similarndings were also observed by Ku et al. [], who reportedthat the increment o ber loading above % causes thereduction in ultimate strength.

.. Flexural est Results. Flexural characteristics representthe exibility o the materials and good exural strengthindicates that the materials have brittle properties and highhardness []. Figure shows the effect o different bercontent on the exural properties o kena/PVB composites.Flexural strength behaved with a similar trend to tensilestrength behavior; the % kena bercontent hasthe higheststress to resist deormation under exural condition. Asa result o good interacial bonding between kena berand PVB lm, the bers are effectively participating inthe stress transer. ensile, compression, and shear stressescaused the exural ailure that occurred at the two sideso the bending samples []. Te average exural strengthis . MPa, .MPa, . MPa, . MPa, and . MPa or

%, %, %, %, and % ber content, respectively.A characteristic stepwise reduction in exural stress wasdemonstrated with increasing both the strain o maximumexural stress and up to % kena ber content. Hence,the ailure in exural testing o the kena/PVB lm is dom-inated by individual ply ailure rather than any observableinterlaminar ailure. It can be concluded that % kenaber content exhibited relatively high exural strength; goodkena ber/PVB bonding offers an advantage over othercomposites. Te comparatively lower exural modulus o the% kena ber content is due to using lower percentageo PVB lm, which might lead to inefficient load transerrom ber to matrix (weak ber adhesion). As reported in


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0

5

10

15

20

25

0 10 20 30 40 50 60

Streng

th(MPa)

Fiber content (%)

Tensile

Flexural

(a)

0

200

400

600

800

1000

0 10 20 30 40 50 60

Modu

lus(MPa)

Fiber content (%)

Tensile

Flexural

(b)

0

3

6

9

12

15

0 10 20 30 40 50 60

Strain(%)

Fiber content (%)

Tensile

Flexural

(c)

F : Comparison o (a) tensile and exural strength with kena ber content, (b) tensile and exural modulus with kena ber content,and (c) tensile and exural strain with kena ber content.

0.5J 2.7J 5.4J 21.6J10% 0.497 1.932 2.052 2.87820% 0.479 1.964 3.506 3.08130% 0.497 2.595 3.557 3.60540% 0.797 2.699 4.642 5.0150% 0.497 1.426 1.748 1.93960% 0.397 1.154 1.462 1.549

0

1

2

3

4

5

6

7

Energy(J)

F : Effect o ber content on impact energy o kena/PVB composites at different energy levels.


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previous studies, the exural strength increased at the %bers content [, ], the stiffer and higher to resist anydeormation.

Figures (a), (b), and (c) show the effects o bercontent on the average tensile andexural strength, modulus,and strain o the kena ber reinorced PVB composites,

respectively. In Figure (a), it is noticed that the tensile andexural strength are increasing gradually with increase inber content up to % kena content and then decreased.Similarly, de Albuquerque et al. [] have reported the sametrend on the Jute reinorced polyester composites. Figure (b)shows that the modulus increased with addition o bers,reaching a maximum value at % kena content, andthen reduced. As discussed earlier, a lower value or tensileand exural modulus is predominantly seen or % kenacontent composites due to increased shear stresses on allplanes parallel to the axes o the bers. Te tensile modulus is. MPa, . MPa, . MPa, . MPa, and .MPaor %, %, %, %, and % ber content, respectively,

while exural modulus is . MPa, . MPa, . MPa,. MPa, and . MPa or %, %, %, %, and% ber content, respectively. Te tensile and exuralstrain show an inverse relationship to strength and modulus.As illustrated in Figure (c), when kena ber content wasincreased until %, ailure took place at the lowest strainrate. It can be indicated that the strain is decreasing withincrease in ber content, up to % ber content. Te tensilestrain is .%, .%, .%, .%, and .% or %, %,%, %, and % ber content, respectively. Te valueo the maximum tensile strain decreased slightly or %;nevertheless, exural strain increased or % continuously(.%). In the % kena ber content composite, insufficient

bers are mixed with large PVB matrix; thus, elongationwill be high because it is high in the PVB matrix. At %kena ber content composite, more kena bers were therewhich could transer stress properly along them, leading toless elongation. Tis prevents creating a crack propagationrate, thus causing the composite to break at a higher ailurestrain. Both bers content and characteristics o individualreinorcing bers are the main actors which have affected the

variation in the modulus and ailure strain o composites.

.. Impact est Results. Figure compares the energyabsorption capability o the different kena ber contentunder varied impact energies, . J, . J, . J, and . J,

respectively. Itshowed the variation o theenergyabsorbed bythe tested specimens under differentenergies levels. However,the Charpy impact energy o different kena content showedalmost the same behavior when tested under the same energylevel. It could be observed that there is an increase in thetotal energy absorption by the specimens up to % then adecrease was observed. Te level o maximum impact energyreached orthe % kena/PVB composite is thehighest valueat different energy levels. At low energy level, . J, there isnot a signicant difference in the absorbed energy that canbe observed or the various kena ber contents. However,when the energy level was increased, a high increment inthe absorbed energy can be seen or kena/PVB composite

0

1

2

3

4

5

6

7

0 10 20 30 40 50 60 70

Energy(J)

Fiber content (%)

0.5J

2.7J

5.4J

21.6J

F : Effect o ber content on impact energy o kena/PVBcomposites at different energy levels.

up to % kena ber content, as shown in Figure . Ten,the energy absorbed is decreased at % and % kenaber content, at different energy levels. Due to the lowerpercentage o resin, both intralayer ailures and delaminationaffect the total absorbed energy values at these kena bercontents, which is ound to change the ailure mechanism othe composites []. However, the amount and the type oailure mechanism depend on the impact energy level andmechanical properties o ber and matrix [].

A similar nding was also observed in the average impactstrength o the kena/PVB composites with different kenacontent and energy levels, as shown in Figure . It was clear

that, or the composite specimens with % kena bercontent, higher values o impact strength were recordedcompared with the other composites, at different energylevels. Tis is attributed to the act that the increase o bercontent above % causes lack o energy absorbance. It couldbe attributed to the increase o the stiffness o the compositeby increase o ber content to reinorced thermoplastics, asreported by Joffe andAndersons []. Generally, it canbe seenthat the impact energy strongly depends on the percentage othe ber content, especially when combining natural berswith thermoplastics [, ], as shown in Figure . Further,low interace shear stress between natural ber and polymerresin might contribute to the increase in the composite

strength. Te incorporation o lignocellulosic bers offersan obstacle to the propagation o an initial crack at thespecimen notch and then causes other cracks at the weakber/matrixinteraceto propagatelongitudinally through theinterace ollowing the specimen length direction. Likewise,Wirawan et al. [] have reported that higher absorbedimpact energy resulting in corresponding higher strength osugarcane reinorced PVC thermoplastic.

Similarly, the Charpy impact toughness seems to havethe same impact energy and impact strength behaviors atdifferent energy levels, as represented in Figures and . Itisclearly seen that the compositematerialswith % kena bercontent have the greatest impact toughness value, at different


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0.5J 2.7J 5.4J 21.6J

10% 28.25 130.64 206.35 278.960

20% 59.92 332.64 427.55 389.96

30% 62.16 349.96 442.81 506.38

40% 109.67 357.7 595.09 642.28

50% 107.17 335.32 364.77 382.03

60% 104.54 245.43 316.78 329.57

0

100

200

300

400

500

600

700

Charpyimpa

ctstrength(J/m)

F : Effect o ber content on impact strength o kena/PVB composites at different energy levels.

0

100

200

300

400

500

600

700

800

0 10 20 30 40 50 60 70

Charpyimpactstrength(J/m)

Fiber content (%)

0.5J2.7J

5.4J

21.6J

F : Effect o ber content on impact strength o kena/PVB composites.

0.5J 2.7J 5.4J 21.6J10% 2.38 12.96 19.82 24.40020% 4.16 23.26 29.9 27.6630% 4.2 23.49 35.71 41.1740% 9.9 30.42 42.81 44.6550% 8.31 24.12 29.91 31.0560% 7.47 17.53 21.4 23.37

0

8

16

24

32

40

48

56

Charpyimp

acttoughness(kJ/m

2

)

F : Effect o ber content on impact toughness o kena/PVB composites at different energy levels.


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0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70

Fiber content (%)

0.5J

2.7J

5.4J

21.6J

Impactto

ughness(kJ/m

2)

F : Effect o ber content on impact toughness o kena/PVB composites.

Rich regions of PVB

Gaps between kenaf bers and PVB

100m

(a) % kena weight

PVB yielding

Kenaf/PVB debonding

1.00 mm

(b) % kena weight

Interfacial bonding

Kenaf bers entanglement

1.00 mm

(c) % kena weight

Kenaf ber breakage

Disorderly distributed kenaf bers

3.00 mm

(d) % kena weight

Debonding

Kenaf ber degradation

3.00 mm

(e) % kena weight

Pores

Kenaf ber pulling out

1.00 mm

() % kena weight

F : Te SEM micrographs o the Charpy impact ailure suraces o kena/PVB lm composite.


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energy levels, while the average impact toughnesso the othercomposites showed almost the same behavior when tested atlow energy levels (. J). As research studies have reported[, ], both ber content and properties o the polymer areaccountable or deciding the impacttoughness o composites.Tis implies that both the effect o interlaminar delimitation

and interacial strength between ber and matrix highlydecide impact properties, especially in the case o weaving

pattern as stated by others [].

.. Morphological Properties. SEM photographs o all theimpacted specimens (%, %, %, %, %, and %kena ber content) are shown in Figure . Te racturedimpact surace with . J energy level was selected as arepresentative sample or the interpretation o the degreeo interacial adhesion. It is evident that the differencesin interacial adhesion resulted in the different racturemechanism, a combination o matrix cracking and gapsbetween kena bers and PVB lm as well as kena berbreakage. Tese ailure mechanisms agree very well with theimpact damage observed by Khan et al. [] or Jute abric-reinorced polypropylene composite and by Dhakal et al. []or nonwoven hemp ber reinorced unsaturated polyestercomposites.

Rich regions and matrix ailure were noted in the SEMimage o the % and % kena ber content, as shownin Figures (a) and (b), because o the lower kena bercontent, attributed to poor kena ber distribution, henceresulting in poor energy dissipation. In % and % kenaber content, an increasing trend in impact strength wasound. As a result o a strong bond at the interace, the impactdamage does not propagate into the vicinity o the impacted

point. Tis was revealed by SEM micrograph in Figures (c)and (d) which showed that the interacial bonding betweenkena ber and PVB lm was the best among all samples,reaching the highest impact strength. However, when thekena ber weight reaches beyond its threshold value, theimpregnation o PVB lm into the interace area is decreasedand results in weak bonding between PVB lm and kenaber. As a result o poor kena ber/PVB lm adhesion,the composites could not withstand urther impact loads, asnoticed in the composites o % and% kena bercontent.Figure (e) shows both entanglement o kena ber and kindo debonding between the kena bers and PVB lm, stillnot appearing to be to the maximum extent as shown in

Figure (). As a result, more shear action is observed inthe interacial zone which leads to layer-by-layer ractureo the matrix (delamination) and corroborates the observeddecrease in impact strength. Also, poor wetting o the kenaber surace and cohesive orce between kena bers maydecrease with the increase in kena bers content.

4. Conclusions

A new type o composite using kena ber reinorced PVBlm was abricated with different ber content, and itsmechanical behavior was studied. Six types o laminatedcomposites were abricated and compared under tensile and

exural andour levelso impactconditions.It was concludedthat the mechanical characteristics o the kena/PVB com-posites were variously affected by the kena ber loading.% kena content composite has optimized mechanicalproperties, ollowed by % kena content, while % and% kena content composites have shown the weakest

perormance. SEM examinations o impact specimens showthat the kena ber content played an important role in theinteracial bonding between kena ber and PVB lm, whichaffects the mechanical properties o composites.

Conflict of Interests

Te authors declare that there is no conict o interestsregarding the publication o this paper.

Acknowledgments

Tis work is supported by UPM under GP-IPS//

and GP-IPB Grant, . Te authors would like toexpress their gratitude and sincere appreciation to theMechanical and Manuacturing Engineering Departmentand Aerospace Manuacturing Research Centre o the Uni-

versiti Putra Malaysia. Teir appreciation and gratitude alsoextend to the Ministry o Higher Education & ScienticResearch o Iraq and to the Material Engineering Depart-ment, College o Engineering, at the Al-Mustansiriya Univer-sity or their scientic assistance and nancial support.

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Influence of Fiber Content on Mechanical and Morphological Properties of Woven Kenaf Reinforced PVB Film Produced Using a Hot Press Technique