Effect of Sequence-Based Incorporation of Fillers, Kenaf Fiber and Graphene Nanoplate, on Polypropylene Composites via a Physicochemical Compounding Method

Abstract

Natural-fiber-reinforced polypropylene (PP) composites are gaining increasing interest as lightweight, sustainable alternatives for various packaging and applications. This study investigates the effect of filler addition sequence on the mechanical, morphological, thermal, and dynamic mechanical properties of PP-based composites reinforced with graphite nanoplatelets (GnP) and kenaf fiber (KF). Two filler incorporation sequences were evaluated: GnP/KF/PP (GnP initially mixed with KF before PP addition) and GnP/PP/KF (KF added after mixing GnP with PP). The GnP/KF/PP composite exhibited superior mechanical properties, with tensile strength and flexural strength increasing by up to 25% compared to the control, while GnP/PP/KF showed a 13% improvement. SEM analyses revealed that initial mixing of GnP with KF significantly improved filler dispersion and interfacial bonding, enhancing stress transfer within the composite. XRD and DSC analyses showed reduced crystallinity and lower crystallization temperatures in the addition of KF due to restricted polymer chain mobility. Thermal stability assessed by TGA indicated minimal differences between the composites regardless of filler sequence. DMA results demonstrated a significantly higher storage modulus and enhanced elastic response in the addition of KF, alongside a slight decrease in glass transition temperature (T_g). The results emphasize the importance of optimizing filler addition sequences to enhance mechanical performance, confirming the potential of these composites in sustainable packaging and structural automotive applications.