Borassus Husk Fibre/Epoxy Composites: Experimental Analysis of Physical, Thermal, Flexural, and Dynamic Mechanical Properties for High-Performance Applications

This study explores the impact of alkali treatment on the physical, thermal, flexural, and thermo-mechanical properties of Borassus flabellifer husk fiber-reinforced epoxy composites in accordance with standards. Using the hand layup method, composites were fabricated with 10% (wt.) untreated and alkali-treated fibers (0.25–2 hours). SEM analysis confirmed improved fiber-matrix adhesion, leading to enhanced properties. Treated fiber composites exhibited reduced moisture regain (0.57−1.28%) and water absorption (0.59−1.55%), indicating superior moisture resistance. Thermal stability increased with alkali treatment, with integral process decomposition temperature (IPDT) reaching 547°C for 2-hr treated fibers. The glass transition temperature (Tg) peaked at 94.5°C for the 0.5-hr treated Borassus fiber-reinforced epoxy (0.5TBHFE). Flexural modulus (up to 3.2 GPa) and strength (up to 108.7 MPa) exceeded many conventional bio-fibers-reinforced composites, making them rational for structural applications. Dynamic mechanical analysis showed enhanced damping properties (tan δ up to 1.21), improving energy dissipation and impact resistance. Overall, 0.5TBHFE offered an optimum balance between stiffness and damping, making it suitable for aerospace and automotive applications. This study highlights the potential of Borassus husk fibers as a sustainable reinforcement alternative, though further optimization and industrial processing are needed for broader application.