Glass fibres are by far the most extensively used fibre reinforcement in thermosetting composites because of their excellent cost-performance ratio. However, glass fibres have some disadvantages such as non- renewability and problems with ultimate disposal at the end of a materials lifetime since they cannot be completely thermally incinerated. The possibility of replacing E-glass fibres with hemp fibres as reinforcement in sheet moulding compounds (SMC) is examined in this thesis. The composites are manufactured with existing SMC processing techniques and similar resin formulation as used in the commercial industry. An attempt is made to enhance/optimise the mechanical properties of hemp/polyester composites. For this the fibre-matrix interface is modified via chemical modifications with alkaline and silane treatments. Influence of hemp fibre volume fraction, calcium carbonate (CaCO3)filler content and fibre-matrix interface modification on the mechanical properties of hemp fibre-mat-reinforced sheet moulding compounds (H-SMC) is studied. The results of H-SMC composites are compared to E-glass fibre-reinforced sheet moulding compounds (G-SMC). In order to get a better insight in the importance of these different parameters for the optimisation of composite performance, the experimental results are compared with theoretical predictions made using modified micromechanical models such as Cox-Krenchel and Kelly- Tyson for random short-fibre-reinforced composites. These models are supplemented with parameters of composite porosity to improve the prediction of natural fibre composite tensile properties. The influence of impact damage on the residual exural strength of the H-SMC composites is investigated to improve the understanding of impact response of natural fibre reinforced composites. The result of penetration and absorbed energies during non-penetrating impact of H-SMC composites are investigated and compared to values for G-SMC. A simple mechanistic model has been developed for H-SMC composites and is used to get an insight into the impact behaviour of these composite as well as to provide a guideline to compare the experimental results with theoretically calculated data. The fracture toughness properties in terms of the critical-stress-intensity factor KIc, and critical strain energy release rate, GIc, of H-SMC and G-SMC composites are studied using the compact tension (CT) method. It was shown that fracture toughness of H-SMC composites is significantly lower than that of glass fibre reinforced composites (G- SMC). However, results show that with an optimum combination of fibre volume fraction, (CaCO3) filler and surface treatment of the hemp fibres can result in H-SMC composites that have fracture toughness properties that can be exploited for low to medium range engineering applications. It is recommended that to further improve the fracture toughness properties of these natural fibre reinforced composites more research needs to be devoted to the optimization of the fibre-matrix interface properties and ways of reducing porosity content in these composites. Finally, environmental impact of H-SMC composite with conventional G-SMC composite for automotive and non-automotive applications was compared. The composites were assumed to be made in a traditional SMC manufacturing method. Two different types of performance requirements; i.e. stiffness and strength were investigated for both the non-automotive and automotive parts. Two different disposal scenarios: landfill and incineration of the SMC product at the end of life was considered. The LCA results demonstrate that the environmental impact of H-SMC composites is lower than the reference G-SMC composites. G-SMC composites have a significantly higher environmental impact on climate change, acidification and fossil fuels than H-SMC composites. Where as H-SMC composites have a much higher impact on land use and ecotoxicity than G-SMC composites.

There is great interest in the plant Cannabis sativa (hemp) as a source of technical fibres for the reinforcement of polymers in composite materials due to its high mechanical properties. As a natural fibre hemp also offers biodegradabilty and is therefore an inexpensive and renewable alternative to glass fibres However, the environmental benefits of natural fibres cannot be fully exploited if the manufacturing of their composites involves polluting processing steps. Unfortunately, there is still a lack of environmetally sustainable processing methods yielding technical fibres of sufficient quality. Enzyme application as a biotechnological processing method is a good candidate for this aim and is therefore actively investigated at present. In this work the effects of a range of enzymes on the morphological, compositional and mechanical properties of hemp was investigated. The enzymes were firstly characterised and then applied to hemp fibre for differing periods of time. After visual inspection, a set of fibre samples were selected and subjected to further analysis by Fourier-Transform Infrared Spectroscopy (FTIR), tensile testing and scanning electron microscopy (SEM). The commercial formulation Pectinex® Ultra-SL emerged as the most efficient in terms of treatment time and fibre quality. The effectiveness of treatments was further investigated by developing a novel experimental method that correlates the adhesion forces measured by atomic force microscopy (AFM) on the fibre surface to the properties of the fibres or composites. In order to identify correlations between the adhesion forces and fibre or composite properties, hemp fibre was subjected to four distinctly different treatments to obtain significant differences between fibre properties. The fibres and composites were then analyzed using a combination of FTIR, tensile testing, 3-point bend testing, dynamic mechanical analysis (DMA) and SEM. Based on this comprehensive dataset the AFM data was correlated using the software SPSS. The information derived from AFM (adhesion forces and surface topology) was useful in the clarification of fibre modifications evoked by the treatments.

Currently, the production of most non-asbestos organic (NAO) friction materials depends on a long and energy intensive manufacturing process and an unsustainable supply of synthetic resins and fibres; it is both expensive and bad for the environment. In this research, a new, more energy efficient, manufacturing process was developed which makes use of a naturally derived resin and natural plant fibres. The new process is known as 'cold moulding' and is fundamentally different from the conventional method. It was used to develop a new brake pad for use in low temperature (<400 °C) applications, such as rapid urban rail transit (RURT) trains. A commercially available resin based upon cashew nut shell liquid (CNSL) was analysed and found to have properties suitable for cold moulding. In addition, hemp fibre was identified as a suitable composite reinforcement. This was processed to improve its morphology and blended with aramid to improve its thermal stability. Each stage of cold mould manufacture was thoroughly investigated and the critical process parameters were identified. The entire procedure was successfully scaled up to produce an industrially sized 250 kg batch of material and the resultant composites were found to have appropriate thermal and mechanical properties for use in a rail brake pad. The tribological performance of these composites was iteratively developed through a rigorous testing and evaluation procedure. This was performed on both sub- and full-scale dynamometers. By adding various abrasives, lubricants, and fillers to the formulation it was possible to produce a brake pad with similar friction characteristics to the current market material, but with a 60% lower wear rate. In addition, this brake pad caused 15% less wear to the brake disc. A detailed examination of both halves of the friction couple found that cold moulded composites exhibit a different wear mechanism from the current market material, which was suggested to be the reason for their superior properties. Cold moulding is 3.5x faster and uses 400% less energy than the conventional method.

In recent years, due to growing environmental awareness, considerable attention has been given to the development and production of natural fibre reinforced polymer (both thermoset and thermoplastic) composites. The main objective of this study was to reinforce epoxy and polylactic acid (PLA) with hemp fibre to produce improved composites by optimising the fibre treatment methods, composite processing methods, and fibre/matrix interfacial bonding. An investigation was conducted to obtain a suitable fibre alkali treatment method to: (i) remove non-cellulosic fibre components such as lignin (sensitive to ultra violet (UV) radiation) and hemicelluloses (sensitive to moisture) to improve long term composites stability (ii) roughen fibre surface to obtain mechanical interlocking with matrices (iii)expose cellulose hydroxyl groups to obtain hydrogen and covalent bonding with matrices (iv) separate the fibres from their fibre bundles to make the fibre surface available for bonding with matrices (v) retain tensile strength by keeping fibre damage to a minimum level and (vi) increase crystalline cellulose by better packing of cellulose chains to enhance the thermal stability of the fibres. An empirical model was developed for fibre tensile strength (TS) obtained with different treatment conditions (different sodium hydroxide (NaOH) and sodium sulphite (Na2SO3) concentrations, treatment temperatures, and digestion times) by a partial factorial design. Upon analysis of the alkali fibre treatments by single fibre tensile testing (SFTT), scanning electron microscopy (SEM), zeta potential measurements, differential thermal analysis/thermogravimetric analysis (DTA/TGA), wide angle X-ray diffraction (WAXRD), lignin analysis and Fourier transform infrared (FTIR) spectroscopy, a treatment consisting of 5 wt% NaOH and 2 wt% Na2SO3 concentrations, with a treatment temperature of 120oC and a digestion time of 60 minutes, was found to give the best combination of the required properties. This alkali treatment produced fibres with an average TS and Young's modulus (YM) of 463 MPa and 33 GPa respectively. The fibres obtained with the optimised alkali treatment were further treated with acetic anhydride and phenyltrimethoxy silane. However, acetylated and silane treated fibres were not found to give overall performance improvement. Cure kinetics of the neat epoxy (NE) and 40 wt% untreated fibre/epoxy (UTFE) composites were studied and it was found that the addition of fibres into epoxy resin increased the reaction rate and decreased the curing time. An increase in the nucleophilic activity of the amine groups in the presence of fibres is believed to have increased the reaction rate of the fibre/epoxy resin system and hence reduced the activation energies compared to NE. The highest interfacial shear strength (IFSS) value for alkali treated fibre/epoxy (ATFE) samples was 5.2 MPa which was larger than the highest value of 2.7 MPa for UTFE samples supporting that there was a stronger interface between alkali treated fibre and epoxy resin. The best fibre/epoxy bonding was found for an epoxy to curing agent ratio of 1:1 (E1C1) followed by epoxy to curing agent ratios of 1:1.2 (E1C1.2), 1: 0.8 (E1C0.8), and finally for 1:0.6 (E1C0.6). Long and short fibre reinforced epoxy composites were produced with various processing conditions using vacuum bag and compression moulding. A 65 wt% untreated long fibre/epoxy (UTLFE) composite produced by compression moulding at 70oC with a TS of 165 MPa, YM of 17 GPa, flexural strength of 180 MPa, flexural modulus of 10.1 GPa, impact energy (IE) of 14.5 kJ/m2, and fracture toughness (KIc) of 5 MPa.m1/2 was found to be the best in contrast to the trend of increased IFSS for ATFE samples. This is considered to be due to stress concentration as a result of increased fibre/fibre contact with the increased fibre content in the ATFE composites compared to the UTFE composites. Hygrothermal ageing of 65 wt% untreated and alkali treated long and short fibre/epoxy composites (produced by curing at 70oC) showed that long fibre/epoxy composites were more resistant than short fibre/epoxy composites and ATFE composites were more resistant than UTFE composites towards hygrothermal ageing environments as revealed from diffusion coefficients and tensile, flexural, impact, fracture toughness, SEM, TGA, and WAXRD test results. Accelerated ageing of 65 wt% UTLFE and alkali treated long fibre/epoxy (ATLFE) composites (produced by curing at 70oC) showed that ATLFE composites were more resistant than UTLFE composites towards hygrothermal ageing environments as revealed from tensile, flexural, impact, KIc, SEM, TGA, WAXRD, FTIR test results. IFSS obtained with untreated fibre/PLA (UFPLA) and alkali treated fibre/PLA (ATPLA) samples showed that ATPLA samples had greater IFSS than that of UFPLA samples. The increase in the formation of hydrogen bonding and mechanical interlocking of the alkali treated fibres with PLA could be responsible for the increased IFSS for ATPLA system compared to UFPLA system. Long and short fibre reinforced PLA composites were also produced with various processing conditions using compression moulding. A 32 wt% alkali treated long fibre PLA composite produced by film stacking with a TS of 83 MPa, YM of 11 GPa, flexural strength of 143 MPa, flexural modulus of 6.5 GPa, IE of 9 kJ/m2, and KIc of 3 MPa.m1/2 was found to be the best. This could be due to the better bonding of the alkali treated fibres with PLA. The mechanical properties of this composite have been found to be the best compared to the available literature. Hygrothermal and accelerated ageing of 32 wt% untreated and alkali treated long fibre/PLA composites ATPLA composites were more resistant than UFPLA composites towards hygrothermal and accelerated ageing environments as revealed from diffusion coefficients and tensile, flexural, impact, KIc, SEM, differential scanning calorimetry (DSC), WAXRD, and FTIR results. Increased potential hydrogen bond formation and mechanical interlocking of the alkali treated fibres with PLA could be responsible for the increased resistance of the ATPLA composites. Based on the present study, it can be said that the performance of natural fibre composites largely depend on fibre properties (e.g. length and orientation), matrix properties (e.g. cure kinetics and crystallinity), fibre treatment and processing methods, and composite processing methods.