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.

O interesse na utilização de fibras naturais com matrizes poliméricas para a preparação de compósitos espalhou-se rapidamente ao longo dos últimos anos. No entanto, a adesão interfacial entre a fibra e a matriz tem ainda de ser aperfeiçoada. Para melhorar a adesão entre os constituintes e, consequentemente as propriedades mecânicas e térmicas dos materiais, duas abordagens foram investigadas: a irradiação por feixe de elétrons e a mercerização. Este trabalho descreve a fabricação e caracterização de biocompósitos de polietileno de alta densidade e fibra do ouriço da castanha do Brasil que foram preparadas por duas metodologias diferentes: a primeira foi irradiar o compósito com 150 kGy e a segunda foi irradiar a matriz com 15 kGy e então produzir o compósito. Para ambas as metodologias foram utilizadas fibras naturais mercerizadas e não mercerizadas. O efeito dos tratamentos estudados para melhorar a adesão entre a fibra e a matriz polimérica foi avaliado através de caracterizações mecânica, química, térmica e morfológica. Com base neste estudo, observou-se que a fibra do ouriço da castanha do Brasil é um material tecnicamente viável para uso como reforço em compósitos poliméricos. Observou-se que o processo de irradiação da matriz seguida da produção dos compósitos é um método eficaz para melhorar as propriedades térmicas e mecânicas dos compósitos biopoliméricos e que, quando comparado com o processo de mercerização, esse método pode ser considerado mais ambientalmente correto (sem produtos químicos e sem geração de resíduo), mais barato e mais simples. / The interest in the use of natural fibres with polymeric matrix for the preparation of composite spread rapidly over the last years. However, the interfacial adhesion between the fiber and the matrix has to be improved. To improve the adhesion between the constituents and consequently the mechanical and thermal properties of materials, two approaches were investigated: electron beam irradiation and mercerization. This paper describes the fabrication and characterization of biocomposites compounds with high density polyethylene and fibre from Brazil nut pod that were prepared by two different methods: the first irradiating the composite with 150 kGy and the second was radiating matrix with 15 kGy and then produce the composite. For both methodologies, natural fibers, mercerized and non-mercerized were used. The effect of the treatments to improve adhesion between the fiber and the polymer matrix was evaluated through mechanical, chemical, thermal and morphology charcterization. Based on this study, it was observed that fibre from Brazil nut pod is a technically viable material for use as reinforcement in polymer composites. It was observed that the process of matrix irradiation followed by the composite fabrication is an effective method for improving the thermal and mechanical properties of the composites, when compared with mercerization process, this method can be considered more environmentally friendly (no chemicals, and without generating waste), cheaper and simpler.

Made available in DSpace on 2014-12-17T14:58:04Z (GMT). No. of bitstreams: 1 JoseAMN_DISSERT.pdf: 2578831 bytes, checksum: 78ca7925672b7876fad1b54e774b3827 (MD5) Previous issue date: 2010-12-30 / With the objective to promote sustainable development, the fibres found in nature in abundance, which are biodegradable, of low cost in comparison to synthetic fibres are being used in the manufacture of composites. The mechanical behavior of the curau? and pineapple leaf fibre (PALF) composites in different proportions, 25% x 75% (P1), 50% x 50% (P2) e 75% x 25% (P3) were respectively studied, being initially treated with a 2% aqueous solution of sodium hydroxide. Mechanical analyses indicated that with respect to studies of traction, for the combination of P1 and P3, better results of 22.17 MPa and 16.98 MPa, were obtained respectively, which are higher than that of the combination P2. The results of the same pattern were obtained for analysis of bending resistance where P1 is 1.21% and P3 represents 0.96%. In the case of resistance to bending, best results were obtained for the combination P1 at 49.07 MPa. However, when Young's modulus values were calculated, the values were different to the pattern of the results of other tests, where the combination P2 with the value of 4.06 GPa is greater than the other combinations. This shows that the PALF had a greater influence in relation to curau? fibre. The analysis of the results generally shows that in combinations of two vegetable fibers of cellulosic origin, the fiber which shows higher percentage (75%) is the best option than to the composition of 50%/50%. In the meantime, according to the results obtained in this study, in the case where the application should withstand bending loads, the better composition would be 50%/50% / Com o objetivo de promover o desenvolvimento sustent?vel, as fibras encontradas em abund?ncia na natureza, que s?o biodegrad?veis e de baixo custo quando comparado com as fibras sint?ticas, vem sendo utilizadas na aplica??o de produ??o de comp?sitos. Neste trabalho foi analisado o comportamento mec?nico ? partir do ensaio de tra??o e flex?o, em um comp?sito h?brido tendo como matriz uma resina sint?tica ortoft?lica refor?ada com fibras de curau? e fibras da folha de abacaxizeiro (PALF), nas propor??es de 25% x 75% (P1), 50% x 50% (P2) e 75% x 25% (P3), respectivamente, com as fibras de curau? e as fibras da folha do abacaxizeiro sendo tratadas quimicamente por uma solu??o aquosa de hidr?xido de s?dio (NaOH) com 8% de concentra??o. As an?lises mec?nicas indicaram que com rela??o aos estudos de tra??o, para a combina??o P1 e P3, foram obtidas melhores resultados de 22,17 MPa e 16,98 MPa, respectivamente, que ? maior que da outra combina??o de P2. Os resultados do mesmo padr?o foram obtidos para an?lise de flex?o onde P1 ? 1,21% e P3 de 0,96% que s?o maiores do que o resultado obtido da combina??o P2. No caso de resist?ncia ? flex?o, melhores resultados foram obtidos para a combina??o P1 de 49,07 MPa. Mas, quando foi calculado o m?dulo de Young, os valores foram diferentes do padr?o dos resultados dos outros testes realizados, com a combina??o P2 com o valor de 4,06 GPa que ? maior que das outras combina??es. Isto mostra que as fibras PALF tiveram uma influ?ncia maior com rela??o ? fibra de curau?. A an?lise dos resultados em geral demonstra que nas combina??es de duas fibras vegetais celul?sicas, uma ou a outra fibra com porcentagem maior (75%) ? a melhor op??o do que na composi??o de 50%/50%, entretanto no caso onde a aplica??o ser? para suportar cargas de flex?o, a melhor composi??o seria 50%/50%

O interesse na utilização de fibras naturais com matrizes poliméricas para a preparação de compósitos espalhou-se rapidamente ao longo dos últimos anos. No entanto, a adesão interfacial entre a fibra e a matriz tem ainda de ser aperfeiçoada. Para melhorar a adesão entre os constituintes e, consequentemente as propriedades mecânicas e térmicas dos materiais, duas abordagens foram investigadas: a irradiação por feixe de elétrons e a mercerização. Este trabalho descreve a fabricação e caracterização de biocompósitos de polietileno de alta densidade e fibra do ouriço da castanha do Brasil que foram preparadas por duas metodologias diferentes: a primeira foi irradiar o compósito com 150 kGy e a segunda foi irradiar a matriz com 15 kGy e então produzir o compósito. Para ambas as metodologias foram utilizadas fibras naturais mercerizadas e não mercerizadas. O efeito dos tratamentos estudados para melhorar a adesão entre a fibra e a matriz polimérica foi avaliado através de caracterizações mecânica, química, térmica e morfológica. Com base neste estudo, observou-se que a fibra do ouriço da castanha do Brasil é um material tecnicamente viável para uso como reforço em compósitos poliméricos. Observou-se que o processo de irradiação da matriz seguida da produção dos compósitos é um método eficaz para melhorar as propriedades térmicas e mecânicas dos compósitos biopoliméricos e que, quando comparado com o processo de mercerização, esse método pode ser considerado mais ambientalmente correto (sem produtos químicos e sem geração de resíduo), mais barato e mais simples. / The interest in the use of natural fibres with polymeric matrix for the preparation of composite spread rapidly over the last years. However, the interfacial adhesion between the fiber and the matrix has to be improved. To improve the adhesion between the constituents and consequently the mechanical and thermal properties of materials, two approaches were investigated: electron beam irradiation and mercerization. This paper describes the fabrication and characterization of biocomposites compounds with high density polyethylene and fibre from Brazil nut pod that were prepared by two different methods: the first irradiating the composite with 150 kGy and the second was radiating matrix with 15 kGy and then produce the composite. For both methodologies, natural fibers, mercerized and non-mercerized were used. The effect of the treatments to improve adhesion between the fiber and the polymer matrix was evaluated through mechanical, chemical, thermal and morphology charcterization. Based on this study, it was observed that fibre from Brazil nut pod is a technically viable material for use as reinforcement in polymer composites. It was observed that the process of matrix irradiation followed by the composite fabrication is an effective method for improving the thermal and mechanical properties of the composites, when compared with mercerization process, this method can be considered more environmentally friendly (no chemicals, and without generating waste), cheaper and simpler.

The thesis discusses possibilities of use new thermal insulation materials based on natural renewable resources (primary technical hemp) in development of the new thermal insulation materials. The main task (in the work) is to find modifications of the thermal insulation mats based on natural fibres by chemicals substances to improve the moisture properties, thermal properties and fire resistance.