J. Inst. Eng. India Ser.
D (October 2012March 2013) 93(2):6571
DOI 10.1007/s40033-012-0013-x
ORIGINAL CONTRIBUTION
Mechanical Properties and Morphological Study
of Fly-AshBagasse Composites
Deepak Verma Prakash Chandra Gope
Mohit Kumar Maheshwari Ravinder Kumar Sharma
Received: 4 May 2012 / Accepted: 2 October 2012 / Published online: 30 October 2012
 The Institution of Engineers (India) 2012
Abstract In recent years the natural fiber epoxy composite
has attracted substantial importance as a potential structural
material. The natural fiber composites can be very cost
effective material. In the present investigation the develop-
ment of a Fly ashBagasse fiber composite material has
been discussed. The Bagasse fiber has been used in two
different sizes for the developed material. In two developed
composites, diameter of Bagasse fiber has been varied
between 1316 lm and 8395 lm in length. Correspond-
ingly in other two developed composites; length of Bagasse
fiber has been varied from 1 to 5 mm. It was observed that
the density decreases by mixing the fiber was more as
compared to the composite having both Bagasse fiber and
Fly ash. A Bagasse fiber composite with size in the range of
lm exhibited better tensile strength than the composite
having Bagasse fiber size in mm. The compressive strength
of the material increases, if Fly ash alone is used for the
composite material but, when Bagasse fiber was mixed with
the Fly ash, it was found that there has been a decrease in the
compressive strength. It was also observed that there has
been a decrease in the flexural strength of the material by
mixing the Bagasse fiber in the matrix. The microstructure of
composite material was investigated by using Scanning
Electron Microscope. The images from Scanning Electron
Microscope demonstrated that the Fly ash and Bagasse fiber
particles are uniformly distributed over the matrix.
D. Verma (&)
M. K. Maheshwari
R. K. Sharma
College of Engineering Roorkee, Roorkee, Uttarakhand, India
e-mail: dverma.mech@gmail.com
P. C. Gope
Department of Mechanical Engineering, College of
Technology,GBPUA&T Pantnagar, Roorkee, Uttarakhand, India
Keywords Fly ash
Bagasse fiber
Tensile

Compression
Flexural
Scanning Electron Microscope
Introduction
The composites are compound materials which differ from
alloys in the fact that the individual components retain their
characteristics but are so incorporated into the composite as
to take advantage only of their attributes and not of their
short comings, in order to obtain improved materials [1].
Bagasse fiberglass fiber reinforced composite material
with 15, 20, 25 and 30 wt% of Bagasse fiber and 5 wt%
glass fiber was mixed in resin [2]. Scanning Electron
Microscope shows that Bagasse fibers are well dispersed in
the resin matrix. Addition of fiber increases the modulus of
elasticity of the epoxy. Addition of Bagasse fibers
decreases the hardness of the composite developed. Dif-
ferent weight percentage of glass fibers (E-300, mat form)
with epoxy resin were taken & comparison with Fly ash
reinforced composite was made [3]. The potential of car-
bonized bagasse as filler in rubber products was studied
and results showed that as the filler loading increased the
tensile strength, abrasion resistance, hardness properties
improved [4]. It was also observed that decrease in filler
loading enhanced the elongation at break and compression
set properties. Flexural modulus of the press-molding
composites made from Bagasse fiber and biodegradable
resin with Coxs model that incorporates the compression
ratio of the Bagasse fiber in the cross section was studied.
The effect of the volume fraction of Bagasse fiber and its
length on the flexural modulus was examined [5]. The
effects of addition of natural san fibres on the fracture
toughness and impact strength of high-volume Fly ash
concrete were analysed. The test results showed that the
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replacement of cement with Fly ash decreased the com-
pressive strength and fracture toughness, and had no sig-
nificant effect on the impact strength of plain (control)
concrete [6]. The tensile and flexural moduli of the com-
posites increased with increasing Fly ash content while the
effect became opposite for tensile, flexural and impact
strengths and tensile strain at break. In the present inves-
tigation a Fly ashBagasse fiber composite with ER as
parent material was developed. The 2 % FA with different
fiber length was used and the mechanical properties such as
hardness of the developed composite was determined. And
also the microstructure of composite material was investi-
gated by Scanning Electron Microscope [7].
Development of Composite
matrix system by mechanical stirring at 3,000 rpm according
to the nomenclature. The solution obtained by mixing of
Bagasse fiber and Fly ash in matrix is kept in the furnace at a
temperature of 90 10 C for 2 h [8]. At each interval of
30 min the solution is taken out from the electric furnace
(because after heating epoxy resin settles down leaving
Bagasse fibers on the upper surface) and remixed by
mechanical stirrer at same speed. After 2 h the whole solution
is taken out and allowed to cool to a temperature of 45 C.
When a temperature of 45 C has been attained the hardener
HY951 (8 wt%) is mixed immediately [9]. Due to addition of
hardener high viscous solution is obtained which is remixed
mechanically by the mechanical stirrer. The viscous solution
so obtained is poured into different moulds for sample prep-
aration. The nomenclature is shown in Table 3.

The matrix system consists of Epoxy Resin (CY230) and
corresponding hardener (HY951). The Resin and Hardener
were purchased from Shankar Dies and Chemicals Ltd,
Delhi, India. Two types of fillers i.e. Bagasse fibers and Fly
ash were used in the matrix system. Bagasse fibers were
collected from Sugar Mill, Kotdwara (India) and Fly ash
was collected from Century Paper and Pulp Industry
Limited, Lal Kuan (India). Average Bagasse fiber compo-
sition and the chemical composition of the Fly ash are
shown in Tables 1 and 2 respectively.
In the present investigation Bagasse fibers and Fly ash with
different weight percentage (wt%) i.e. 10 wt% Bagasse of
different fiber length and 2 wt% of Fly ash were mixed in
Table 1 Average bagasse composition
Items Percentage
1. Moisture 49.0
2. Soluble solids 2.3
3. Fibre 48.7
Table 2 Composition of Fly-ash
Composition Percentage
Results and Discussion
Density
Density is one of the most important mechanical properties
of the material. The density of Bagasse fiberFly ash
reinforced composite with different composition of com-
posites are presented in Table 4. For determination of
density of composites of different compositions, exact one
cm cubes were prepared and weighed in digital electronic
balance having least count of 0.0001 g and density was
determined by using the following formula:
(Density) q = mass/volume.
Table 4 reveals that the developed composite is having
low density as compared to the neat epoxy composite
material. By mixing the fiber; the density decreases more in
C2 and C4 as compared to C1 and C3 respectively. This is
related to the fact that the Fly ash particles are having
cenospheres (hollow spheres). Highest numbers of the
cenospheres trap not only the epoxy matrix but also lm
sized particle of the fiber. Density of the composite is
strongly influenced by the lm sized Bagasse fiber in C3.

Silica 52.50 Table 3 Nomenclature

Alumina 26.20
Composition Specification
Fe2O3 6.50
Titanium 1.28 C0 Neat epoxy
CaO 1.12 C1 10 wt% of bagasse (lm fiber)
Potassium oxide 0.96 C2 10 wt% of bagasse (15 mm fiber)
Mg and MgO 0.29 C3 10 wt% of bagasse (lm fiber) ? 2 wt% of Fly ash
Na2O 0.29 C4 10 wt% of bagasse(15 mm fiber) ? 2 wt% of Fly ash
Sulphates 0.34 CY 230 Epoxy resin
Phosphates 0.05 HY 951 Hardener
Unburnt coal 9.16 Wt/Wt Weight to weight

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J. Inst. Eng. India Ser. D (October 2012March 2013) 93(2):6571 67

Water Absorption Capacity period of time. Water absorption is used to determine the
amount of water absorbed under specified conditions.The
It is defined as the amount of water absorbed by a com- results are presented in Table 5.
posite material when immersed in water for a stipulated The effect of water absorption is important in case the
material that has been developed when used for applications
Table 4 Density (gm/cm3) of epoxy resin and Bagasse fiberFly ash that comes in contact of water. This substantial increase with
reinforced composite regards to the epoxy resin can be attributed to the fact that the
S. No C0 C1 C2 C3 C4 Bagasse fibers have maximum capacity of water absorption
in comparison to the Fly ash and the resin particles.
1. 1.159 1.122 0.969 1.188 1.037
2. 1.184 1.102 1.031 1.260 1.070
3. 1.186 1.076 0.919 1.188 1.057 Mechanical Properties
4. 1.195 1.130 0.918 1.212 1.128
5. 1.172 1.085 1.075 1.229 1.143 Tensile Strength
Mean 1.176 1.097 0.983 1.215 1.087
SD 0.013 0.023 0.069 0.030 0.046 The mechanical properties of the Bagasse fiber and Bagasse
Variance 0.00019 0.00054 0.0047 0.0009 0.0021 fiberFly ash filled epoxy resin composite materials were
determined by 100 kN ADMET make servo controlled uni-
versal testing machine at 0.5 mm/min crosshead speed under
Table 5 Water absorption capacity (gm/hr) of epoxy resin and
displacement control mode. Tensile test was conducted in
Bagasse fiberFly ash reinforced composite
accordance with ASTM D 3039 method. The specimens of the
S. No C0 C1 C2 C3 C4 dimension 100 9 10 9 5 mm were used for analysis.
1. 0.633 2.26 2.60 0.72 1.15 Tensile stressstrain curves for composite materials C2,
2. 0.699 2.14 2.18 0.81 1.02 C3, C4 are shown in Fig. 1a. Remarkable differences can
3. 0.609 2.17 2.57 0.75 1.11 be seen in the stressstrain behaviour due to addition of
Mean 0.647 2.19 2.45 0.76 1.09 different compositions.
SD 0.046 0.062 0.023 0.045 0.066
Variance 0.0021 0.0039 0.0549 0.0021 0.0044
Tensile Properties The results of modulus of elasticity,
the ultimate tensile strength, yield stress and percentage

Fig. 1 a Stress-strain diagram

for tensile strength of different
composites with 0.5 mm/min
cross head speed b Stress-strain
diagram for compression
strength of different composites
at the rate of 0.5 mm/min cross
head speed

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68 J. Inst. Eng. India Ser. D (October 2012March 2013) 93(2):6571

elongation are shown in the Table 6 for strain rate of of 0.5 mm/min. A large difference can be seen on the
0.5 mm/min. Noticeable differences can be seen on the ultimate tensile strength of the composite material having
ultimate tensile strength of the composite material having different compositions. With Bagasse fiber, the decrease in
different compositions. C1 and C3 (composites),exhibited modulus of elasticity is observed, but with Bagasse fiber
better tensile strength because fibers are in the form of a Fly ash further decrease in the modulus of elasticity is
particulate with no fiber end available. So crack initiation is noticed compared to that of the pure epoxy. When Bagasse
not much as in the C2 and C4 composite which is having fiber size is decreased then the value of the ultimate
longer fiber leading to greater quantity of fiber ends which strength is about 58.16 MPa and with addition of Fly ash to
is available for the initiation of the cracks. Fiber insertion Bagasse fiber its value decreases to 50.183 MPa. The
contribute to an increase in modulus in C1 and C3 because reason for the decrease in the ultimate compression
the youngs modulus of the fiber is higher as compared to strength is due to the fact that the Bagasse fiber is less rigid
the modulus of the thermoplastic matrix. However, to and also the strength of the fiber is less as compared to that
obtain a significant increase, a good interfacial bond of the epoxy resin. If Fly ash alone is used for the com-
between the fiber and the matrix is necessary [10]. The posite material then it increases the compressive strength of
degradation of the fiber matrix interfacial region is due to the material [3]. But, when the Bagasse fiber is mixed with
the moisture absorption. Because of this it creates poor the Fly ash then it is found that there is decrease in the
stress transfer efficiency and results in a reduction of compressive strength of all the composite i.e. C3, and C4.
mechanical and dimensional properties [11]. It is also Decrease in compressive strength is attributed to the fact
observed that C3 shows good tensile strength as compared that the cross-sectional structure of the Bagasse fiber and
to C4 composites; but less tensile strength compared to of the fiber matrix distribution is not good in the mould cyl-
C0 and C1 composites because Fly ash particulates make inder. The percentage elongation of material increases with
the composite brittle in nature and also the long fiber for Bagasse fiber (lm) composites. It is seen in Table 8 that
absorb moisture from the matrix and once the moisture the ratio of ultimate compressive strength to ultimate ten-
penetrate inside the composite material, the fiber tends to sile strength varies from 1.62 to 4.39.
swell.
Flexural Strength
Compressive Strength
The bending strength properties of bagasse fiber and Fly
The compressive properties of the Bagasse fiber and ash filled epoxy resin composite materials were determined
Bagasse fiberFly ash filled epoxy resin composite mate- by 100 kN ADMET make servo controlled universal test-
rials were determined by 100 kN ADMET make servo ing machine at 0.5 mm/min strain rate under displacement
controlled universal testing machine at 0.5 mm/min control mode. The three point-bend flexural test was con-
crosshead speed under displacement control mode. The ducted in accordance with ASTM D 790 method.
compression test was conducted in accordance with ASTM
D 3410 method.
Compressive stressstrain curves for composite materials Table 7 Compressive properties of epoxy resin and Bagasse fiber
Fly ash reinforced composite
C2, C3, C4 are shown in Fig. 1b. Remarkable differences can
be seen in the stressstrain behaviour for different Property C0 C1 C2 C3 C4
compositions. E (GPa) 0.736 0.51 0.461 0.289 0.434
Ultimate stress (MPa) 65.28 49.85 58.16 33.66 50.183
Compressive Properties The values of modulus of elas- Yield stress (MPa) 13.5 1.14 1.34 1.076 1.30
ticity, the ultimate tensile strength, yield stress and per- % Elongation 22 27.40 11.7 17.8 17.31
centage elongation are shown in the Table 7 for strain rate

Table 8 The ratio of ultimate compressive strength to ultimate ten-

Table 6 Tensile properties of epoxy resin and Bagasse fiberFly ash sile strength
reinforced composite
C0 C1 C2 C3 C4
Property C0 C1 C2 C3 C4
Ultimate tensile strength (MPa) 43.79 22.26 15.53 20.79 12.09
E (GPa) 1.359 1.64 1.03 1.555 1.14
Ultimate compression strength 65.28 49.85 58.16 33.66 50.183
Ultimate stress (MPa) 43.790 22.26 15.53 20.79 12.09 (MPa)
Yield stress (MPa) 9.82 10.23 9.85 9.36 8.4 Ratio of ultimate compression/ 1.49 2.24 3.75 1.62 4.39
% Elongation 1.410 1.867 1.2 2.59 2.15 tensile strength

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J. Inst. Eng. India Ser. D (October 2012March 2013) 93(2):6571 69

In the developed composite material, the matrix gener- than that of the composite C1 because fiber length is in mm
ally acts as a load transfer medium between the fibers, range, hence there is not so good interaction between the
hence the performance of the composite depends on the fiber and the matrix as compared to fiber of lm size which
capability of the matrix to transfer load through the inter- promote micro crack formation at the interface as well as
face [12]. It is observed from the Table 9 that there is the non-uniform stress transfer due to fiber agglomeration
decrease in the flexural strength of the material by mixing within the matrix [13]. The increase in moisture absorbance
the bagasse fiber in the matrix as compared to the com- by short fiber reinforced composites is explained on the
posite C0. The flexural strength of composite C2 is less basis that moisture diffuses into polymer matrix during
aging under humid environment and properties of fibre
reinforced polymer composites are degraded as a result of
Table 9 Flexural strength (MPa) of epoxy resin and Bagasse fiber attack by absorbed moisture on the fibre content in the
Fly ash reinforced composite fibre/matrix interface region and the matrix itself. The
S. No C0 C1 C2 C3 C4 interface acts as a binder and it transform the load between
the matrix and reinforcing fibres. The interfacial area plays
1. 52.85 33.09 30.83 52.96 24.18
a major role in determining the strength of polymer com-
2. 49.82 31.29 32.24 51.57 23.58
posite materials because each fibre forms an individual
3. 50 33.42 31.68 51.07 25.43
interface with the matrix [14].
Mean 50.89 32.6 31.58 51.87 24.40
SD 1.699 1.146 0.71 0.979 0.943
Variance 2.889 1.314 0.504 0.959 0.890

Fig. 4 10 wt% of bagasse (15 mm fiber)

Fig. 2 Neat epoxy resin and hardener

Fig. 3 10 wt% of bagasse (lm fiber) Fig. 5 10 wt% of bagasse (lm fiber) ?2 wt% of Fly ash

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Microstructure
The microstructure of Fly ash and Bagasse fiber composite
material was investigated using Scanning Electron Micro-
scope. The analysis shows that Fly ash particles and
Bagasse fibers are uniformly dispersed into the matrix. It
can be analyzed whether there is any fracture or defect in
the material resides or not. Figures 2, 3, 4, 5, 6 and 7 show
the Scanning Electron Microscope micrographs of different
composite material investigated in the present work. In all
the cases, good dispersion of Bagasse fiber and Fly ash in
the resin matrix has been observed. Hence, from the
micrographs it can be concluded that due to uniform dis-
persion of Bagasse fiber in epoxy resin, a perceptibly effect
on the mechanical properties are obtained.
Fig. 6 10 wt% of bagasse (lm fiber) ?2 wt% of Fly ash
Fig. 7 10 wt% of bagasse (15 mm fiber) ?2 wt% of fly ash
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J. Inst. Eng. India Ser. D (October 2012March 2013) 93(2):6571
Figure 2 shows the Scanning Electron Microscope
analysis of the neat epoxy resin and hardener composite
without any reinforcing element.
Figure 3 shows the Scanning Electron Microscope
micrographs of 10 % Bagasse fiber with 86 lm length and
varied diameter in the composite material.
Figure 4 shows the Scanning Electron Microscope micro-
graphs of 10 % Bagasse fiber with diameter 13.4514.14 lm
with length of 15 mm in the composite material.
Figure 5 shows the Scanning Electron Microscope
micrographs of 10 % Bagasse fiber ? 2 % Fly ash with
fiber of diameter 12.513.45 lm and length 83.586 lm
and the Fly ash particles are completely mixed with the
matrix material.
Figure 6 shows the Scanning Electron Microscope
micrographs of 10 % Bagasse fiber ? 2 % Fly ash with
fiber of diameter 14.3516.37 lm and length 95 lm and
the Fly ash particles are completely mixed with the matrix
material.
Figure 7 shows the Scanning Electron Microscope
micrographs of 10 % Bagasse fiber ? 2 % Fly ash with
fiber of length of 15 mm and of diameter 16.216.37 lm
and the Fly ash particles are uniformly dispersed into with
the matrix material.
Conclusions
New composite materials have been developed by using
Fly ash and Bagasse fiber and the key observations were
made as follows:
The main objective behind the development of com-
posite is to utilize the natural waste such as bagasse and
Fly ash. Thus, regarding the cost factor, the composite
developed is cheaper than that of the neat epoxy
system.
The density decreases by increasing the fiber size and
further decrease is observed in composites having both
Bagasse fiber and Fly ash.
A lm size Bagasse fiber composite exhibited better
tensile strength than the composite having Bagasse
fiber size in mm range.
The compressive strength of the material increases, if
Fly ash alone is used for the composite material but,
when the Bagasse fiber is mixed with the Fly ash then it
is found that there is decrease in the compressive
strength.
It is also observed that there is decrease in the flexural
strength of the material by mixing the Bagasse fiber in
the matrix.
The microstructure of composite material is investi-
gated by using Scanning Electron Microscope. The
J. Inst. Eng. India Ser. D (October 2012March 2013) 93(2):6571
Scanning Electron Microscope images demonstrated
that the Fly ash and Bagasse fiber particles are
uniformly distributed over the matrix.
The composite developed can certainly be considered
as a very promising material for the fabrication of
lightweight materials used in office furniture, packag-
ing industry, partition panels, etc. compared to con-
ventional wood based plywood or particle boards.
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