Article

Journal of Reinforced Plastics

and Composites

Continuous glass fiber reinforced wood 32(1) 52–60

! The Author(s) 2013
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DOI: 10.1177/0731684412461461
Feasibility and processing jrp.sagepub.com

Abbas Zolfaghari, Amir Hossein Behravesh, Alireza Adli and

Majid TabkhPaz Sarabi

Abstract
This article presents an experimental investigation on developing wood plastic composites reinforced with continuous
glass fibers in an extrusion process. The main role of wood component in wood plastic composite is mainly as a filler to
reduce cost, and not reinforcing. Adding wood component causes a noticeable reduction in strength and toughness. This
will hinder their usage in load-bearing applications. In this study, a novel method for production of hybrid wood plastic
composites is introduced. This manufacturing process takes the advantages of a cost-effective and flexible production
line. First, E-glass rovings were impregnated with a polymer in an especially designed (impregnating) die. Then, six melt
impregnated glass rovings were integrated with wood plastic composites in a single step via an extrusion process.
Another unique die was designed and manufactured to feed and position the impregnated glass rovings into a round
shaped wood plastic composite profile. Wood content was changed in three levels to investigate its effect on the
processability and the final properties of the hybrid composites. The experimentation on the extruded hybrid wood
plastic composites proved the feasibility of the process and the relative uniformity of the roving positions in the
extrudate. Three-point bending tests were conducted to evaluate the flexural properties. Improvements in strength,
modulus, and toughness were dramatic.

Keywords
Wood plastic composites, extrusion, reinforcing, mechanical properties

WPCs, an example of them is pallet.3 To introduce

Introduction WPC as a structural material, it is necessary to improve
The incorporation of cellulosic materials into thermo- their mechanical properties, convincingly.
plastics results in a new class of materials called wood Literature survey shows that the research studies on
plastic composites (WPCs). Recently, WPCs have the mechanical properties of WPCs are subjectively
experienced an outstanding growth due to their advan- categorized to: the compatibilization of wood particles
tages such as ability to use recycled materials, recyc- and polymer surfaces,4–9 type and geometry of
lability, and reasonable increased stiffness.1 The main wood,9–15 the effect of processing parameters,15–22 the
usage of WPCs, nowadays, is in building industry such
as decking, roofing, and door and window frames.2
Generally, low strength and toughness (or impact
strength) of these composites hindered their usage in Department of Mechanical Engineering, Tarbiat Modares University,
the load-bearing applications. Further addition of Tehran, Iran
wood to the composite, while making them more
Corresponding author:
cost-effective and stiff, significantly compromises their Amir Hossein Behravesh, Department of Mechanical Engineering, Tarbiat
strength and impact tolerance. There are many poten- Modares University, PO Box 14115-143, Tehran, Iran.
tial structural applications in material replacement for Email: [email protected]

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Zolfaghari et al. 53

type of polymer matrix,22–25 and usage of impact modi-

fier, e.g. rubber.26–28 Recently, short glass fibers were
incorporated into WPC29–37 to produce hybrid WPCs.
Hybridizing glass fibers with wood flour (WF) leads to
a composite having a balance of performance and cost.
The results of the published research works on
improving the properties of WPCs are not still convin-
cing in regards to the requirements for load-bearing
applications. On the way toward strengthening WPCs
to be used in structural application, recently WPCs
were externally reinforced by fiber-reinforced polymer
and metallic sheets. Significant improvements on flex-
ural and tensile strength were obtained. In previous
works,38–42 reinforcement sheets were bonded on top
and bottom of the WPC surfaces by epoxy adhesives.
Also, local heating at the interface of WPC and sheet
was another way for bonding in the mentioned research
works. Regarding that these reinforcing methods are
semi-continuous, they are expensive and time consum-
ing for mass production. Also by this method, surface
texture of WPCs is lost. Besides, the application of this
method for various profiles is questionable.
Profile extrusion is the most common process for
production of WPCs. To benefit the ease and low-cost
process of extruding, one objective of this study was to
reinforce WPC in this process. Applying long fiber
reinforcements can increase the mechanical properties
of the composites much higher than the short Figure 1. The equipment, designed and manufactured, for melt
fibers.15,43 This is related to the higher efficiency of impregnation of glass roving.
stress transfer between fibers and matrix. But mechan-
ical properties could be improved if the two following
conditions are satisfied: (a) the fibers must be well dis- sieved with a mesh size of 40 (420 mm), was used as the
tributed within matrix and agglomeration is minimized filler in three levels of weight ratios: 50, 60, and 70 wt%.
and (b) the breakage of long fibers during processing Prior to extruding, WFs were dried in an oven at a
should be minimized. In the extrusion process of poly- temperature of 80 C for 24 h to minimize the moisture
mer composites, the two above conditions are incom- content. E-glass roving 2400 tex was used as the rein-
patible with each other, where good mixing requires a forcing fibers. Since the interface quality between the
severe compounding which consequently causes the glass fibers and WPC presents a significant effect on the
fibers to break down to shorter ones. mechanical properties, an attempt was made to
Embedding continuous fibers in WPC profiles is the improve compatibility of the glass roving with the
most effective usage of reinforcements to enhance prop- matrix (WPC). For this purpose, the roving was melt
erties, in a high order of magnitude. However, the impregnated with the same HDPE grade via a labora-
method of embedding and attaining an acceptable tory impregnating die (Figure 1). The glass roving was
product where the fibers are well positioned is highly passed through a melt chamber with a filament die
challenging. The idea of continuous reinforcing in an located at the exit with a diameter of 2 mm. Glass
extrusion process of WPCs is presented in this study weight percentage was measured to be 62 wt% via
where a feasibility study is carried experimentally. As burning 10 g of the impregnated glass roving (IMGR)
a case study, a circular-shaped profile with a diameter in an oven.
of 14 mm is produced.
Equipment
Materials and procedure
A schematic view of the process is illustrated in
High-density polyethylene (HDPE) grade 5620 was Figure 2. A laboratory, counter-rotating twin-screw
used as the polymeric matrix, supplied by Arak extruder with a screw diameter of 62.5 mm and an
Petrochemical Corporation, Iran. WF of oak species, L-to-D ratio of 22 was utilized. The temperatures of

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54 Journal of Reinforced Plastics and Composites 32(1)

Figure 2. Schematic view of the extrusion process used in this study.

Figure 3. Schematic of the designed die: (1) WPC melt; (2) IMGR; (3) mandrel; (4) deflector; (5) flow balancer; (6) adjusting screw;
(7) adjusting ring; (8) IMGR guide; and (9) shaping die.
WPC: wood plastic composite; IMGR: impregnated glass roving.

zones 1–3 were set at 170 C in all the experiments. The turns 90 with respect to the extruder, this configur-
temperatures of zone 4 and the die were set according ation made flow balancing complicated. Literatures
to the WPC compositions to yield appropriate surface survey indicated that few research works investigated
quality. To investigate the effect of extrusion speed, two the design methodology of dies for WPCs.44–46 Based
levels, 2 and 5 r/min, were considered in this study. on the few published works, the die shown in Figure 3
was designed, balanced, and manufactured. The
IMGRs (2) are entered into the die from a central
Die design
hole at first segment of the mandrel (3) and then
Regarding the high viscosity of WPC melt, it was pre- passes through a guide (8) where six orifices of 2 mm
dicted that in the extrusion process of hybrid WPC, the in diameter were drilled on the guide.
IMGRs could be pulled in by the melt flow with no To take the full advantage of the high mechanical
extra puller facility (self-pulling system) as opposed to strength of the reinforcements in flexural loading,
the thermoset pultrusion system, where a puller is IMGRs had to be located as close as possible to the
required to pull the product due to presence of a low surface of the WPC profile. The flow deflector (4) with
viscose resin. 1 ¼ 67 , two flow balancers (5) with 2 ¼ 50 and 60 ,
A die with the similar concept to the wire coating die three adjusting screws (6), and adjusting ring (7) were
was designed and manufactured. Since the melt flow used to obtain a balanced flow.

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Zolfaghari et al. 55

Table 1. Parameters and the process-ability

Wood content (wt%) Zone 4 temperature ( C) Die temperature ( C) 2 (degree) Process ability

50 160 129 50 Fail

60 162 133 60 Good
70 168 138 60 Very good

For start-up, six IMGRs were manually passed into

the guide. An adjustable ring was implemented to yield
a uniform flow as it affects the uniformity of IMGRs
positioning across the section of extrudate.
Three-point bending tests were conducted utilizing a
universal testing machine, Instron 5500R. Span length
and crosshead speed were set at 240 mm and 5 mm/min,
respectively. To compare the mechanical properties,
unreinforced composites were also extruded at the Figure 4. Extruded HWPCs at 2 r/min: (a) HWPC50; (b)
same conditions. HWPC60; and (c) HWPC70.
WPC: wood plastic composite; HWPC: hybrid continuous glass
fiber/wood plastic composite.

Results and discussions

Figure 5 shows HWPC60 extruded at a speed of 5 r/
Process parameters min. By increasing extrusion RPM, or flow velocity, the
Table 1 presents the summary of the results and the melt residence time in the land section of shaping die
final appropriate adjustment of the parameters in this became too short to produce a strong skin, and a blis-
study. As it is shown, via decreasing the WF content, tered surface was resulted.48 As the length of the land
the temperatures had to be decreased to yield a suitable section was maintained unchanged in this study, further
surface quality. A larger entering angle, 2, was resulted research is required to investigate the effect of high-
in for the composites with 60 and 70 wt% wood content speed extrusion and the die land length on the produc-
to yield a balanced flow, which can be attributed to tion of the hybrid composite.
their plug flow behavior.46 In Figure 4, samples of the The proper positioning of IMGRs into the extrudate
produced hybrid continuous glass fiber/WPC (HWPC) is another important parameter affecting the mechan-
profiles are shown. ical properties. To detect the position of the IMGRs
As illustrated, for HWPC60 and HWPC70 with 60 inside the produced extrudate, arbitrary specimens of
and 70 wt% wood contents, respectively, the process 300 mm in length was selected and cut into pieces of
resulted in a good surface quality. In the case of 60 mm in length. Figure 6 shows the positions
WPC with 50 wt% wood content, the obtained surface of IMGRs for the produced HWPCs. The distance of
quality was highly poor, attempts to improve the qual- IMGRs from the rod center at each section was mea-
ity failed. Literatures indicate that at a low WF content sured via an appropriate software. Figure 7 shows the
WPC, a surface fracture can occur in the extrusion pro- average distance of the IMGRs from the center of cross
cessing.46,47 It is to be noted that no calibrator was used sections, along the 300 mm of extruded HWPCs. The
in this study as it could further complicate the process. miniature unbalanced flow could be responsible for the
Besides that, a higher amount of wood content is pre- non-uniform distances of IMGRs from the center. It
ferred due to its economic advantage. must be mentioned that, while the designed die
As stated in this study, WPC melt flow could pull the seemed to be balanced for the unreinforced WPC, it
IMGRs into the die, favorably. At a higher WF content was shown that further attempt was needed to balance
(60 and 70 wt%), WPC melt behaves more like solid the die while inserting the continuous glass rovings. It
(plug flow) through the land section. Therefore, the revealed that the position of the guiding holes had to be
melt pulling force could overcome the friction between changed to a larger distance to locate the IMGRs closer
the IMGRs and the guiding orifices. But for the WPC to the surface. Exploring the relation between the ori-
with 50 wt% wood content, the melt strength seemed to fice positions on the guide and the final location of
be too low to pull the roving in, and the melt slipped IMGRs through the extrudate could be a subject of
over the IMGRs. research interest.

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56 Journal of Reinforced Plastics and Composites 32(1)

Figure 5. Gross surface texture at a higher extrusion speed for HWPC60.

HWPC: hybrid continuous glass fiber/wood plastic composite.

Figure 6. The positions of IMGRs in the extrudates: (a) HWPC60 and (b) HWPC70.
IMGR: impregnated glass roving; HWPC: hybrid continuous glass fiber/wood plastic composite.

Flexural tests
Figure 8 shows the ultimate flexural strength of the
unreinforced and the produced hybrid WPCs.
Embedding the continuous glass fiber into the WPCs
resulted in an outstanding increase in flexural strength
by 120% and 132%, respectively, for HWPC60 and
HWPC70. Figure 9 shows flexural modulus calculated
from the stress–strain curve slope at the strain range
0.1–0.4%. An improvement in flexural modulus by
19% and 28% were obtained for HWPC60 and 70,
respectively. The mechanical properties of WPCs with
60 wt% of wood content are higher than those of WPCs
with 70 wt% wood content. But it seems that reinfor-
cing effect of continuous fibers is higher for the higher
wood content WPCs (compared to the unreinforced
WPCs). Due to the enormous increase in mechanical
strength and toughness, and adequate increase in
modulus, when applying continuous fibers, it seems
that usage of a higher wood content of WPC is pre-
ferred for its lower cost. It is known that highly filled
WPCs (above 60 wt% of wood content) exhibit a low
Figure 7. Average distance of IMGRs from the rod center strength and specially toughness, despite an increase in
along the HWPCs. stiffness. When embedding the continuous fibers, even
IMGR: impregnated glass roving; HWPC: hybrid continuous glass at a low percentages (a few rovings: here, six rovings),
fiber/wood plastic composite. the strength increases so significantly that the inherent

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Zolfaghari et al. 57

Figure 8. Flexural strength of the extruded unreinforced and HWPCs.

HWPC: hybrid continuous glass fiber/wood plastic composite.

Figure 9. Flexural modulus of the extruded unreinforced and HWPCs.

HWPC: hybrid continuous glass fiber/wood plastic composite.

weakness of the highly filled WPCs is compensated to a the contrary to the unreinforced WPC60 that exhibited
large extent. Hence, adding more wood presents more a sudden breakage (sudden drop of the force at the
cost effective HWPCs. highest load), HWPC60 exhibited a gradual loss of
An interesting observation in bending tests was the load from the peak, point B to point C. This behavior
evidence of non-catastrophic failure in the reinforced enables the HWPC to be used for the applications
WPCs against the catastrophic fracture in the unre- where safety requirement is more severe. Besides, it is
inforced ones. Figure 10 shows the flexural load–deflec- evident that the HWPC60 endures higher load at point
tion curves of the both composites. As illustrated, on B than that of Point C, which is a signature of a tough

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58 Journal of Reinforced Plastics and Composites 32(1)

Figure 10. Flexural load–deflection curves obtained from the three-point bending test for unreinforced WPC60 and HWPC60.
WPC: wood plastic composite; HWPC: hybrid continuous glass fiber/wood plastic composite.

material. Figure 11 shows the pictures of the fractured

specimens at points A and C, respectively, for WPC60
and HWPC60.
Toughness is the ability of the material to absorb
energy and is characterized by the area under the
load–deflection curve. The areas measured for WPC60
and HWPC60 shows an outstanding improvement, by
1970% (about 20 times larger), for the HWPCs. The
fracture behavior of these hybrid composites opens a
wide spectrum of structural applications where load- Figure 11. Fractured specimens: (a) at point A for WPC60 and
bearing requirements are to be met. (b) at point C for HWPC60.
WPC: wood plastic composite; HWPC: hybrid continuous glass
Conclusions fiber/wood plastic composite.

Manufacturing and evaluating the HWPCs in extrusion

process was experimentally investigated. Impregnated locations. The deviations of reinforcement fibers
glass fibers were first produced in a twin-screw extruder from the desired diameter along 300 mm length of
via an especially designed die and then fed into to the extrdates were acceptable.
another extrusion system to produce hybrid WPCs. 3. Three-point bending tests on the extruded unre-
Three levels of wood loading were applied and flexural inforced and hybrid composites showed 2.19 and
tests were performed. The experimental results present 2.32 times improvement on the flexural strength,
the following conclusions: respectively, for HWPC60 and HWPC70.
4. This reinforcing mechanism was more effective for
1. The results showed that the WPCs with the wood higher wood content WPCs.
contents of 60 and 70 wt% behave well in the pro- 5. An outstanding improvement of about 20 times for
cess, while the WPC with a wood content of 50% the absorbed energy was obtained via continuous
causes inappropriate extrudate for reinforcing pur- reinforcing the WPCs.
pose. The main reason was the ability of the higher
wood content WPCs in pulling the melt IMGRs into
its matrix (due to their plug flow behavior). Funding
2. Some deviations were observed regarding the pos- This research was funded by the Tarbiat Modares University,
ition of the glass rovings in the perfect and planned Iran.

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Zolfaghari et al. 59

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