Development of Polymer–Micro-Aluminum Composites for Lightweight Engineering Applications

Year : 2025 | Volume : 13 | Issue : 06 | Page : 1 12
    By

    P. Saravana Kumar,

  • D. Sudha,

  • Nantha kumar P,

  • N. Rajesh,

  • T. Venkatamuni,

  • Sivakumar A.,

  • J. Sharmila,

  • Shailendra Kumar Bohidar,

  • Zakir Hussain,

  1. Assistant Professor, Department of Mechanical Engineering, University college of Engineering Arni, Thatchur, Tamil Nadu, India
  2. Associate Professor, Department of Physics, R.M.K. Engineering College, Kavaraipettai, Tamil Nadu, India
  3. Associate Professor, Department of Mechanical Engineering, Sri Sairam Engineering College, Chennai, Tamil Nadu, India
  4. Associate Professor, Department of Mechanical Engineering, Sri Venkateswara college of Engineering, Tirupati, Andhra Pradesh, India
  5. Professor, Department of Mechanical Engineering, VSB Engineering College, Karur, Tamil Nadu, India
  6. Professor, Department of Mechanical Engineering, Varuvan Vadivelan Institute of Technology, Dharmapuri, Tamil Nadu, India
  7. Assistant Professor, Department of Chemistry, St. Joseph’s College of Engineering, OMR, Chennai, Tamil Nadu, India
  8. Associate Professor, Department of Mechanical Engineering, School of Engineering & I.T., MATS University, Arang, Raipur, Chhattisgarh, India
  9. Assistant Professor, Department of Chemical Technology, Loyola Academy, Secunderabad, Telangana, India

Abstract

This research focuses on the systematic development of polymer–micro aluminum composites, with polypropylene (PP) and epoxy selected as representative polymer matrices. Micro aluminum fillers in the range of 5–25 wt.% were incorporated through melt blending (PP) and casting (epoxy), and the resulting composites were evaluated in terms of mechanical performance, microstructural integrity, and crystalline characteristics. Tensile strength of the composites increased significantly, from 31 MPa in neat PP to 44 MPa in PP–20 wt.% Al (~42% improvement), and from 62 MPa in neat epoxy to 86 MPa in epoxy–20 wt.% Al (~38% improvement). Flexural strength exhibited similar enhancements, peaking at 70 MPa for PP composites and 125 MPa for epoxy composites, corresponding to ~67% and ~39% improvements, respectively. Hardness of both polymer composites improved progressively up to 20 wt.% filler, followed by marginal decline due to particle clustering and void formation. SEM microstructural characterization confirmed that filler dispersion and polymer–filler adhesion were critical to composite strengthening, with well-bonded particles at intermediate contents and severe agglomeration at 25 wt.%. XRD diffraction patterns revealed the preservation of crystalline aluminum peaks ((111), (200), (220), (311)) within both polymer matrices, with sharper intensities in epoxy composites due to superior interfacial compatibility. The results clearly establish that polymer–micro aluminum composites achieve optimum performance at 20 wt.% filler loading, beyond which agglomeration undermines their advantages. These findings highlight the potential of polymer composites reinforced with micro aluminum for multifunctional lightweight engineering applications.

Keywords: Polymer–micro aluminum composites, Epoxy composites, Flexural strength, Tensile strength.

[This article belongs to Journal of Polymer and Composites ]

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How to cite this article:
P. Saravana Kumar, D. Sudha, Nantha kumar P, N. Rajesh, T. Venkatamuni, Sivakumar A., J. Sharmila, Shailendra Kumar Bohidar, Zakir Hussain. Development of Polymer–Micro-Aluminum Composites for Lightweight Engineering Applications. Journal of Polymer and Composites. 2025; 13(06):1-12.
How to cite this URL:
P. Saravana Kumar, D. Sudha, Nantha kumar P, N. Rajesh, T. Venkatamuni, Sivakumar A., J. Sharmila, Shailendra Kumar Bohidar, Zakir Hussain. Development of Polymer–Micro-Aluminum Composites for Lightweight Engineering Applications. Journal of Polymer and Composites. 2025; 13(06):1-12. Available from: https://journals.stmjournals.com/jopc/article=2025/view=228984


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Regular Issue Subscription Original Research
Volume 13
Issue 06
Received 04/09/2025
Accepted 08/09/2025
Published 18/09/2025
Publication Time 14 Days
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