Examining the Mechanical and Thermal Properties of a Novel Hybrid Thermoplastic Rubber Composite Made with Polypropylene, Polybutadiene, S-Glass Fibre, and Flax Fibre

In this work, twin-screw extruder and compression moulding techniques were utilized to fabricate polymer blends: polypropylene (PP), polybutadiene (PB), and composites using glass fibre (GF) and flax fibre (FF). During fabrication, the polymer ratios maintained between PP and PB were 90:10, 80:20, and 70:30. Likewise, the composites were fabricated by varying the ratios between the PP, PB, and GF, which were 90PP:10PB:10GF, 80PP:20PB:10GF, and 70PP:30PB:10GF. Additionally, a hybrid composite was fabricated by adding 20% FF to the 90PP/10PB/10GF blend. The mechanical characterization revealed that the tensile strength and modulus increased by approximately 24% and 23%, respectively, for the hybrid combination (90PP/10PB/10GF/20FF) compared to pure PP (from 21.47 MPa and 1123 MPa to 26.54 MPa and 1382 MPa). Similarly, flexural strength and impact resistance showed significant improvements in hybrid samples, with flexural strength increasing by approximately 15%. Scanning electron microscopy (SEM) was also carried out for impact-tested samples to understand the fibre-to-matrix adhesion behaviour. Regarding the DSC results, PP exhibited a melting peak between 160 °C and 170 °C. When incorporating PP into PB, a reduction in crystallinity was observed. Further, by adding GF to polymer blends, the crystallinity was increased. HDT and Vicat softening temperature results reported that the hybrid samples showed higher values of 79.3 °C and 88.2 °C, respectively, resulting in improvements of approximately 3.9% and 2.9% over standard PP. Findings from this study suggest that the novel combinations offer a promising synergy of flexibility, strength, and thermal resistance, making them suitable for medium engineering applications.