Analysis of the Mechanical Properties and Microstructure of Wood‐Plastic Foam Using Walnut Shell and Teak Sawdust

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Abstract

Wood‐plastic composites (WPCs) combine natural fibers with polymers, resulting in versatile materials suitable for various applications. The incorporation of foam manufacturing enhances their properties, making them lightweight and strong. This study builds on previous research by examining two WPCs, walnut shells with high‐density polyethylene (HDPE) and Teak wood with HDPE, each with specified ratios and manufacturing conditions developed using a twin‐screw extruder and a plastic injection molding machine. Different percentages of the blowing agent azodicarbonamide (1%, 1.5%, and 2%) were added to the samples, with injection temperatures set at 185°C, 190°C, and 195°C. Pure HDPE was also tested for comparison. Mechanical properties, including tensile, flexural, and impact strength, were assessed alongside microstructural analysis via scanning electron microscopy (SEM). Results indicated that foaming technology significantly improved WPCs' mechanical properties, particularly flexural and impact resistance, depending on the additive used. Teak composites achieved the highest tensile strength (32.16 MPa) and flexural strength (51.25 MPa) while HDPE excelled in impact strength (83.78 kJ/m 2 ). Taguchi analysis revealed that material type and temperature were key factors influencing performance. SEM analysis showed variations in cell density and size among the samples, reinforcing the advantages of foaming technology in WPC applications.

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