Selection, Fabrication, and Testing of Hybridized Natural Fibers and Wooden Materials for Sustainable Lightweighting

Abstract

To reduce the significant carbon footprint of synthetic and natural fibers, which depend on auxiliary materials, this thesis proposes a hybridization approach by synergistically combining natural materials to create a lightweighting bio-composite solution. Natural materials, such as flax fibers, veneer-based wood, and oriented strand board-based wood variants, were carefully selected through a comprehensive literature review and life cycle assessment screening. A specific fabrication process was developed to create the composite variants that underwent both quasi-static and dynamic 3-point bending tests. To reinforce the different variants, a sandwich configuration comprising one layer of reinforcement was adopted on each side. The experimental results showed a significant improvement in the material’s flexure and energy absorption properties, with further improvements observed at higher impact speeds. Additionally, elevated temperature testing confirmed the material’s high performance and consistency. The crash-worthiness of the bio-composite was evaluated through specific energy absorption values obtained from the dynamic tests. To showcase the material’s formability in complex 3D geometries, a prototype was created in collaboration with the U-shift team from the Institute of Vehicle Concepts. The results suggest that the proposed biocomposite has great potential to promote sustainable lightweighting,in the industry, with an outlook provided on further steps required to advance its industrial implementation.