Multi-objective response surface optimization with mechanical, microstructural, and thermal evaluation of areca fiber–SiC reinforced hybrid polymer composites for automotive components
This study investigates the development and comprehensive characterization of areca fibre–silicon carbide (SiC) reinforced hybrid epoxy composites for lightweight automotive applications. Hybrid composites containing 10–25 wt% areca fibre and 5–15 wt% SiC were fabricated and evaluated through mechanical, tribological, thermal, and microstructural analyses. The tensile strength increased from 32.4 MPa for AF1 to 45.2 MPa for AF3, while Young’s modulus improved from 1.8 to 2.8 GPa, demonstrating enhanced load transfer and improved fibre–matrix interfacial bonding. The maximum flexural strength and hardness of 64.8 MPa and 74 Shore D, respectively, were obtained for the AF3 composite. Tribological testing revealed a reduction in wear rate from 4.8 × 10⁻⁴ to 2.5 × 10⁻⁴ mm³/N·m, accompanied by a decrease in the coefficient of friction from 0.62 to 0.47, indicating superior wear resistance. Thermal characterization showed that AF3 exhibited improved thermal stability with an initial degradation temperature of 301 °C and a residual mass of 55%. Differential scanning calorimetry demonstrated an increase in glass transition temperature from 72 °C to 85 °C, suggesting restricted polymer chain mobility due to effective reinforcement. Scanning electron microscopy revealed uniform reinforcement distribution and strong interfacial adhesion for AF3, whereas higher reinforcement levels resulted in particle agglomeration and localized defects. Response Surface Methodology (RSM) was employed to examine the influence of reinforcement composition on the measured responses, confirming that the AF3 composite (20 wt% areca fibre and 15 wt% SiC) provided the most balanced combination of mechanical strength, wear resistance, and thermal stability. These findings demonstrate the potential of areca fibre–SiC hybrid epoxy composites as sustainable materials for lightweight automotive applications.