International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.

11 (2012)
Research India Publications; http://www.ripublication.com/ijaer.htm

Utilization Of Flyash As Filler In Hdpe/Flyash Polymer Composites: A Review

Baljeev Kumar1 Rajeev Garg2 and Upinderpal Singh3

1
Assistant Professor, Department of Chemical Engg,
Beant College of Engineering and Technology, Gurdaspur City, India
Email: baljeevk@yahoo.co.in
2
Assistant Professor, Department of Chemical Engg
Shaheed Bhagat Singh College of Engineering and Technology, Ferozpur City, India
Email: rkg_garg@rediffmail.com
3
Manager (Training) Central Institute of Engineering and Technology Bhuvneshvar City, India
Email: upinderpalsingh@hotmail.com

Abstract oxide (CaO), both being endemic ingredients in many coal-

Fly ash (FA), a waste by-product is generated abundantly by
combustion of coal in thermal power stations. It is a mixture
of oxides rich in silicon (SiO2), iron (Fe2O3), and aluminum
(Al2O3). Fly ash poses severe environmental threat by
contaminating the surrounding atmosphere and occupies huge
land area for its dumping. Increasing production of fly ash
year by year, from the coal based thermal power plant, is
posing a serious problem in terms of its safe disposal and
utilization. The utilization of fly ash as filler material in
polymer composites is considered important from both
economic and commercial point of view Fly ash is used as
reinforcing filler in High density polyethylene (HDPE) to
develop lightweight composites. Some studies have pointed to
the excellent compatibility between fly ash and polymers.
Other researchers have also shown the advantageous use of
treated fly ash in a wide variety of polymer matrices.
Modification of Fly ash accompanied by compatibilization
leads to the substantial improvement to mechanical properties
and thermal stability of the composites. Compatibilizers are
polymeric interfacial agents that facilitate formation of
uniform blends of normally immiscible polymers with
desirable end properties. Fly ash/polymer composites present
significant opportunities to basic science and technology and
pose significant challenges for future work in polymer
composite field.. Such fly ash filled polymer composites
possess attractive mechanical, thermal, electrical properties,
better dimensional stability and are cost effective. A review of
effect of Fly ash as a filler on various properties of HDPE/ Fly
ash polymer composites has been discussed in this paper.
Keywords Fly ash, HDPE, Compatibilizer, Polymer
Composites
INTRODUCTION
In order to reduce the production cost of plastic products, and
to improve certain characteristics, one or more fillers are
usually used as an addition to the resin matrix. Due to the
environmental concerns and disposal difficulties, the
utilization of fly ash has become of great importance. .
Depending upon the source and makeup of the coal being
burned, the components of fly ash vary considerably, but all
fly ash as already said includes substantial amounts of silicon
dioxide (SiO2) (both amorphous and crystalline) and Calcium
bearing rock strata.
The ways of fly ash utilization include concrete
production, as a substitute material for Portland cement and
sand, Embankments and other structural fills (usually for road
construction),Grout and Flow able fill production, waste
stabilization and solidification, cement clinkers production
(as a substitute material for clay) and mine reclamation. It can
also be utilized for stabilization of soft soils, road sub base
construction, as Aggregate substitute material (e.g. for brick
production), mineral filler in asphaltic concrete, agricultural
uses: soil amendment, fertilizer, cattle feeders, soil
stabilization in stock feed yards, and agricultural stakes. Other
applications include cosmetics, toothpaste, kitchen counter
tops, floor and ceiling tiles, bowling balls, flotation devices,
stucco, utensils, tool handles, picture frames, auto bodies and
boat hulls, cellular concrete, geopolymers, roofing tiles,
roofing granules, decking, fireplace mantles, cinder block,
PVC pipe, Structural Insulated Panels, house siding and trim,
running tracks, blasting grit, recycled plastic lumber, utility
poles and cross arms, railway sleepers, highway sound
barriers, marine pilings, doors, window frames, scaffolding,
sign posts, crypts, columns, railroad ties, vinyl flooring,
paving stones, shower stalls, garage doors, park benches,
landscape timbers, planters, pallet blocks, molding, mail
boxes, artificial reef, binding agent, paints and under coatings,
metal castings, and filler in wood and plastic products.
The granulometry of fly ash filler and filler blends are
reported to be attractive as filler material in polymer
composites. Such fly ash filled polymer composites possess
attractive mechanical, thermal, electrical properties, better
dimensional stability and are cost effective. High-density
polyethylene (HDPE) plays an important role in various
industries like in packaging and is widely used for various
commercial products, because of its relatively low cost, low
permeability to moisture and other oxidizing agents, sufficient
ability to elongate and to withstand occasional surface
impacts.
Reviewing the present status of HDPE/polymer
composites, based on the results up to now, Fly ash is
promising for fabricating composites which can be widely
used in various important fields. In order to improve the
interaction between the inorganic filler and the organic matrix,
the Fly ash may be treated with a compatibilizer
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
Research India Publications; http://www.ripublication.com/ijaer.htm
Literature survey
Ahmad and Mahanwar (2010) studied the effect of fly ash as
filler on the mechanical properties of HDPE. Three different
particle sizes of fly ash were used. Concentration of fly ash
was varied up to 40 % by weight. The composites were
prepared using twin screw extruder and then test specimens
were prepared by injection molding. Tensile, flexural and
impact properties were tested. The microstructure was
investigated through scanning electron microscopy (SEM) of
the fractured samples. Both tensile and flexural strengths and
moduli were found to increase with fly ash addition. Tensile
elongation drastically reduced at fly ash concentration greater
than 10%. With increasing fly ash concentration impact
resistance decreased up to about 15% fly ash concentration
and then did not reduce significantly on further addition.
Composites with smallest size fly ash particles proved to be
better in enhancing strength and relative elongation. Modulus
and impact resistance did not seem to depend much on particle
size.
Atikler et al. (2006) studied mechanical and
morphological properties of composites made up of recycled
high-density polyethylene (HDPE) filled with calcium
carbonate and fly ash. Interfacial interactions were modified to
improve the filler compatibility and mechanical properties of
the composites by surface treatment of the FA filler with 3-
amino propyl triethoxy silane. The composites were prepared
by using a Thermo Haake Rheomixer. Effect of filler loading
and treatment of FA with silane coupling agent on mechanical
and morphological properties were investigated and it was
found that silane treatment indicated significant improvements
on the mechanical properties of the HDPE-FA composites.
This was also confirmed by applying the Pukanszky model.
Scanning electron microscopy on the fracture surface of
composites had given direct evidence of better interfacial
adhesion via silane treatment.
Deepthi et al. (2010) have reported that Fly ash
Cenospheres was used as reinforcing filler in HDPE to
develop lightweight composites. Cenospheres are inert hollow
silicate spheres, which are a naturally occurring by-product of
the burning process at coal-fired power plants. Cenospheres
are primarily used to reduce the weight of plastics, rubbers,
resins, cements, etc. used extensively as filler lubricants in oil
drilling operations under high heat and high stress conditions
down the hole. Also used as oil well cementing, mud putty and
similar applications. Cenospheres are compatible with
plastisols thermoplastics, Latex, Polyesters, Epoxies, Phenolic
resins and urethanes. The advantages include reduced weight,
increased filler loadings, better flow characteristics, less
shrinkage and warping and reduced water absorption. In order
to improve the interaction between the inorganic filler and the
organic matrix, the Cenospheres were surface treated with
silane coupling agent and HDPE-g-dibutyl maleate was used
as compatibilizer. The tensile and thermal properties of the
composites were measured according to ASTM methods. The
results reveal that, both surface modifications of Cenospheres
accompanied by compatibilization led to the substantial
improvement to mechanical properties and thermal stability of
the composites.
Chand et al. (2010) studied that Fly ash cenospheres
obtained as industrial waste from thermal power plants is an
effective cost and weight reducing filler for developing
lightweight polymer composites. Cenospheres as fillers also
help in improving the mechanical properties of base polymer
matrices. However, the desired enhancement depends on
homogeneous dispersion of cenospheres and excellent
compatibility between cenospheres and polymer matrix. In the
present work, this was achieved by modifying the surface of
cenospheres using silane treatment and incorporating them in
a versatile thermoplastic high density polyethylene. The silane
treatment resulted in considerable improvement in the impact
strength and density of the composites which ultimately
translated into better wear performance of composites even in
severe abrasive conditions. LancasterRatner correlation
between mechanical properties and wear resistance was found
to be almost linear for the silane treated cenospheres filled
composites unlike the untreated cenospheres filled composites.
Scanning electron microscopy was used to understand the
wear modes and mechanisms and supported using X-ray
diffractograms.
Ishidi et al. (2010) have determined the physio -
mechanical properties of the proposed polymer composite
which is a combination of two distinct materials- HDPE and
palm kernel nut shell particulate. The materials compounding
and sample formation was done using Reliable Two Roll Mill
Model 5183 and Carvers Hydraulic Hot Press. Tensile strength
of the fabricated composites was tested using standard
equipment in accordance to the ASTM standard specifications;
Advanced Material Testing Machine, Resil Tensile impactor
and Quanta 200 Environmental Electron Scanning
Microscope. Percentage water absorption of the composite
was also investigated. The results obtained showed that tensile
properties changed with the filler content. The tensile strength
first increased with increase in filler content. At a higher filler
load the tensile strength dropped. Composite hardness and %
water absorption increased with increase in filler content.
Environmental Scanning Electron Microscope (ESEM)
showed good filler- matrix interaction. The results obtained
showed matrix filler compatibility especially for the sodium
hydroxide treated filler.
Biglari and Kole (2011) have investigated the effective
thermal conductivity and coefficient of thermal expansion
(CTE) of composites synthesized with fly ash filler embedded
in HDPE matrix. Incorporation of fly ash in HDPE enhances
both the thermal stability and the effective thermal
conductivity of the composites. CTE, however, significantly
decreases as the FA content increases in HDPE. Effective
thermal conductivity for HDPE containing 70-volume fraction
(%) fly ash becomes almost twice than that for unfilled HDPE.
Results on both the effective thermal conductivity and CTE of
HDPE/FA composites have been discussed in light of various
theoretical models.
Nasuha et al. (2012) present the development of a new
polymer-ceramic composite material for use in injection
molding machine. The material consists of palm oil fly ash
(POFA) in HDPE powder. In this study, the effect of POFA
was investigated as a filler material in polymer-ceramic matrix
composite and HDPE was chosen as a matrix material. The
detailed formulations of mixing ratio with various
combinations of the new polymer-ceramic composite are
investigated experimentally. Based on the result obtained, it
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol.7 No.11 (2012)
Research India Publications; http://www.ripublication.com/ijaer.htm
was found that, the weight percentage increment of POFA
filler affected the flexural and hardness strength. This work
represents a major development in recycling of waste material
from palm oil empty fruit bunch out of the refinery to produce
polymer/ceramic matrix composite.
Satapathy et al. (2010) have reported the melt blending of
waste collected polyethylene (WPE) from the municipality
solid waste (MSW) and reclaimed rubber (RR) in different
proportions and preparation and characterization of
composites with fly ash (FA). Mechanical and dynamic
mechanical properties of the blends and composites were
studied in presence as well as in absence of a silane-coupling
agent (Si-69). Tensile strength, flexural strength, flexural
modulus, impact strength and hardness properties of the
FA composites was found to improve in presence of Si-69.
Phase morphology of the blends has been reported.
CONCLUSION
From the literature survey it is concluded that Fly ash is used
as reinforcing filler in High density polyethylene (HDPE)
Some studies have pointed to the excellent compatibility
between fly ash and polymers.. Although incidental success
stories are published, a systematic approach on investigating
the influence of fly ash on polymer properties for the various
different polymer types and the enormous amount of possible
formulations has not yet been properly undertaken.
Modification of Fly ash accompanied by compatibilization
leads to the substantial improvement properties of the
composites. However, it is obvious that the potential as
reinforcing fillers in polymers especially for Fly ash/HDPE
composites have not been fully brought into play. The state-
of-art indicates that efforts should be continuously made
before widely employing these advanced composites into
practical usage.
The critical challenges lie in how to prepare structure-
controllable composites with high purity, geometrical identity
and consistently dependable high performance, how to
fabricate composites with uniformly dispersed Fly ash etc.
Scientists in different fields are worming their ways to
improve the status HDPE/polymer composites. Nevertheless,
Fly ash/polymer composites present significant opportunities
to basic science and technology and pose significant
challenges for future work in polymer composite field.
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