Characterization of <i>bauxite residue</i> filled sisal/glass fiber reinforced hybrid composites for structural applications

Abstract Composite materials with high compressive, flexural, and shear strength are essential for constructing various structural elements in automotive, aerospace, marine, and construction sectors. The present research aims to create bauxite residue filled sisal/glass fiber reinforced polyester composites. The different weight percentages of sisal fiber (35 %, 30 %, 25 %, and 20 %), red mud (0 %, 5 %, 10 %, and 15 %), glass fiber (5 %), and polyester matrix (60 %) were used to fabricate composites. The combined use of compression molding and hand layup technique was employed in the creation of composite materials due to its frequent utilization in the manufacturing of large-scale components found in various sectors, including automotive, aerospace, marine, and construction. In this work, investigated the physical, compressive, flexural and v notch rail shear strength of the fabricated composites. Results revealed that the composites with 30 % of sisal fiber and 5 % of red mud has the highest compressive, flexural, and v notch rail shear strength of 83.45 MPa, 182.74 MPa, and 10 MPa, respectively. Further, this composite showed high density, less void content, and less thickness swelling than other composites. According to the outcomes, this composite material demonstrates suitability for various structural applications across automotive, aerospace, marine, and construction sectors.