A comprehensive study of agricultural waste maize husk as a potential reinforcement in maize fiber/glass fiber hybrid composites

Abstract This study presents a detailed analysis of hybrid composites fabricated using the hand lay‐up method with unsaturated polyester resin (UPR) reinforced by glass fiber (GF) and varying contents of maize fiber (MF). The performance of these hybrid composites were compared with neat UPR, GF‐reinforced UPR, and MF‐reinforced UPR composites. MF was chemically treated and finely chopped to improve the matrix‐reinforcement adhesion. Physical, mechanical, thermal, and electrical properties were assessed. GF composites exhibited superior mechanical strength, which dropped by replacing GF with MF in M/GFC1. However, with increasing MF content in the hybrid system, enhanced tensile strength, flexural strength, and micro‐hardness, while compressive and impact strength declined. MF‐only composite appeared with highest micro‐hardness among other composites. A center GF layer composite displayed higher micro‐hardness compared to those with GF on opposite sides. The incorporation of MF made the composites lightweight and thermally insulating, though thermal stability and water resistance somewhat compromised. Fabrication defects, such as voids, fiber agglomeration, fiber pull out were identified through scanning electron microscopy and density measurement. The presence of voids in the composite led to a decrease in tensile properties and an increase in initial water absorption. Additionally, an unexpected rise in thermal diffusivity was observed in these cases. Highlights Agricultural waste natural fiber as a potential alternative of synthetic fiber. Development of hybrid layered composites with maize fiber and glass fiber. Glass fiber and chemically treated maize fiber enhanced the properties of composites. Incorporation of maize fiber in composites increased water absorption, balancing insulation with resistance. Finding the optimal fiber fraction and composite system for better performance. Mechanical tests show superior strength and durability.