EB Radiation Processing of HDPE/Rice Husk Ash Composites

High-density polyethylene (HDPE) is a valuable material, but its application under certain operational conditions is limited by oxidation resistance. To mitigate this, rice husk ash (RHA), a silica-rich (~95%) byproduct, was incorporated as a reinforcing filler. This study evaluates the effect of electron beam (EB) irradiation, at doses up to 100 kGy, on the properties of HDPE/RHA composites, focusing on mechanical performance and the polymer–filler interface. The results demonstrate that EB irradiation induces crosslinking and enhances interfacial interaction between the HDPE matrix and RHA filler. While the overall tensile strength of neat HDPE tended to decrease with irradiation dose (from 28.5 ± 1.2 MPa to 24.1 ± 1.5 MPa at 100 kGy), the optimization of dose and filler contents produced notable results: A maximum tensile strength of 29.0 ± 1.1 MPa was achieved in the composite containing 5 wt% RHA at 75 kGy. Furthermore, irradiation stabilized the material’s behavior, resolving the heterogeneous dispersion observed in non-irradiated samples with low RHA content. Regarding toughness, Izod’s impact resistance increased from 3.2 ± 0.2 kJ/m2 to 3.7 ± 0.3 kJ/m2 for the 10 wt% RHA composites irradiated at 50 kGy. Statistical analysis (ANOVA, p < 0.05) confirmed the significance of these changes. In conclusion, electron beam irradiation is an effective tool for optimizing the mechanical properties and performance uniformity of HDPE/RHA composites, making them promising candidates for applications requiring enhanced durability and consistency, such as food packaging.