Sustainable hemp–basalt/epoxy composites with tobacco waste and zeolite fillers for agricultural machinery components

Natural fiber–reinforced composites are promising alternatives to conventional plastics and, in some cases, metallic materials for automotive, food processing, aerospace, and construction applications. This study investigates composite panels reinforced with hemp and basalt fabrics for selected tractor and agricultural machinery components. Epoxy resin was used as the matrix, while tobacco waste and zeolite powder served as hybrid fillers. The physical, mechanical, thermal, thermomechanical, dynamic–mechanical, and microstructural properties were evaluated experimentally and supported by finite element analysis. The composites exhibited porosity values ranging from 3.35% to 5.84%. Tensile and flexural strengths of hybrid-filled samples (2 wt% and 4 wt% each filler) increased by approximately 5% and 45%, respectively, compared with the sample containing 4 wt% tobacco filler, despite the higher porosity. Thermal diffusivity and effusivity decreased from 3.26 × 10 -7 m 2 /s and 858.47 W.s 1/2 /m 2 .K in the filler-free sample to 1.09 × 10 -7 m 2 /s and 706.61 W.s 1/2 /m 2 .K in the composite with the highest hybrid filler content, indicating reduced heat transfer and improved thermal insulation. The composite containing 4 wt% hybrid filler exhibited the highest storage modulus, decreasing from 3522 MPa at 25 °C to 421 MPa at 200 °C. SEM observations and finite element simulations agreed well with the experimental results. Impact simulations of two tractor components—the front bumper bracket and the engine side panel—indicated that damage and plastic deformation are primarily governed by component thickness and density. Overall, the developed composites demonstrate strong potential as lightweight, sustainable, and mechanically reliable materials for agricultural machinery applications.