Effect of Hollow Glass Microspheres on Properties of Virgin and Recycled High-Density Polyethylene-Fly Ash Composites

Abstract

High-density polyethylene (HDPE) offers an exceptional combination of mechanical properties, chemical resistance, and adaptability. A hybrid composite material was created by reinforcing virgin and recycled HDPE with HGMs and FAs to address current deficiencies. Fly ash from heavy fuel combustion and lightweight HGMs served as eco-friendly reinforcements, enhancing the physical, mechanical, and thermal properties of HDPE composites. Composite samples were fabricated by extrusion and injection molding and evaluated for density, water absorption, void content, tensile strength, flexural strength, impact resistance, and thermal stability. The findings indicated an enhancement in physical attributes, i.e., density, water absorption, and void content, with increased filler content. Fly ash improved the tensile strength by 7.1% in virgin HDPE and 2.3% in recycled HDPE. The findings indicated that the hardness of the fly ash polyethylene composite was inversely affected by the addition of hollow glass beads, with a detrimental impact on the virgin material and a beneficial effect on the recycled material. Nonetheless, HGMs were useful in enhancing thermal stability. The thermogravimetric study validated the enhancement in thermal performance with increasing filler content, underscoring its potential use in temperature-sensitive settings. The present study demonstrates the potential to enhance high-density polyethylene (HDPE) composites with fillers derived from industrial waste, thereby promoting sustainability and expanding their applications in the automotive, packaging, and construction industries.