Biocomposites are increasingly used in the industry for the replacement of synthetic materials, thanks to their good mechanical properties, being lightweight, and having low cost. Unfortunately, in several potential fields of structural application their static strength and fatigue life are not high enough. For this reason, several chemical treatments on the fibers have been proposed in literature, although still without fully satisfactory results. To overcome this drawback, in this study we present a procedure based on the addition of a carbonaceous filler to a green epoxy matrix reinforced by Agave sisalana fibers. Among all carbon-based materials, biochar was selected for its environmental friendliness, along with its ability to improve the mechanical properties of polymers. Different percentages of biochar, 1, 2, and 4 wt %, were finely dispersed into the resin using a mixer and a sonicator, then a compression molding process coupled with an optimized thermomechanical cure process was used to produce a short fiber biocomposite with Vf = 35%. Systematic experimental tests have shown that the presence of biochar, in the amount 2 wt %, has significant effects on the matrix and fiber interphase, and leads to an increase of up to three orders of magnitude in the fatigue life, together with an appreciable improvement in static tensile strength.

The use of natural fiber-based composites is on the rise in many industries. Thanks to their eco-sustainability, these innovative materials make it possible to adapt the production of components, systems and machines to the increasingly stringent regulations on environmental protection, while at the same time reducing production costs, weight and operating costs. Optimizing the mechanical properties of biocomposites is an important goal of applied research. In this work, using a new numerical approach, the effects of the volume fraction, average length, distribution of orientation and curvature of fibers on the Young’s modulus of a biocomposite reinforced with short natural fibers were studied. Although the proposed approach could be applied to any biocomposite, sisal fibers and an eco-sustainable thermosetting matrix (green epoxy) were considered in both simulations and the associated experimental assessment. The results of the simulations showed the following effects of the aforementioned parameters on Young’s modulus: a linear growth with the volume fraction, nonlinear growth as the length of the fibers increased, a reduction as the average curvature increased and an increase in stiffness in the x-y plane as the distribution of fiber orientation in the z direction decreased.

In recent decades, in order to replace traditional synthetic polymer composites, engineering research has focused on the development of new alternatives such as green biocomposites constituted by an eco-sustainable matrix reinforced by natural fibers. Such innovative biocomposites are divided into two different typologies: random short fiber biocomposites characterized by low mechanical strength, used for non-structural applications such as covering panels, etc., and high-performance biocomposites reinforced by long fibers that can be used for semi-structural and structural applications by replacing traditional materials such as metal (carbon steel and aluminum) or synthetic composites such as fiberglass. The present research work focuses on the high-performance biocomposites reinforced by optimized sisal fibers. In detail, in order to contribute to the extension of their application under fatigue loading, a systematic experimental fatigue test campaign has been accomplished by considering four different lay-up configurations (unidirectional, cross-ply, angle-ply and quasi-isotropic) with volume fraction V_f = 70%. The results analysis found that such laminates exhibit good fatigue performance, with fatigue ratios close to 0.5 for unidirectional and angle-ply (±7.5°) laminates. However, by passing from isotropic to unidirectional lay-up, the fatigue strength increases significantly by about four times; higher increases are revealed in terms of fatigue life. In terms of damage, it has been observed that, thanks to the high quality of the proposed laminates, in any case, the fatigue failure involves the fiber failure, although secondary debonding and delamination can occur, especially in orthotropic and cross-ply lay-up. The comparison with classical synthetic composites and other similar biocomposite has shown that in terms of fatigue ratio, the examined biocomposites exhibit performance comparable with the biocomposites reinforced by the more expensive flax and with common fiberglass. Finally, appropriate models, that can be advantageously used at the design stage, have also been proposed to predict the fatigue behavior of the laminates analyzed.

The increasing attention given to environmental protection, largely through specific regulations on environmental impact and the recycling of materials, has led to a considerable interest of researchers in biocomposites, materials consisting of bio-based or green polymer matrixes reinforced by natural fibers. Among the various reinforcing natural fibers, sisal fibers are particularly promising for their good mechanical properties, low specific weight and wide availability on the current market. As proven in literature by various authors, the hybridization of biocomposites by synthetical fibers or different natural fibers can lead to an interesting improvement of the mechanical properties or, in turn, of the strength against environmental agents. Consequently, this can lead to a significant enlargement of their practical applications, in particular from quite common non-structural applications (dashboards, fillings, soundproofing, etc.) towards semi-structural (panels, etc.) and structural applications (structural elements of civil construction and/or machine components). Hybridizations with natural fibers or with ecofriendly basalt fibers are the most interesting ones, since they permit the improvement of the biocomposite’s performance without an appreciable increment on environmental impact, as occurs instead for synthetic fiber hybridizations that are also widely proposed in the literature. In order to further increase the mechanical performance and, above all, to reduce the aging effects on high-performance sisal-reinforced biocomposites due to environmental agents, the hybridization of such biocomposites with basalt fibers are studied with tensile, compression and delamination tests performed by varying the exposition to environmental agents. In brief, the experimental analysis has shown that hybridization can lead to further enhancements of mechanical performance (strength and stiffness) that increase with basalt volume fraction and can lead to appreciable reductions in the aging effects on mechanical performance by simple hybridization of the surface laminae. Therefore, such a hybridization can be advantageously used in all practical outdoor applications in which high-performance sisal biocomposites can be exposed to significant environmental agents (temperature, humidity, UV).