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Towards a sustainable substitute for Acrylonitrile Butadiene Styrene (ABS) in automotive industry

Master’s Thesis

Author: Amalia Roza Christoula

Examiners: Karin Odelius / Jukka Seppälä
Academic adviser: Aji Mathew
Industrial adviser: Nowshir Fatima

Abstract

This thesis aims to develop sustainable replacement for Acrylonitrile Butadiene Styrene (ABS) in highimpact applications within construction equipment’s Cab interior. Adhering to the principles of Green Chemistry and Engineering, the study focused on developing and accessing an environmentally friendly substitute for ABS, a commonly used non-biodegradable plastic. Investigating novel materials with a tailored requirements list is vital in materials science and engineering. Theoretical approaches can yield results which drive further innovation, ensuring comprehensive alignment with application expectations through a holistic approach to address critical factors. Following this guideline, the chosen alternative was Polylactide (PLA), fortified with a blend of lignocellulose nanofibers (LCNFs) and natural rubber (NR) at a 10 wt.% concentration, with the addition of Maleic Anhydride (MA) as a compatibilizer. This modification strategy aimed to enhance PLA's strength and reduce its brittleness. The investigation encompassed various parameters, including different LCNF drying methods and variations in additive treatment before melt-mixing with PLA. The outcomes from thermal analysis indicated that the inclusion of reinforcements does not significantly affect the degradation temperature of the PLA matrix. Crystallinity, on the other hand, was found to be influenced by the presence of lignocellulose reinforcements and natural rubber, with intriguing nuances emerging from the interplay of these components and different treatment methods. PLA-based alternatives performed similarly to low grade ABS and had similar stiffness levels. In terms of elasticity, most materials behaved similarly to neat PLA, but the addition of natural rubber enhanced their deformation capacity. Successful compatibilization between lignocellulose reinforcements, natural rubber, and PLA was assumed from the observed fibrous structures and interwoven networks within the PLA matrix. Additionally, the presence of aggregates and porous structures highlighted the challenges posed by rubber agglomeration. Finally, the observation of larger agglomerates beyond typical interphase sizes raised concerns about brittle behavior, emphasizing the need for optimizing blend toughening strategies. The input for a Life Cycle Assessment (LCA), following a cradle-to-gate approach, is anticipated to show lower carbon emissions for the proposed alternative in comparison to ABS due to the principles of Green Engineering applied in the product design, denoting the environmental viability of the PLAbased substitute.

Keywords: Polylactide (PLA), Biobased, Life Cycle Analysis (LCA), Impact modifiers, Lignocellulose nanofibers
(LCNF)