Enhancing the mechanical and thermal properties of ABS polymers through steel scale reinforcement: a sustainable approach to waste utilization

Abstract

Steel scale, a byproduct of the iron and steel industry, primarily composed of iron oxide phases, is typically considered an industrial waste. This study investigates its potential use as a reinforcing filler in acrylonitrile–butadiene–styrene (ABS) polymer composites to enhance both mechanical and thermal properties while promoting sustainable material utilization. Composites were produced via melt blending ABS with varying steel scale contents (3%, 5%, 7% and 9% by wt), followed by injection molding. Mechanical properties were evaluated through tensile, hardness, and impact tests. In contrast, thermal and structural properties were analyzed using dynamic mechanical analysis (DMA), thermogravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM). Results showed that incorporating the steel scale increased both the modulus of elasticity and hardness. Notably, at 9% filler content, the modulus rose by 28.9% (from 968 to 1248 MPa), and hardness increased by 9.2% (from 63.1 to 68.9) compared to pure ABS. However, higher filler content led to slight decreases in tensile and break strength—tensile strength dropped by 14.2% (from 42.9 MPa to 36.8 MPa), and break strength by 7% (from 39.6 MPa to 36.8 MPa). Thermal analyses confirmed improved thermal stability of the composites, demonstrating the steel scale’s effectiveness as a thermally resistant additive. These findings support the feasibility of recycling steel scale into polymer composites, presenting a sustainable alternative for reducing industrial waste. The developed composites show promise for applications in non-structural automotive parts, construction materials, and durable consumer products.

Graphical abstract