Metallic (Al and Fe) Powder-Reinforced Styrene–Butadiene Rubber Composites for Triboelectric Energy Harvesting

This study explores the energy-harvesting performance of aluminum (Al)- and iron (Fe)-filled styrene–butadiene rubber (SBR) composites, with a focus on their mechanical durability and triboelectric properties. Comprehensive mechanical characterization—including tensile strength, elongation at break, fracture toughness, and elasticity—reveals that Fe-filled composites exhibit significantly enhanced reinforcement compared to Al-filled systems at equivalent filler loadings. Raman spectroscopy indicates that Fe atoms can coordinate with the benzene rings of SBR chains through stronger physicochemical bonding, a feature less present in Al-based composites. In addition to improved mechanical properties, Fe-filled composites demonstrate higher electrical conductivity and superior triboelectric energy-harvesting performance. Notably, the composite containing 15 vol% Fe under 1% cyclic compressive strain achieves a peak current density of 127.05 µA/m2, a total generated charge of 5.01 nC, and a peak power density of 48.22 µW/m2. These values represent substantial enhancements of 246%, 236%, and 2398%, respectively, compared to Al-filled counterparts. Cyclic energy-harvesting tests confirm stable performance with negligible degradation in output or mechanical integrity over repeated cycles. Rubber composite shows good humidity resistance in current and voltage outputs. Furthermore, a layer-by-layer triboelectric nanogenerator (TENG) based on the Fe-filled composite produces output signals of approximately ±1.0 µA and ±5 V under biomechanical hand patting. The superior performance of Fe-based composites is attributed to stronger filler–rubber interactions, likely facilitated by electrostatic interactions, which enhances interfacial charge transfer during mechanical deformation. Overall, Fe-filled SBR composites demonstrate strong potential for cost-effective, environmentally friendly, and durable self-powered energy-harvesting applications.