Composites and Methods of Formation Thereof

A method of forming a composite material, the method comprising:

• drying organic raw material to remove moisture to less than about 18%;
• milling the dried organic raw material to form organic fiber particles having a size less than about 10 mm;
• forming a glue by adding magnesium oxide, magnesium chloride, and water;
• forming a slurry by mixing the glue with the organic fiber particles;
• filling a mold cavity of a mold with the slurry;
• and
• forming a pattern by allowing the slurry to set within the mold cavity.

A method of forming a composite material, the method comprising:

• milling an inorganic crystalline material to form pellets having a size less than about 1 mm;
• forming a glue by adding magnesium oxide, magnesium chloride, and water;
• mixing the glue with the pellets to form a slurry;
• filling a mold cavity of a mold with the slurry;
• and
• forming a pattern by allowing the slurry to set within the mold cavity.

A production process for making a composite material, the process comprising:

• drying organic raw material to remove moisture to less than about 18%;
• milling the organic raw material to form organic fiber particles having a size less than about 10 mm;
• incorporating ground solid waste with the organic fiber particles;
• forming a pre-glue mixture by adding magnesium oxide, magnesium chloride, and water;
• adding a catalyst to the pre-glue mixture to form a glue, wherein the catalyst is selected from the group consisting of K2SO4, ZnSO4, CuSO4, and K3(Fe(CN)6);
• mixing the glue with the organic fiber particles to form a slurry;
• filling a mold cavity of a mold with the slurry;
• and
• forming a pattern by allowing the slurry to set within the mold cavity, wherein the ground solid waste is a scrap product of the production process.

A method of forming a composite material, the method comprising:

• forming a magnesium cement matrix comprising magnesium oxide and magnesium chloride;
• and
• forming organic fiber particles disposed in the magnesium cement matrix, the organic fiber particles having less than 15% moisture, wherein the organic fiber particles are less than 10 mm in size;
• and
• forming inorganic crystalline material pellets disposed in the magnesium cement matrix, the inorganic crystalline material pellets having a size less than about 1 mm, and wherein the magnesium cement matrix, the organic fiber particles, and the inorganic crystalline material pellets form the composite material.