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Although carbon nanotubes (CNTs) have displayed great potential for enhancement of multifunctional properties of a polymer matrix, still incorporation of CNTs with the polymeric matrices requires further improvement in terms synthesis, processing, functionalization etc. In this study, we decorated the surfaces of multi‐walled CNTs (MWCNTs) by zirconium dioxide (ZrO2) nanoparticles to fully utilize former's remarkable mechanical properties, and then MWCNT/ZrO2‐based hybrid epoxy nanocomposites (MNCs) were synthesized via a novel ultrasonic dual mixing (UDM) technique. The fracture strength and toughness of prepared MNCs were studied using a 3‐point (3‐P) single edge notch bending test. The surface morphology and fracture mechanisms were examined through field emission scanning electron microscope images of the fracture surfaces of samples of MNCs. Apart from experimental investigations, the mechanics of materials (MOM) and finite element (FE) models were also developed to predict the effective elastic properties of two‐ and three‐phase MNCs. The mechanical response of MNC‐based beams was studied using 3‐P bending test via FE simulations and the numerical predictions are found to be in good agreement with the experimental results with maximum discrepancy of ~6% at 1 wt% loading of hybrid nanofillers. Our results also reveal that the fracture toughness of MNCs is improved by ~31% compared to the neat epoxy when 1.0 wt% loading of MWCNT/ZrO2 hybrid nanofillers is used to fabricate MNC.

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Carbon nanotube (CNT) acts as the most promising nanofiller due to its high aspect ratio and exceptional nanoscale-level properties. However, the dispersibility of CNTs in the conventional polymer matrices is a very critical issue in developing the high-strength and light-weight polymer-based nanocomposites. In this study, an attempt was made to develop cluster-free and uniform dispersion of multiwalled carbon nanotubes (MWCNTs) in the epoxy matrix using an innovative ultrasonic dual mixing technique. The effect of dispersion of MWCNTs on the mechanical and viscoelastic properties of MWCNT-epoxy nanocomposites was comprehensively studied. Our results reveal that the tensile strength and toughness of epoxy nanocomposites with 0.50 wt.% of MWCNTs improved by 21% and 46%, respectively, as compared to neat epoxy. The nanocomposite samples with the same CNT loading show maximum enhancements of 22% and 26% in the lap shear strength and storage modulus, respectively. The tensile fracture surface examination of MWCNT-epoxy nanocomposites using field emission scanning electron microscopy indicated the cluster-free and uniform dispersion of MWC-NTs in the epoxy matrix.

Exploiting the boundless potential of multi-walled carbon nanotubes (MWCNTs) is the critical issue in developing multifunctional nanocomposites. In this study, the MWCNTs are exfoliated by ZrO2 nanoparticles using the ultrasonication technique. The obtained MWCNT/ZrO2 hybrid nanofiller is infused in the epoxy matrix to produce multifunctional nanocomposites with superior thermo-mechanical and anti-corrosive properties. The physical, morphological, and structural properties of MWCNT/ZrO2 hybrid nanofiller are successfully studied by using XRD crystallography, Raman spectroscopy, and transmission electron microscopy analysis. The chemical interaction between the MWCNT/ZrO2 hybrid nanofiller with the epoxy (EP) matrix is evaluated using FTIR spectroscopy. Results indicated that the corrosion protection performance of mild steel coated with MWCNT/ZrO2 hybrid epoxy nanocomposite (MNC) is considerably increased at 1.0 wt.% of MWCNT/ZrO2 hybrid nanofiller by reducing the corrosion rate from 8.82 MPY to 56 × 10−3 MPY. Furthermore, the tensile strength and lap shear strength of MNC with the same loading content is improved by 67.8% and 58.04%, respectively, compared to neat EP. The field emission scanning electron microscopy images of tensile fracture surfaces of MNC (1.0 wt.%) confirm the cluster-free uniform dispersion of MWCNTs in the EP matrix.

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