In order to study the effect of healing materials viscosity on the self‐healing performance of polymer composite, mostly available epoxy resin of viscosity 10–12 Pa.s and amine hardener of viscosity 0.01–0.02 Pa.s were chosen as two different healing materials and successfully encapsulated. Effect of core to shell(c/s) ratio on the synthesis of epoxy microcapsules was investigated and 1:1 c/s ratio is suggested as an ideal ratio to synthesize epoxy capsules. Chemical structure and thermal decomposition patterns of both microcapsules and capsules reinforced composite were analyzed. Tensile strength, impact strength and fracture toughness of capsules reinforced self‐healing epoxy composite were evaluated. It was observed that the toughness of epoxy composite increased with the increase in microcapsules concentration. An optimum healing efficiency of 66% was observed with the addition of 7.5 wt% epoxy and hardener microcapsules at equal weight ratio. Stresses developed in the pure epoxy composite crack front were analyzed using Ansys V18.1.
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