Enhancing Mechanical and Physical Properties of Epoxy Composites with Eco-Friendly Metakaolin Filler: An Experimental Study

Abstract

This paper focuses on the preparation and characterization of the reinforcement of an epoxy with metakaolin clay of grain size (45 ≤ d ≤60) μm as an eco-friendly inorganic material to improve its mechanical and physical properties with low-cost filler. Various proportions of (0, 15, 30, 45, and 60) wt.% of metakaolin were intrinsically mixed with epoxy to invistigate their physical properties represented by moisture absorption. Tensile test was employed to determine their mechanical properties such as ultimate tensile strength, yield strength, modulus of elasticity, as well as compressive strength, flexural strength and Vickers hardness test which was used to specify hardness number. The obtained experimental results showed improvement in the modulus of elasticity, compressive strength, and hardness with the addition of metakaolin. In contrast, the yield and tensile strength of the composite specimens which decrease with the increase in metakaolin content. Also, absorption of moisture test at different immersion times was carried out with different filler loadings of the prepared composite. The results of the test showed that a decreasing in water uptake for specimens with higher metakaolin content. From optical surface investigation using an optical microscope, it was found a reduction in porosity with an increase in the concentration of metakaolin and the specimen with weight percent of 60% is the highest homogeneity and less porosity and voids as compared to the other specimens. The prepared composite may find potential practical applications such as anti-corrosion coating, automotive components and medical devices.