A thermosetting epoxy resin was modified and four different types of bulk epoxy polymer sheets were prepared: (i) neat epoxy, (ii) epoxy with 9 wt.% rubber micro-particles, (iii) epoxy with 10 wt. % silica nano-particles, and (iv) epoxy with both 9 wt.% micron-rubber and 10 wt.% nano-silica particles. The tensile fatigue behaviour at a stress ratio R = 0.1 was investigated for all the materials. Addition of either the micron-rubber or nano-silica particles alone in the epoxy polymer had almost a similar beneficial effect and enhanced the fatigue life by about three to four times. The presence of both micron-rubber and nano-silica particles resulted in a further significant enhancement of the fatigue life, by about six to ten times. Fractographic studies suggested that the energy-dissipating mechanisms such as rubber cavitation and silica particle debonding, both being followed by plastic void growth of the epoxy, contributed to the enhanced fatigue lives which were observed in the modified epoxy polymers.
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