Effect of Processing Conditions on Properties of Fly ash-Epoxy Composite

Fly ash being generated in massive scale has minimum utilisation as compared to its rate of production. It is the waste generated from thermal power plants, which find its primary usage in road embankment, cement making, making of fly ash bricks, etc. This current research focuses on finding out the ways of utilising fly ash as reinforcement to fabricate polymer composite. Fly ash comprises of oxides of silicon, aluminum, iron and titanium along with some other minor constituents. Here investigation has been done for processing and characterization of fly ash reinforced epoxy composites. Fly ash being immiscible is mixed with the epoxy using an ultrasonic sonicator for varied time periods. Various mechanical tests viz. tensile, flexural, impact, dielectric properties and tribological analysis are carried out to find out its proper application according to its suitability. The composite is treated in different environments viz. acid, base, fuel and sea water to find its proper environmental/chemical degradation/stability. The percentage of fly ash reinforcement is varied from 10 to 40%. For composite fabrication different mixing time i.e. 10, 20 and 30 minutes are chosen to check the effect of mixing time on the mechanical behaviour of the material. The prepared samples are cured at three different conditions i.e. standard atmosphere at room temperature, inside the oven and in the micro oven. Combinations of all these variables have been taken into consideration to analyse the effect on the mechanical properties of the material. The dielectric properties of the composites are evaluated. The sliding wear behaviour of the samples was studied with a pin on disc type sliding wear testing machine of DUCOM make; by varying the parameters, viz., time, RPM and applied load, etc. Optimisation techniques have been implemented to reduce the number of experiments and to find out the percentage contribution of each parameter. Simultaneously, a suitable combination of parameters has been given and the confirmatory test has been done to determine the percentage of error in the experiments. Finally, the samples are treated with an acid solution, basic solution, fuel (Petrol), sea water and acetone for 28 days; and change in mechanical properties has been recorded periodically. From the above-detailed examinations, these fly ash reinforced epoxy composites found to be moderately suitable for the automobile industry, to be used as the dashboard, brake pads, seat assembly plates, bumpers and in the interior portion of aircraft, etc. due to its mechanical properties. Most suited for construction industry for making of floor and wall tiles partition wall etc. Out of the treatment conditions, these composites are found to be most suitable for use in the petroleum industry for fuel carrying tanks and containers. Finally, it can also be used for making of beautiful decorative articles and household appliances