Mayana 2022 IOP Conf. Ser. Mater. Sci. Eng. 1248 012081

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International Conference on Materials Science and Engineering (ICMSE 2022) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1248 (2022) 012081 doi:10.1088/1757-899X/1248/1/012081
Fabrication and Mechanical Characterization of Glass Fiber

Reinforced Epoxy with CFA and SiC
Pachakhan Mayana1*, Kavyasree. G2, Lakshmi Narasimhulu. P3,

Althaf Hussain. SG4, Maheshwar Reddy. E5, Syman. N6
1
Assistant Professor of MED, MeRITS Engineering College, Udayagiri 524226, India
23456
UG Student of MED, MeRITS Engineering College, Udayagiri 524226, India
1
pachakhan@gmail.com, 2 kavyasree842@gmail.com,
3
pnarasimhulu996@gmail.com, 4anonymousvariant0@gmail.com, 5maheshwarreddy87
90@gmail.com, 6symansam5@gmail.com
Abstract. From early history, builders, manufacturers, and engineers continued to develop
composites of wide assortments of materials. Furthermore, chemical upheaval changed the
composite development of plastics such as polyvinyl, polystyrene, etc., and reinforcement was
reinforced essential to provide strength and rigidity. At present composites finds many
applications in every aspects of day to day life. The utilization of raw materials like coal,
baggase and agricultural wastes are used in large scales in industries for power generation and
food production. The utilization of these fuels causing huge environmental pollution liberating
in the form of ashes. These ashes can be utilized in effective way for manufacturing and
structural applications with their incorporation in polymer matrix composites. To enhance the
mechanical properties and in reducing the manufacturing cost, these industrial wastes plays a
major role. The present research work mainly focuses on the influence of Coal Fly Ash (CFA),
Silicon Carbide (SiC) and a mixture of CFA & SiC as filler materials on the mechanical
behavior of Epoxy Glass fiber composite. Various types of composites are fabricated by
manual hand lay-up process with varying weight percentages of the filler materials and epoxy
resin as matrix material. The filler materials weight proportions are taken as 5%, 10% and
15%. The prepared composites are cut into tests specimen as per the ASTM standards of
mechanical characterization. The mechanical properties of the composites (like Tensile
strength (ASTM D3039/D3039M: 2017), Flexural strength (ASTM D790: 2015), Impact
strength (ASTM D 229 el: 2019), Interlaminar shear strength (ASTM D2240: 2015), Hardness
(ASTM D2240: 2015)) are determined by using corresponding testing machines and it is
observed that the properties exhibited by the composites are enhanced with the incorporation of
CFA, SiC & mixture of CFA and SiC when compared with the unfilled composites. So, these
composites are considered a multifunctional composite material where the individual fillers are
used in some applications and the combined proportions are used in different applications.
They replace the existing materials that are very high in cost and cause more pollution at the
time of manufacturing. These composites give the ability to improve and increase the
efficiency, autonomy, and life expectancy of a structure.
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
1. Introduction
From our forefathers to us, many changes have occurred. In those changes, the major change has
happened in the usage of the material. Nowadays, the material that we use daily becomes a curse to
our next generation, normally known as plastic. But these plastics are getting replaced by composite
materials which have great mechanical properties. Composites can be defined as the combination of
two or more materials into one constituent or one material. The two distinct materials used are
reinforcement and matrix. These two don’t react, chemically but they physically remain as a single
unit. Matrix tends to keep the reinforcement to be fixed to a place and reinforcement is responsible for
enhancing the mechanical properties of composites. The materials used may be different in physical
and chemical properties but when integrated it possesses improved properties, unlike the individual.
Composites are diverse at the microscopic level but scientifically similar at the macroscopic level.
Composites replace metals because of their similarities in properties, less weight, and low cost
compared to metals. composites are rapidly increasing in aerospace, automobiles, marine, industries,
and also in domestic purposes. By using composite it’s possible to design new multifunctional
materials with unique properties.
[1] Raffi Mohammed et al. scrutinized the mechanical properties of dissimilar fillers like Bagasse
fiber/Bagasse ash/ Coal powder/CFA and the effects of epoxy and glass fiber. The composites were
fabricated using the hand lay-up technique and observed the tensile modulus of coal fly ash modified
epoxy is compared to bagasse fiber 10% of CFA was exhibiting a higher value. [2] Rajesh Purohit et
al. estimated the CFA has used the filler with glass fiber and epoxy resin in the polymer matrix. By
increasing the percentage of the filler material with the interval of 2% from 4-10 % proportions using
the hand lay-up method which develops the Impact & Flexural strength [3] K. Devendra and
Rangaswamy investigated the mechanical properties of E-Glass fiber which was reinforced in epoxy
resin matrix with fillers as coal fly ash, Al2O3, Mg(OH)2, and hematite powder and fabricated with
hand lay-up technique and mechanical properties were evaluated and it was observed that the
improvement of hardness and impact strength.[4] R. Sateesh Raja et al. assessed that the development
of the mechanical behaviour is directly proportional to the increased proportions of the filler materials
as the reinforcing components with epoxy and glass fiber composites.[5] Shyamkumar shah et al.
inspected the fiber-reinforced polymer composites where the filler material was CFA and its effects on
mechanical properties. The composites were fabricated with the standard hand lay-up technique with
the varied proportions of CFA of 5%- 10%. The fabricated composites are examined as per ASTM
standards and found that the addition of filler enhances the impact strength and the tensile properties
are not satisfactory in filled one.
[6] M. Kamaraj et al. scrutinized the effects on the epoxy by using sisal fiber and Silicon Carbide, the
mechanical behaviour of the composite. In this, the sisal fiber is fixed and the weight percentages of
the Silicon Carbide are varied from 2-10% with the regular interval of 2% and were fabricated and
then subjected to mechanical characterization as per ASTM standards. The results were as observed as
the fracture strength and impact strength were increased when the proportions were increasing.[7]
Arpitha G R et al. examined the glass fiber with Silicon Carbide hybrid composite’s mechanical
properties. The Silicon Carbide weight percentages varied from 3%-9% with sisal/glass fiber at 3%,
6%, and 9%. The composites were fabricated with a manual hand lay-up technique. It was observed
that the flexural and impact strength increased. [8] Mehdi Derradji et al. evaluated the thermal
properties of composite material which were prepared by using Silicon Carbide as micro filler particle
with the change of weight composition of 0 %-20 % with pthalonitrile reinforcing material It exhibited
an increase in mechanical properties like stiffness, flexural strength, and microhardness with the
increase of micro-SiC particles with good thermal stability. [9] Ramesh Ganugapenta et al. observed
the composites with epoxy filled with Silicon Carbide and CFA and their effects on glass fiber’s
mechanical properties. Here they fabricated the composite material by using the hand-lay-up technique
2
by changing the proportion of the filler material from 5% to 20% with an interval of 5%. The results
were observed that the hardness, tensile strength, and impact strength were increased.[10] R. Satheesh
Raja studied the mechanical behavior of the fly ash impregnated Glass fiber-reinforced polymer
composite. By adapting the Mixture Design Method, mathematical calculations are carried out for
getting the results. The CFA with 10% exhibits improved mechanical properties.[11] V. Manikandan
has an Experimental study carried out on the effect of fly ash fillers on mechanical and tribological
behaviour of woven jute fiber reinforced polymer hybrid composite. Composites were fabricated using
the hand layup method with varying the weight percentage of fly ash as filler material varying from
2% to 10% with 3 plies [0/90] s woven jute fiber as reinforcement having a weight percentage of 40%.
In this study, the increase of CFA percentage on the composite material will intensify wear resistance
and hardness. [13] Venkateshwara Rao. T has investigated the mechanical properties of the bamboo
fiber filled with fly ash filler reinforced hybrid composites. The composite has prepared by using the
standard technique which is the hand-lay-up technique. Here maximum mean tensile strength of
bamboo fiber filled with Fly ash filler reinforced Hybrid composite is 84.61 MPa.[14] V. K.
Srivastava and P. S. Shembekar scrutinized filler materials that can enhance the toughness and surface
fracture energy by accumulating the CFA particles with epoxy resin due to fracture interrelating with
particles of CFA can improve the surface properties.
2. Material And Methods
2.1 Materials
2.1.1 Epoxy
Epoxy is a widely used thermosetting polymer broadly used. Epoxy resins are also known as poly-
epoxides. The epoxide functional group is called epoxy, they are polymeric, semi-polymeric materials,
or oligomers that rarely exist in pure form. We use epoxy resin of LY556. Epoxy possesses high
mechanical strength, chemical resistance, electrical insulation, and reduced corrosion and is mainly
used for adhering to dissimilar substrates.
2.1.2 Glass Fiber
Glass fiber is a material consisting of several fine fibers of glass. They are very flexible and
multifaceted. Glass fibers are manufactured from sand, clay, and calcite. There are many types of glass
fibers. In this project, we use E-Glass fibers as the reinforcement in composites because of their
admirable fiber-forming competence, lightweight, and less price with high mechanical properties.
2.1.3 Hardener
Hardener is a constituent of certain kinds of the mixture, hardner is regularly an amine it is combined
with the epoxy which stimuli chemical reactions between the two. This involves epoxides and other
chemicals and is also known as curing agents. We use HY951 hardner (Araldite hardener) which has
less stickiness and cures at normal atmospheric temperature and appreciable resistance to atmospheric
and chemical deprivation.
2.1.4 Coal Fly Ash (CFA)
The constituent formed after burning pulverized coal in power plants is known as fly ash, its deposit
produced in the combustion of coal in industries. It incorporates some amount of silica and lime,
silicon oxide, aluminium oxides, iron oxides, and a slight amount of oxides of, M, Ca, Na, and K. Fly
3
ash is globular in profile with a defined surface area. Fly ash can also be used in concrete as
supplementary material, but it affects the quality and strength of cement. CFA is filler we are
incorporating in the fabrication of the composite.
2.1.5 Silicon carbide (SiC)
SiC is the crystal-like compound of silicon and carbon which is very hard in nature, it’s also termed
‘carborundum’. By using woodchips petroleum coke and quartz sand, it was manufactured. It is
widely used as an abrasive and steel additive in industries. Sic is available in two types. i.e., black
Silicon Carbide and green Silicon Carbide. We use black SiC as one of the fillers in the present work.
This possesses appreciable mechanical, chemical, and thermal properties.
Figure1. Glass Fiber Figure2.Epoxy Figure3. Hardener
Figure4. Coal Fly Ash Figure5. Silicon Carbide
4
2.2 Manufacturing Methods
Figure 6. Manufacturing Techniques
2.2.1 Hand lay-up Technique
The technique that is utilized for fabrication is Hand lay-up. It is one of the simplest and most
traditional techniques which is suitable for preparing prototypes and for small production of fiber-
reinforced composite materials. This consists of numerous fibers which are placed on another with
resin, which are arranged together in unidirectional ply. It is the most commonly used technique in
some industries due to its capabilities of high performance. This method is also known as wet lay-up
because the resin is coated before the plies are laid and then they are compacted at the end. This
method is chosen because of its low cost of tooling, simplicity in processing, and minimal investment
in equipment. This needs skilled operators for high production rates to obtain constant quality.
Figure7. Hand-lay-Up Technique
5
2.3 Fabrication Process
The below flow chart describes the steps involved in the fabrication of composites.
Mould preparation, Resin preparation, Cutting glass fiber
Hand lay-up moulding
Curing
Demoulding
Laminate
Figure 8. Fabrication process
2.3.1 Mould Preparation:
It is the initial stage of fabrication in which the mould is prepared, first the G. I sheet of
300mm×300mm.The mansion white wax was used as the intermediate layer between G. I sheet and
the composite material. It will be applied evenly on the plates and leave it in atmosphere for 1 hour.
Similarly, another sheet is prepared.
2.3.2 Hand lay-up moulding:
First, the woven glass fiber is cut in the dimensions 200mm×200mm. Then the epoxy and hardener are
mixed according to the standard ratio which is 10:1. The epoxy is applied on the G.I sheet and a ply of
glass fiber is placed and rolled using rollers, Next, the epoxy is applied to the glass fiber and then the
glass fiber is placed on the resin and then rolled using rollers, this process is repeated for 8 layers of
glass fibers. The resin mixture should be completed by the end of the last layer of glass fiber.
2.3.3 Curing:
After laying the composite another G.I sheet is placed on the last ply of glass fiber and some weight is
placed on it. The initial curing is done for 24 hours without any disturbance of the fabricated
composite.
2.3.4 Demoulding:
After curing for 24 hrs the weight is removed and the G.I sheets are separated easily because of the
wax coating, both the sheets are separated and then the prepared composite is dried for another 24 hrs
in exposure to air and sunlight.
6
2.3.5 Laminates:
The laminates are commonly used as the finishing layer which enhances the specific properties of the
composites.
(a)
(b) (c)
Figure 9(a). Solidified composite material after curing pro
Figure 9(b). Cutting of composite material by jig-saw machine
Figure 9(c). Cutting of composite material as per ASTM standards
7
2.4 Designation of Composite Materials
Composite designation and Composition
S. No Composite Designation Composition
1. GE50 50 wt. % of Glass fiber (G.F) + 50 wt.% of Epoxy Resin (E.R)
2. GE60 40 wt. % of G.F + 60 wt.% of E. R
50 wt. % of G.F + 45 wt.% of E.R + 5 wt. % of Coal Fly Ash

3. GECFA 5
(CFA)

4. GECFA 10
(CFA)

5. GECFA 15
(CFA)
50 wt. % of G.F + 45 wt.% of E.R + 5 wt. % of Silicon

6. GESiC 5
carbide (SiC)

7. GESiC 10
carbide (SiC)

8. GESiC 15
carbide (SiC)
9. GECFASiC 5 50 wt. % of G.F + 45 wt.% of E.R + 5 wt. % of SiCCFA
10. GECFASiC10 50 wt. % of G.F + 40 wt.% of E.R + 10wt. % of SiCCFA
11. GECFASiC 15 50wt. % of G.F + 35 wt.% of E.R + 15 wt. % of SiCCFA
Table 1. Proportions and Designations of composite materials.
8
3. Results and Discussion
The specimens are tested according to ASTM standards and test methods like Tensile strength (ASTM
D3039/D3039M: 2017), Flexural strength (ASTM D790: 2015), Impact strength (ASTM D 229 el:
2019), Interlaminar shear strength (ASTM D2240: 2015), Hardness (ASTM D2240: 2015) are
considered.
S. No Composite Type T.S(MPa) F.S(MPa) I.L.S.S I.S(J/m) Hardness
1. GE50 255.05 277.58 7.72773 1319.0 92
2. GE60 139.35 294.39 7.9 1207.5 93
3. GECFA 5 249.68 278.31 8.13533 945.9 90
4. GECFA 10 207.4 232.95 7.8439 797.5 88
5. GECFA 15 266.29 284.65 8.95375 758 90
6. GESiC 5 198.91 274.2 8.8723 1056.3 88
7. GESiC 10 173.76 229.68 7.433 830.6 92
8. GESiC 15 204.44 249 5.805 638.2 92
9. GECFASiC 5 238.98 301.73 6.9 620.1 90
10. GECFASiC 10 229.51 276.73 10.542 738.2 91
11. GECFASiC 15 187.94 283.48 7.89 848 93
Table 2. Mechanical Properties of composite materials.
Figure10.Specimens after carrying out mechanical testing.
9
3.1 Tensile Strength
The specimen for the testing of tensile strength is dumble shape has conventional side and end tabs.
The specimen dimension was 170×24×3mm3. One of the ends was applied uniaxial load. The testing
was carried out according to the ASTM D3039/D3039M: 2017 and the tensile property of composites
was examined. The tensile strength of the composite with 15 wt% of CFA has exhibited more tensile
property of 266. 29MPa.The test was carried out in UTM at a crosshead speed of 2mm/min.
Tensile strength (Mpa)

300
266.29
255.05 249.68
238.98 229.51
250
207.4 198.91 204.44
200 187.94
173.76
139.35
150
100
50
0
GE- (50- GE- (40- GECFA - GECFA - GECFA - GESiC - GESiC - GESiC - GECFASiC GECFASiC GECFASiC
50) 60) (5%) (10%) (15%) (5%) (10%) (15%) - (5%) - (10%) - (15%)
Figure11. Tensile Strength comparison Graph of composites.
3.2 Flexural Strength
The flexural strength of the composite is found where the maximum stress it can withstand is just
before the breaking point. The specimen dimensions are 125×12.7×3.2 mm3. The test is carried out
according to the standard ASTM D790: 2015, and the flexural strength was examined among the
composites. The composite with 5 wt% of combined CFA & SiC exhibits high flexural strength of
301.73 MPa. The test was carried out on the Universal Testing Machine.
Flexural strength (Mpa)

350 301.73
294.39 278.31 284.65 283.48
300 277.58 274.2 276.11
232.95 249
250 229.68
200
150
100
50
0
50) 60) (5%) (10%) (15%) (5%) (10%) (15%) - (5%) - (10%) - (15%)
Figure12. Flexural Strength comparison Graph of composite materials.
10
3.3 Hardness
The hardness is the test done to find how harder the material is by putting fixed force on the specimen
using an indenter. This method applies a predetermined test load on a small indenter in which hardness
values are attained. The test is carried out according to the standards of ASTM D2240: 2015. From the
values obtained in which the unfilled composite with 40 wt% of glass fiber exhibited a high hardness
of 93 and the filled composite with 15 wt% combined filler exhibited a high hardness of 93. The
testing is conducted using Brinell Hardness Testing Machine.
94 93 93
93 92 Hardness 92 92
92 91
91 90 90 90
90
89 88 88
88
87
86
85
50) 60) (5%) (10%) (15%) (5%) (10%) (15%) - (5%) - (10%) - (15%)
Figure13. Hardness comparison Graph of composite materials.
3.4 Impact Strength
The Izod impact test is done on the specimen of size 65x12.7x3.2 mm3 (ASTM D256) by hitting with
a heavy loaded hammer suddenly, due to this the specimens’ strength will be recorded in the machine
dial indicator, which reflect the energy spent to break the specimen. The specimen with un-filled
composite exhibited high impact strength of 1319.4 J/m and in the filled composites the composite
with 5 wt% of SiC showed high impact strength of 1056.3 J/m. The test was carried out in the
Pendulum Impact Testing Machine.
.
1400 1319.4
1207.5
1200 1056.3
945.9
1000 797.5 830.6 848
758 738.2
800 638.2 620.1
600
400
200
0
50) 60) (5%) (10%) (15%) (5%) (10%) (15%) - (5%) - (10%) - (15%)
Figure14. Impact strength comparison of composite materials.
11
3.5 Interlaminar Shear Strength (I.L.S.S)
I.L.S. S is a measure of the resistance of the composites to delamination when parallel shear forces are
applied to them. This describes the shear strength between the laminates present in the composites.
The specimen dimensions are 125×12.7×3.2 mm3. The I.L.S.S was observed and the combined filler
composite of 10 wt% exhibited a higher ILSS of 10.542 MPa. The ILSS was calculated with the
formula given below
3P
ILSS = 4lh
ILSS
12 10.542
10 8.95375 8.8723
7.72773 7.9 8.13533 7.8439 7.89
7.433 6.9
8
5.805
6
4
2
0
50) 60) (5%) (10%) (15%) (5%) (10%) (15%) - (5%) - (10%) - (15%)
Figure15. ILSS Comparison of composite materials.
4. Conclusion
Experimental Study on Mechanical Properties of Glass Fiber Reinforced Epoxy with CFA and SiC
which was fabricated with different weight percentages of 5%, 10%, and 15%. The results were
concluded as follows,
 With the incorporation of industrial wastes as filler materials can reduce the environmental
pollution, reduces the disposal problems, costs and reduces the manufacturing cost.
 The tensile strength of the composite GECFA 15 exhibited more tensile property of 266.
29MPa.
 The composite material GECFASIC 5 poses high Flexural strength of 301.73 MPa.
 The composites possess high hardness with GE60 and GECFASIC 15 have value of 93.
 The composite of GE60 possessed high impact strength of 1319.4 J/m.
 The composite of GECFASIC 10 exhibited a higher ILSS of 10.542 MPa
.
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14

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- The Gilbert damping of thickness-

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This content was downloaded from IP address 117.254.83.178 on 02/08/2022 at 10:51

Fabrication and Mechanical Characterization of Glass Fiber

Pachakhan Mayana1*, Kavyasree. G2, Lakshmi Narasimhulu. P3,

2. Material And Methods

2.1.2 Glass Fiber

2.1.4 Coal Fly Ash (CFA)

2.1.5 Silicon carbide (SiC)

Figure1. Glass Fiber Figure2.Epoxy Figure3. Hardener

Figure4. Coal Fly Ash Figure5. Silicon Carbide

2.2 Manufacturing Methods

Figure 6. Manufacturing Techniques

2.2.1 Hand lay-up Technique

Figure7. Hand-lay-Up Technique

2.3 Fabrication Process

Mould preparation, Resin preparation, Cutting glass fiber

Hand lay-up moulding

Figure 8. Fabrication process

2.3.1 Mould Preparation:

2.3.2 Hand lay-up moulding:

2.4 Designation of Composite Materials

Composite designation and Composition

S. No Composite Designation Composition

1. GE50 50 wt. % of Glass fiber (G.F) + 50 wt.% of Epoxy Resin (E.R)

2. GE60 40 wt. % of G.F + 60 wt.% of E. R

50 wt. % of G.F + 45 wt.% of E.R + 5 wt. % of Coal Fly Ash

50 wt. % of G.F + 40 wt.% of E.R + 10 wt. % of Coal Fly Ash

50 wt. % of G.F + 35 wt.% of E.R + 15 wt. % of Coal Fly Ash

50 wt. % of G.F + 45 wt.% of E.R + 5 wt. % of Silicon

50 wt. % of G.F + 40 wt.% of E.R + 10 wt. % of Silicon

50 wt. % of G.F + 35 wt.% of E.R + 15 wt. % of Silicon

9. GECFASiC 5 50 wt. % of G.F + 45 wt.% of E.R + 5 wt. % of SiCCFA

10. GECFASiC10 50 wt. % of G.F + 40 wt.% of E.R + 10wt. % of SiCCFA

11. GECFASiC 15 50wt. % of G.F + 35 wt.% of E.R + 15 wt. % of SiCCFA

Table 1. Proportions and Designations of composite materials.

3. Results and Discussion

S. No Composite Type T.S(MPa) F.S(MPa) I.L.S.S I.S(J/m) Hardness

1. GE50 255.05 277.58 7.72773 1319.0 92

2. GE60 139.35 294.39 7.9 1207.5 93

3. GECFA 5 249.68 278.31 8.13533 945.9 90

4. GECFA 10 207.4 232.95 7.8439 797.5 88

5. GECFA 15 266.29 284.65 8.95375 758 90

6. GESiC 5 198.91 274.2 8.8723 1056.3 88

7. GESiC 10 173.76 229.68 7.433 830.6 92

8. GESiC 15 204.44 249 5.805 638.2 92

9. GECFASiC 5 238.98 301.73 6.9 620.1 90

10. GECFASiC 10 229.51 276.73 10.542 738.2 91

11. GECFASiC 15 187.94 283.48 7.89 848 93

Table 2. Mechanical Properties of composite materials.

Figure10.Specimens after carrying out mechanical testing.

3.1 Tensile Strength

Tensile strength (Mpa)

Figure11. Tensile Strength comparison Graph of composites.

3.2 Flexural Strength

Flexural strength (Mpa)

Figure12. Flexural Strength comparison Graph of composite materials.