Erosion wear response of epoxy composites filled with steel industry slag and sludge particles: A comparative study

Abstract

In the field of composite research, use of industrial wastes such as slag and sludge particles as filler in wear resistant polymer composites has not been very common. Owing to the very high cost of conventional filler materials in polymer composites, exploring the possibility of using low cost minerals and industrial wastes for this purpose has become the need of the hour. In this context this work explores the possibility of such polymer composites filled with low cost industrial wastes and presents a comparison of mechanical characteristics among three types of epoxy based composites filled with Linz - Donawitz sludge (LD sludge), blast furnace slag (BF slag) and Linz - Donawitz slag (LD slag) respectively. A comparative study in regard to their solid particle erosion wear characteristics under similar test conditions is also included. Composites with different weight proportions (0, 5, 10, 15 and 20 wt. %) of LD sludge are fabricated by solution casting technique. Mechanical properties such as micro- hardness, tensile strength and flexural strength of three types of composites have been evaluated as per ASTM test standards and solid particle erosion wear test is performed following a design of experiment approach based on Taguchi’s orthogonal array. Five control factors (impact velocity, erodent size, filler content, impingement angle and erodent temperature) each at five levels are considered to conduct erosion wear tests. The test results for epoxy-LD sludge composites are compared with those of epoxy-BF slag and epoxy-LD slag composites reported by previous investigators. The comparison reveals that epoxy filled with LD sludge exhibits superior mechanical and erosion wear characteristics among the three types of composites considered in this study. This work also opens up a new avenue for value added utilization of an abundant industrial waste in the making of epoxy based functional composites.