Fabrication and evaluation of uniform and gradient density epoxies

Abstract

Filled epoxy materials which vary in density in a designed manner have been fabricated and their mechanical properties evaluated. Density variations were produced by incorporating different volume fractions of either glass microballoons (GMB) or alumina. Several different sample types were evaluated including uniform density (0.8 g/cm{sup 3} < {rho} < 2.0 g/cm{sup 3}) samples and gradient density samples (GMB only, 0.8 g/cm{sup 3} < {rho} < 1.2 g/cm{sup 3}). The uniform density specimens were evaluated for the effects of filler type and concentration on modulus and toughness. Results indicated that addition of alumina filler significantly increased the resulting modulus while addition of GMB had little measurable effect. These differences could be understood in terms of the differing moduli of the additives relative to that of the epoxy matrix. In the former case the alumina particulates had a modulus much greater than that of the epoxy while in the latter case, the modulus of the GMB additive was only slightly greater than that of the matrix. Addition of either filler significantly degraded the toughness of the composite specimens and precluded the use of gradients to enhance toughness performance. Discontinuous {open_quotes}block{close_quotes} gradients used for testing were fabricated by simple sequential pours of formulations with different GMB loadings and were evaluated for modulus, strength and ductility. Continuous gradients were fabricated in process studies by programmed shifts in the peristaltic pumping/mixing ratio of epoxies filled with either alumina or GMB. None of the continuous gradient materials were mechanically tested. These results suggest that applications utilizing gradient materials containing alumina and similar high modulus fillers to provide designed stiffness rather than improved toughness are the most appropriate targets for future investigation.