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Abstract — Carbon fabric reinforced epoxy (C-E) composites

filled with different weight proportions of fly ash cenosphere (CSP)

were fabricated by hand lay up technique followed by compression

molding. The solid particle erosion characteristics of the CSP filled

C-E composites have been studied and the experimental results were

compared with those of unfilled C-E composites. For this, an air jet

type erosion test rig and Taguchi orthogonal arrays have been used.

The findings of the experiments indicate that the rate of erosion by

impact of solid erodent was greatly influenced by various controlfactors. The tensile modulus and flexural modulus of cenospheres-

filled C-E composites showed good improvement compared with that

of the unfilled C-E composites. Low density (0.6 g/cm3) and higher

silica content (60%) of cenospheres seems to be the reason for this

observation. The comparative study indicates that the CSP filled C-E

composites exhibit better erosive wear performance than that of the

unfilled C-E composites. The CSP filled and unfilled C-E composites

showed ductile erosion behaviour, with maximum erosion at 300

impingement angle. Overall the erosion rate was found to increase

with impact velocity. Furthermore, the filler content is the powerful

influencing factor followed by impact velocity, impingement angle,

erodent size and erosion time during the erosive wear process.

Keywords — Mechanical properties, Polymer matrix composites,

Solid particle erosion, Taguchi method.

I. I NTRODUCTION

POXY is one of the extensively used thermoset resins due

to its ease of handling, molding and curing.[1]. In

composites technology, particulate organic and inorganic

fillers are added into the polymers, may provide a good

method to improve their stiffness, modulus and reduce costs

[2–4]. Fillers affect the tensile properties according to their

packing characteristics, size and interfacial bonding [5-8]. The

maximum volumetric packing fraction of filler reflects the size

distribution and shapes of the particles. Srivastava and

Shembekar [8] showed that the fracture toughness of epoxyresin could be improved by addition of fly ash particles as

filler.

Mohammed Ismail, Department of Industrial & Production Engineering, The

National Institute of Engineering, Mysore – 08 ( Phone:

08212480475;fax:08212485802 ; e-mail:ail: [email protected])

Suresha Bheemappa, Department of Mechanical Engineering, The National

Institute of Engineering, Mysore – 08 ( e-mail: [email protected])

Rajendra N, Department of Industrial & Production Engineering, The National

Institute of Engineering, Mysore – 08(e-mail: [email protected])

Polymer composites are increasingly used in engineering

applications such as gears, pump impellers where the

components undergo erosive wear. However, these composite

materials present a rather poor erosion resistance [8, 9].

Hence, it is essential to evaluate their strength as well as their

erosive behavior. Solid particle erosion is the progressive loss

of original material from a solid surface due to mechanical

interaction between that surface and solid particles. Generally,

variables influencing the erosive wear of composite materials

are, mechanical properties of the composites, fiber content,

filler content, eroding particle size, impingement angle and

velocity. Solid particle erosion of polymers and their

composites have not been investigated to the same extent as

for metals or ceramics. In viewing past work on erosive wear

of polymer composites, most efforts were focused on the

study of the influence of the material properties rather than the

operating parameters [10–14]. Srivastava and Pawar [15]

studied the effect of additives and impingement angle and

eroding particle velocity on erosive wear of neat E-glass fiber

reinforced epoxy resin composite materials and composites

with 2 and 4 g fly ash additive particles. They concluded that

the erosive wear rate of glass fiber reinforced polymer

composite with 4 g fly ash is the lowest and that the maximum

erosion occurs at 60°. Finnie [16] and Barkoula and Karger-

Kocsis [17] studied the influences of operating condition such

as impingement angle and speed on the erosion of polymer

composites under small particle erodes.

It is widely recognized that polymers and their composites

have a poor erosion resistance. Their erosion rates are

considerably higher than metals. Barkoula and Karger-Kocsis

[17] summarized the behavior of polymer composite materials

under erosion conditions in schematic diagram see Figure 1.

However, elastomers and rubbers are being used as protective

coatings for erosion resistance [18]. The erosion resistance of

polymers is two or three orders of magnitude lower than thatof metallic materials. Also, it is well known that the erosion

rate of polymer composites is usually higher than that of neat

polymers [19]. Hutchings [20] observed that material behavior

can vary with the variation of erosion conditions. Häger et al.

[21] carried out erosion test for several thermoset and

thermoplastics composites and observed a semi-ductile

behavior. Maximum erosion is observed at 60° impingement

angle for most of the tested composites. A different

observation was made by Tsiang [22] as using Al2O3 particles

erosion sand. He concluded that in glass fiber reinforced

Investigations on Mechanical and Erosive Wear

Behaviour of Cenosphere Filled Carbon-Epoxy

Composites

Mohammed Ismail, Suresha Bheemappa and Rajendra N

E

International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2012) Jan. 7-8, 2012 Dubai

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epoxy and some other thermoset matrices, the erosion

occurred in a brittle manner, while in thermoplastic matrices a

semi-ductile erosion was dominant. Rajesh et al. [23] studied

erosive wear of five different polyamides and observed that all

polyamides showed maximum erosion wear at 30°

impingement angle indicating a ductile failure behavior. Tilly

and Sage [24] have investigated the influence of velocity,

impingement angle, eroding particle size and weight on the

erosion wear of nylon, carbon fiber reinforced nylon, epoxyresin, polypropylene and glass fiber reinforced plastics. Their

results show that these particulate filled materials behave in an

ideal brittle fashion and E-glass fiber reinforced epoxy

composite exhibits erosion rates less than those of the other

composites by a factor of 5. The E-glass epoxy composite

exhibits semi-ductile erosion at 45° and 60° impingement

angle while others eroded in brittle manner with a maximum

weight loss occurring at 75–90° impinging angles. Zahavi and

Schmitt [25], Miyazaki and Takeda [26] also studied the

erosive behavior of fiber reinforced polymer composites and

concluded that the maximum erosion rate is at 90°

impingement angle. Bitter [27, 28] in his study on erosion phenomenon, stated that ductile behavior shows a peak

erosion rate around 30° impingement angle because the

cutting mechanism is the dominant in erosion. Past work

shows some uncertainty in this respect, because most of

studies concentrated on erosive and strength behaviors of

polymer composites separately. To reach more clear

conclusions there is a need to investigate both strength and

erosive behavior of polymer composites in parallel. In

composite technology additives have been used in composite

materials to minimize the overall material cost. This is also the

case for the addition of fly ash cenosphere to carbon fabric

reinforced epoxy composite. It is believed that the CSP filler

is influencing the strength and the erosive wear behavior of C-

E composites. In this study, the hardness and the erosive wear

behaviors of CSP filled C-E composites were examined. The

variation in hardness and the erosion resistance with CSP

filler loading, erodent particle size and impingement angle

were studied and evaluated.

Erosive wear resistance of polymers and their composites is

therefore of substantial interest. From literature survey it is

evident that very little work has been reported on solid particle

erosion studies of epoxy and their composites [17, 29, and

30]. Fiber reinforced polymer composites represent the basic

element of complex composite structures. Epoxy resins are

superior to polyesters in resisting moisture and other environmental influences and offer lower shrinkage and better

mechanical properties. Woven fabric reinforced polymer

matrix composites are gaining popularity because of their

balanced properties in the fabric plane as well as their ease of

handling during fabrication. Also, the simultaneous existence

of parallel and anti parallel fibers in a woven configuration

leads to a synergetic effect on the enhancement of the wear

resistance of the composite [31]. The role played by fly ash

cenosphere in different matrices and fiber reinforced polymer

composites, and its effect on friction and wear is of interest to

material technologists. This is because of the ability of fly ash

cenosphere which could act as a load bearing filler material

Therefore, study of their behaviour is an important component

of the analysis of erosive wear of polymer composites. The

objective of the present investigation was to study the solid

particle erosion characteristics of fly ash cenosphere filled and

unfilled C-E composites under various experimental

conditions. A plan of experiments, to acquire the data in a

controlled way has been designed on the basis of Taguchitechnique.

II. EXPERIMENTAL PROCEDURE

Materials

The Carbon fabric reinforced epoxy laminates were

prepared by hand lay up followed by compression molding

technique using epoxy resin as the matrix material and carbon

woven cloth as the reinforcement. The fly ash cenosphere

particles of average size of about 25 to 50 µm were employed

as filler material. The fly ash cenosphere particles were treated

with 2% organo-reactive sliane coupling agent. Table 1 gives

the details in respect of designation and the wt% of epoxy,carbon fiber, and fly ash cenosphere filler used in this

investigation. Erosion test specimens of geometry (50 mm×50

mm×2.5 mm) were cut from the laminates using a diamond

tipped cutter.

TABLE 1. COMPOSITES USED IN THE PRESENT STUDY.

Mechanical property measurements

Mechanical properties namely tensile strength, tensile

modulus, flexural strength and flexural modulus for different

compositions of the CSP filled C-E composites were

measured according to ASTM D 638 and ASTM D 790

standards using Shimadzu Universal testing machine (Kyoto,

Japan). The data reported here is the average of 4 to 5 trials

taken for each composition. The experimental errors on the

measured parameters are around 2%.

Erosion testing

Erosion testing were carried out as per ASTM G 76. The

test is conducted for 2, 4, and 6 minutes and weighed todetermine the weight loss. Samples of size (50 mm×50

mm×2.5 mm) were cut from the plaque. The conditions under

which erosion tests were carried out are listed in Table 2.

Using test data, the ratio of weight loss to the weight of the

eroding particles causing the loss is then computed as a

dimensionless incremental erosion rate. Samples were eroded

with silica sand at different impingement angles (i.e. 300, 600,

and 900).

Experimental design

Material (designation) Epoxy

(wt. %)

Fly ash cenosphere

(wt. %)

Carbon-epoxy (C-E) 40 --

Fly ash cenosphere filled

C-E (2CSP-C-E)

38 2


C-E (4CSP-C-E)

36 4


C-E (6CSP-C-E)

34 6


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Design of experiments is a powerful analysis tool for

modeling and analyzing the influence of control factors on

performance output. Therefore, a large number of factors are

initially included so that non-significant variables can be

identified at earliest opportunity. Exhaustive literature review

on erosion behavior of polymer composites reveals that

parameters viz., impact velocity, impingement angle, fiber

loading, erodent size and stand off distance etc., largely

influence the erosion rate of polymer composites. The impactof five such parameters are studied using L27 (313) orthogonal

array design. The operating conditions under which erosion

tests are carried out are given in Table 2. In Table 4, each

column represents a test parameter whereas a row stands for a

treatment or test condition which is nothing but a combination

of parameter levels. In conventional full factorial experiment

design, it would require 35 = 243 runs to study five parameters

each at three levels whereas, Taguchi’s factorial experiment

approach reduces it to only 27 runs offering a great advantage

in terms of experimental time and cost. The experimental

observations are further transformed into signal-to-noise (S/N)

ratios. The S/N ratio for minimum erosion rate can be

expressed as ‘‘lower is better” characteristic, which iscalculated as logarithmic transformation of loss function as

per the equation shown below Smaller is the better.

( )21log10 yn N

S ∑−= (1)

Where n is the number of observations, and y the observed

data. The lower is better (LB) characteristic, with the above

S/N ratio transformation, is suitable for minimization of

erosion rate.

TABLE. 2 LEVELS OF VARIABLES USED IN THE EXPERIMENT

Control Factors Levels1 2 3

A: Impact Velocity (m/s) 30 40 50

B: Filler Content (wt%) 0 2 4

C: Impingement Angle

(degree)30 60 90

D: Erosion Time ( min) 2 4 6

E: Erodent Size (µm) 212 425 600

III. R ESULTS A ND DISCUSSION

Density

The theoretical and measured densities of all composite

samples along with the corresponding volume fraction of

voids are presented in Table 3. It may be noted that the

composite density values calculated theoretically from weight

fractions using rule of mixtures and are not in agreement with

the experimentally determined values. The difference is a

measure of voids and pores present in the composites. It is

clear from Table 3 that the percentage of voids in an unfilled

C-E is negligibly small i.e. 0.20% and this may be due to the

absence of any filler. With the addition of light weight fly ash

cenosphere, the volume fraction of voids is found to be at

about 1%.

TABLE 3. DENSITIES AND HARDNESS OF THE COMPOSITES

Mechanical properties

The mechanical properties of carbon fabric reinforced

epoxy (C-E) filled with different content of cenospheres

(CSP) are shown in Figures 1 and 2 From these figures, it can

be seen that the loading of CSP greatly decreased the tensile

strength, flexural strength, and significantly increased the

tensile modulus and flexural modulus of C-E composite,

which can be attributed to the high modulus and hardness of

the carbon fibers. In the experimental range, the best

mechanical properties were obtained with the C-E composite

with 4 wt.% CSP.

769.69

664

708.915

675

600

620

640

660

680

700

720

740

760

780

C-E C-E +

2%Ceno

C-E +

4%Ceno

C-E +

6%Ceno

Composites

T e n s i l e s t r e n g t h ( M P a )

(a)

72.84 72.98

97.8 95.9

0

20

40

60

80

100

120

C-E C-E +

2%Ceno

C-E +

4%Ceno

C-E +

6%Ceno

Composites

T e n s i l e m o d u l u s ( G P a )

(b)Fig. 1 Mechanical properties of CSP-filled C-E. (a) Tensile strength,

(b) Tensile modulus.

968.735

800

996.205

865.245

0

200

400

600

800

1000

1200

C-E C-E +

2%Ceno

C-E +

4%Ceno

C-E +

6%Ceno

Composites

F l e x u r a l s t r e n g t h ( M P a )

(a)

66.467.4

7473.5

62

64

66

68

70

72

74

76

C-E C-E +

2%Ceno

C-E +

4%Ceno

C-E +

6%Ceno

Composites

F l e x u r a l n o d u l u s ( G P a )

(b)

Fig. 2 Mechanical properties of CSP-filled C-E. (a) Flexural strength,

(b) Flexural modulus.

From the above discussion on the mechanical properties of

C-E composites filled with CSP, it is clear that improvement

in tensile modulus and flexural modulus in case of

Sample Theoretical

density

(g/cm3)

Measured

density

(g/cm3)

Void

fraction

(%)

C-E 1.64 1.636 2.4

2CSP-C-E 1.53 1.518 7.8

4CSP-C-E 1.55 1.532 12.9

6CSP-C-E 1.58 1.556 22.1


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cenospheres-filled composites is high compared with unfilled

C-E ones. In the present work, the cenospheres used are of

bigger size particles with less specific surface area. Therefore,

it is clear that for particles with micron size, the surface area

seems to play an insignificant role in so for as the

improvement in mechanical properties is concerned.

Therefore, we are of the opinion that the density and higher

silica content of cenospheres is responsible for the

enhancement in tensile modulus and flexural modulus incenospheres-filled C-E composites. Because of the low

density (0.7 g/cm3), the cenospheres fillers provide good flow

properties and hence results in uniform distribution in the C-E

composite and this enhances more number of Si-O-Si

interactions due to higher silica content (60%). Therefore,

good interfacial adhesion between the cenospheres particles

and the matrix occurs.

Erosion rate

Main effects plots for S/N ratios and their interactions of

samples are shown in Figures 5 and 6 respectively. It can be

seen that the erosion rate was a maximum at 300 impingement

angle for both composites at the different impact velocities

studied. It is known that impingement angle is one of the mostimportant parameters for the erosion behaviour of materials.

In the erosion literature, materials are broadly classified as

ductile or brittle, based on the dependence of their erosion rate

on impingement angle. The behaviour of ductile materials is

characterized by maximum erosion rate at low impingement

angles (15–30◦). Brittle materials, on the other hand, show

maximum erosion under normal impingement angle (90◦).

Reinforced composites have been shown, however, to exhibit

a semi-ductile behaviour with maximum erosion occurring in

the angular range 450 –600 [3]. However, in the literature

mixed trends have been reported even for nominally brittle or

ductile materials. According to Hutchings [20], materials can

show either ductile or brittle behaviour. If the erosionconditions are changed, such as impingement angle, impact

velocity, particle flux, erodent properties such as shape,

hardness or size, etc. Tilly and Sage [25] investigated the

influence of velocity, impingement angle, particle size and

weight of impacted abrasive for nylon, carbon fiber reinforced

nylon, epoxy, polypropylene and glass fiber reinforced plastic.

Their results showed that, for the particular materials and

conditions of their test, composite materials generally behaved

in an ideally brittle fashion (i.e. maximum erosion rate

occurred at normal impact). Miyazaki and Takeda [26],

Miyazaki and Hamao [30], reported that the peak erosion rate

for neat nylon, ABS and epoxy matrix occurs at around 300

impingement angle. However, in the case of carbon or glassfiber reinforced nylon, ABS, and epoxy composites the peak

of the erosion rate shifts to a larger value of impingement

angle (60◦). However, in the present study, peak erosion rate

were observed at 300

for both composites. A possible reason

for the erosion behaviour found in the present study is that

high modulus carbon fiber was used as reinforcement for the

epoxy matrix are typical semi-ductile materials, so that

erosion is mainly caused by such damage mechanisms as

micro-cracking due to the impact of solid particles. The

maximum erosion rates were at impingement angle of 30◦, for

all the composites tested.

The S/N ratios given in Table 3 are in fact the average of two

replications. The overall mean for the S/N ratios of

composites reinforced with CSP, are found to be -59.40db.

The analysis is made using the popular software known as

MINITAB 14.TABLE 4

SIGNAL TO

NOISE RATIO

(S/N)TABLE FOR EROSION RATE

TABLE 5

A NALYSIS OF VARIANCE FOR SN RATIOS

504030

-52

-56

-60

-64

-68

420 906030

642

-52

-56

-60

-64

-68

600425212

VELOCIT Y

M e a n o f S N r a t i o s

FILLER ANGLE

ERO TIME ERO SIZE

Main Effects Plot for SN ratios

Data Means

Signal-to-noise: Smaller is better

Fig. 3 Relative effect of main factors on erosion rate.

Before any attempt is made to use this simple model as a

predictor for the measure of performance, the possible

interactions between the control factors must be considered.

Thus factorial design incorporates a simple means of testing

for the presence of the interaction effects. The effects of

control factors on erosion rate for different filler materials are

shown in Fig.3. The analysis of the result gives the

combination of factors producing minimum wear of the

LevelVelocity

(A)

Filler

(B)Angle (C)

Erosion

time (D)

Erodent

size (E)

1 -58.06 -66.76 -61.19 -59.44 -59.23

2 -58.59 -60.80 -57.78 -60.20 -60.70

3 -63.18 -52.26 -60.84 -60.18 -59.89

Delta 5.12 14.50 3.41 0.76 1.48

Rank 2 1 3 5 4

Source DF Seq SS Adj SS Adj MS F

Vel 2 142.66 142.662 71.331 3.91

Filler 2 955.91 955.911 477.956 26.17

Angle 2 63.26 63.265 31.632 1.73

Erosion

time2 3.43 3.430 1.715 0.09

Erodent

size2 9.83 9.833 4.916 0.27

Residual

Error 16 292.20 292.196 18.262

Total 26 1467.3


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composites. These combinations are found to be different for

different filler materials. For CE filled with CSP, the factor

combination of A1, B3, C2, D1, and E1 gives minimum erosion

rate. As far as minimization of erosion rate is concerned,

factors B,A,C, and E have significant effects on the

composites whereas factor D has the least effect. It is

observed from Fig. 4 that the interaction (A x B) shows most

significant effect on erosion rate.

420

-50

-55

-60

-65

-70

FILLER

M e a n

30

40

50

VELOCI TY

Interaction Plot for SN ratios

Data Means

Fig. 4 Interaction graph between A×B for erosion rate.

IV. CONCLUSIONS

Based on the research presented in this paper the following

conclusions are drawn:

1. Inclusion of cenospheres filler in the C-E composite

decreases the tensile strength as well as the density.

However, CSP filler loading into C-E greatly

increased the tensile modulus and flexural modulus.

2. The addition of cenospheres filler in carbon fabric

reinforcement epoxy composites have shown marked

improvement in erosion wear behaviour.

3. Erosion characteristics of the composites have

successfully analyzed using Taguchi experimental

design. Taguchi method provides a simple,

systematic and efficient methodology for the

optimization of the control factors.

4. Factors like filler content, impact velocity,

impingement angle, erodent time and erodent size are

found to be the significant control factors affecting

the erosion rate. The erosion time is identified as the

least significant parameter as far as the wear of such

composites is concerned.

5. From the Taguchi experimental design, Filler content

is identified as the most significant factor influencing

the erosion wear of cenosphere filled carbon fabric

reinforced epoxy composite. Further, this

investigation reveals that maximum erosion takes

place at the impingement angle of 30˚.

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