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Mechanical Behaviour of Copper and Aluminium Particles Reinforced Epoxy

Resin Composites

Article · January 2015

DOI: 10.5923/j.materials.20150504.02

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American Journal of Materials Science 2015, 5(4): 84-89
DOI: 10.5923/j.materials.20150504.02

Mechanical Behaviour of Copper and Aluminium

Particles Reinforced Epoxy Resin Composites
V. K. Srivastava*, Ansul Verma

Department of Mechanical Engineering, Indian Institute of Technology (BHU), Varanasi, India

Abstract In this study, copper and aluminium particles reinforced epoxy resin was fabricated to investigate the effect of
particles on the mechanical properties of epoxy resin (PL-411). Copper (Cu) and aluminium (Al) particles were added in the
epoxy resin as filler with the variation of weight percentage (1%, 5%, 8% and 10%). The tensile strength, compressive
strength, vicker’s hardness, friction coefficient and wear properties were evaluated and compared. The fracture behavior was
investigated under scanning electron microscope. Experimental data from tensile tests were compared with Bigg’s equations.
The results indicate that the tensile strength and wear loss gradually reduced with the increase of filler content. The hardness,
compressive strength and coefficient of friction increased with an increase of weight percentage of Cu and Al fillers content.
Keywords Aluminium, Copper: Epoxy resin, Tensile strength, Compressive strength, Vicker’s hardness, Coefficient of
friction, Scanning electron microscopy

1. Introduction aspect ratio can improve some of its mechanical properties

[4]. Hussian et al [5] reported that ceramic fillers as
Epoxy resin is established well as a thermosetting polymer
reinforcement in epoxy composites results in improved
matrix for advanced composites, displaying a series of
physical, rheological and thermal properties. Youngs
interesting characteristics, which can be identified within
modulus and flexural modulus can also be improved.
boundaries. Due to their high-adhesion, low-weight, and
Goyanes et al [6] reported that for aluminium-epoxy
good chemical resistance, epoxy-based composite materials
composites, density increases with increasing filler content
are being increasingly used as structural components in
which also follows the rule of mixture. A correlation
various industries. It is well known that the mechanical
between the Youngs modulus and its density for filled epoxy
properties of cured epoxy resins depend on their structure,
composites was also justified by Tilbrook et al [7]. The
the curing time and temperature [1].
matrix volume is at an optimum value for a given system,
The low cost particles are added into polymer matrix
which acts as individual pockets or segments to support a
because of economic and improvements in molding
tensile or compressive load.
characteristics. It is not clear fracture behaviour depends on
For a glass bead filled polypropylene system as suggested
only material properties or volume fraction of the filler,
by Ramsteiner and Theysohn [8] that at higher temperature
which includes shape, size, orientation and interface between
(about 70ºC) the tensile strength is independent of filler
filler and the matrix [2]. Polymer matrix composites (PMC)
concentration, i.e. the model is valid at lower temperature
can exhibit unique properties with the combination of
where the matrix is brittle and the beads are not stress
particles such as thermal conductivities, dielectric constants
bearing. But however corresponding to a tough matrix state,
and ductility, scratch resistant and modulus, toughness and
some stress can be transferred from the matrix into the beads.
wear properties, impact performance, and compressive
The simple model proposed by Bigg [9], the tensile
strength. Such polymers have also found their practical
strength of particulate filled composites can be described as
importance in several novel applications [3]. Epoxy
(thermoset) is a widely used polymer in numerous 𝜎𝜎c = 𝜎𝜎𝑚𝑚 (1 − 𝑓𝑓𝑉𝑉𝑓𝑓 2/3 ) (1)
applications. However its behavior is brittle when compared Where σm is the tensile strength of matrix, σc is the tensile
to metals and possess low thermal conductivity and limited strength of composite and Vf is the volume fraction. Value of
mechanical properties. Reinforcement of fillers with lower f depends upon the adhesion quality between the matrix and
filler such that f = 1.21 means poor adhesion and f =1.1
* Corresponding author:
[email protected] (V. K. Srivastava)
means better adhesion.
Published online at http://journal.sapub.org/materials For estimating the strength of elastically deforming
Copyright © 2015 Scientific & Academic Publishing. All Rights Reserved material which is susceptible to brittle fracture, diametrical
American Journal of Materials Science 2015, 5(4): 84-89 85

compression test is used. A mathematical expression was universal testing machine. The extension rate was set at 2mm
developed by Hertz [10] to determine the stress states of the per min to determine the tensile strength and compressive
elastic disks under diametrical compression under point strength. Hardness test (LV-700AT) was carried out to
loading conditions. determine the Vickers hardness. Wear and coefficient of
−2𝑃𝑃 𝑥𝑥 2 (𝑅𝑅−𝑦𝑦) 𝑥𝑥 2 (𝑅𝑅+𝑦𝑦) 1 friction was measured from reciprocation sliding wear and
𝜎𝜎𝑥𝑥 = � + − � (2) friction monitor instrument (TE-200ST). Reciprocating wear
𝜋𝜋𝜋𝜋 𝛽𝛽 14 𝛽𝛽 24 2𝑅𝑅
−2𝑃𝑃 (𝑅𝑅−𝑦𝑦)3 (𝑅𝑅+𝑦𝑦)3 1 test was performed against mild steel ball having a diameter
𝜎𝜎𝑦𝑦 = � + − � (3) 10mm with receiprocating frequency 3.3Hz. The total stroke
𝜋𝜋𝜋𝜋 𝛽𝛽 14 𝛽𝛽 24 2𝑅𝑅
2𝑃𝑃 𝑥𝑥(𝑅𝑅−𝑦𝑦)2 𝑥𝑥(𝑅𝑅+𝑦𝑦)2
length was set at 3mm for all tests and was conducted for 10
𝜎𝜎𝑥𝑥𝑥𝑥 = � + � (4) min at a normal load 50N. The variation in coefficient of
𝜋𝜋𝜋𝜋 𝛽𝛽 14 𝛽𝛽 24
friction and temperature were obtained from the machine
Where σx is stress in horizontal direction when specimen itself and the wear loss was measured with the help of
loaded in vertical direction, σy is stress in vertical direction, electronic digital balance.
σxy is shear stress, P is applied load, R is radius of disk, t is
thickness and β12 = (R - y)2 + x2, β22 = (R + y)2 + x2.
When the bonding in particles is enough to prevent the 3. Results and Discussion
crushing of disk, it is predicted by the Hertz solution that the
maximum principle stress occurs at the center of the disk. 3.1. Tensile Strength
This stress is assumed to be responsible for the failure of the
To measure the influence of fillers on the tensile strength
disk, the tensile and compressive strength thus can be
of epoxy resin matrix, the samples with specific size of
obtained by putting x = y = 0 in (2), (3), and (4) (at the center
composite were prepared according to the requirements of
of the disk) [11].
tensile test. The results of tensile test are shown in Fig. 1.
2P
σx = (5) It can be found that the tensile strength decreases with
πDt
increasing weight percentage of Cu and Al fillers. It is also
6𝑃𝑃
𝜎𝜎𝑦𝑦 = (6) noted that tensile strength is independent on the filler
𝜋𝜋𝜋𝜋𝜋𝜋
concentration. Fig.1 shows that the tensile strength decreases
𝜎𝜎𝑥𝑥𝑥𝑥 = 0 (7) continuously with increase in the weight percentage of the
The main purpose of present research was to study the fillers. Al with a weight percentage of 1% experienced
tensile strength, compressive strength, hardness, wear and maximum tensile strength of all and then decreased
coefficient of friction Cu/epoxy resin and Al/epoxy resin thereafter. For 10% of Cu and Al, the maximum tensile
composites with the variation of weight percentage. strength was less than that of pure epoxy (85 MPa). The
experimental values of tensile strength of Cu and Al particles
filled epoxy resin were compared with the Bigg model
2. Experimentation (equation-1) with due consideration of poor (f=1.21) and
high (f=1.1) interface bond adhesion. The results are
Aluminium (Al) and copper (Cu) powder were selected as presented in Figs. 2 and 3, this indicates the 10 to 20%
the metal fillers. Aluminium powder was obtained from differences in model and experimental values.
CDH Laboratories New Delhi and Copper powder was
obtained from Otto Kemi, Mumbai. Particle size for both the 3.2. Compressive Strength
powders was 80µm. Fig. 4 shows the variation of compressive strength as a
Epoxy resin contains a three membered oxide ring called function of filler weight percentage. It can be noticed that the
as epoxide group. Resin PL-411 and hardener PH-861 were trend observed for compressive strength was quite different
used as a matrix material. from those observed for tensile strength (Fig. 1). Epoxy
Metal powders were added into the epoxy resin with the matrix being brittle in nature has good compressive
variation of weight percentages, ranging from 1%, 5%, 8%, properties. In the case of Cu, it could be assumed that the
and 10%. The mixture was stirred for almost 10 minutes to brittleness was retained by the matrix when weight
ensure proper mixing. Hardener was then added to the resin percentage was 1%. Initial compressive strength was thus
in the ratio of 1:10 by weight and again mixed thoroughly till high for Cu particles with 1% by weight. But it decreased
the mixture started to cure. when the weight percentage was increased to 5%. The
The mixture was then poured into different molds to ductility of Cu particles caused the overall compressive
prepare the desired samples. For tensile test, dog-bone strength to decrease. Because of the agglomeration of copper
shaped samples based on the ASTM standard D-638 and for particles, matrix again gained its brittleness with increasing
compression test brazalian (circular) disk samples were weight percentage of Cu to 10%. For Al particles, the initial
prepared as per ASTM standard D-3967. The hardness and compressive strength was low but increased with increase in
wear tests specimen were prepared from the cured samples. its weight percentage because of the agglomeration of Al
Tensile and compressive tests were preformed on the Instron particles in the matrix.
86 V. K. Srivastava et al.: Mechanical Behaviour of Copper and Aluminium
Particles Reinforced Epoxy Resin Composites

This increase in compressive strength was estimated as the

favorable deformation process facilitated by the presence of

Compressive strength
fillers in the matrix. Thus under compressive loading, fillers
60
aided the load bearing capability of the composite, rather
50
than being a stress raiser as was in the case of tensile loading.

(MPa)
Similar results were shown by Singha [12] in which the
40
compressive strength was increased with the particle
reinforcement. Cu Al
30

20
Tensile strength (MPa)

Cu Al
95 0 5 10 15
Weight percentage of filler (%)
Figure 4. Compressive strength versus weight percentage of filler in
75 epoxy resin composite

3.3. Vicker’s Hardness

55 Fig.5 shows that the vicker’s hardness increased with the
0 5 10 15 increase of Cu filler in epoxy resin upto 8% by weight but
after that it decreased. In the case of Al filled epoxy resin,
Weight percentage of filler (%) hardness decreased with addition of weight percentage of
Figure 1. Variation of tensile strength with weight percentage of filler of filler upto 5%. Then, hardness gradually increased with
Cu/epoxy resin and Al/epoxy resin composites increase of filler. Lam et al [13] in their investigation found a
similar trend in the hardness values in which the hardness
Al experimental tensile strength increases up to certain filler content.
Tensile strength (MPa)

Al tensile strength using f=1.21 23

95 in eq (1)
Vickers Hardness

Al tensile strength using f=1.1 in 22

(kgf/mm2)

eq (1)
21
75
20
Cu Al
55 19
0 5 10 0 5 10 15
Weight percentage of Al (%) Weight percentage of filler (%)
Figure 2. Tensile strength versus weight percentage of Al/epoxy resin Figure 5. Vicker’s hardness versus weight percentage of filler in epoxy
composite resin composite

3.4. Friction and Wear

Fig. 6 shows how the wear loss varies when the weight
Tensile strength (MPa)

85 percentage of the fillers was increased. When the

reciprocating ball moved over the sample surface, it removed
Cu experimental tensile strength a part of it. But because of the different concentration of
80 fillers in the samples, there was a variation in the removal of
Cu tensile strength using f=1.21 in material due to wear [14]. As evident from results that
75 eq (1) increasing weight percentage of filler beyond 5% increased
Cu tensile strength using f=1.1 in the wear loss. Copper filled polymer matrix composites
eq (1) initially showed a lower wear loss at lower weight
70 percentages, but with an increasing weight percentage up to
10%, showed more wear loss than that of aluminium filled
0 5 10
Weight prcentage of Cu (%) polymer matrix composite. However, aluminum content of
8% by weight showed maximum wear loss. But overall both
Figure 3. Tensile strength versus weight percentage of Cu/epoxy resin the metallic fillers showed much less wear loss as compared
composite
to neat epoxy.
American Journal of Materials Science 2015, 5(4): 84-89 87

reduced with increase of wear loss due to transfer of soft Al

Wear loss (gms)

debries on mild steel side.

0.007 Cu
Al
0.004

0.001
0 5 10 15
Weight percentage of fillef (%)
(a) (b)
Figure 6. Wear loss versus weight percentage of filler in epoxy resin
Figure 9. Optical micrograph of Cu/epoxy resin composites sliding over
composite
steel ball
Fig. 7 shows the average values of coefficient of friction
for both aluminium and copper filled composite materials.
As evident from Fig. 8, a lower value of coefficient of 4. Descriptions
friction was shown by copper filled epoxy resin composite The results indicate that the tensile strength decreases
with the lowest when the weight percentage of copper was continuously with increase of weight percentage of fillers.
8%. As compared to aluminium, copper particles have been Aluminium filled polymer matrix composite with a weight
proved to be more efficient in reducing friction. percentage of 1% experienced maximum tensile strength of
0.039 all and then the tensile strength decreased thereafter. For
Al 10% of copper and aluminium filled polymer matrix
Coefficient of friction

Cu composite, the maximum tensile strength was less than that

of pure epoxy resin (85.0MPa). At lower weight percentage,
0.029 when the particles were added to the matrix, they were
uniformly distributed and this caused crack deviation as
shown in Figs. 10 (a &b).
0.019
0 5 10 15
Weight percentage of filler (%)
Figure 7. Coefficient of friction versus weight percentage of Cu and Al
particles in epoxy resin composite

Fig. 8 shows the optical images of worn out particles from

the sample containing 8%aluminium by weight in epoxy (a) (b)
matrix composite. Similar particles with sharp edges were
Figure 10. SEM micrograph shows (a) deviation of crackline and (b)
observed. The average length of the particles was increased brittle type fracture in Al/epoxy resin composite
(Fig. 8b) due to increase of wear loss and coefficient of
friction along receiprocating direction. Due to pinning action, the stress lines deviated from their
actual path (Fig.11a) and caused the tensile strength to
increase.

(a) (b)
Figure 8. Optical micrograph of (a) worn surface and (b) length of particle
in Al/epoxy resin composites sliding over steel ball (a) (b)
Figure 11. SEM micrograph shows that (a) particles displaced and (b)
Fig. 9 shows the optical images of worn out particles from particles debonded from matrix in Al/epoxy resin composite
the sample containing 8% copper by weight in epoxy matrix
composite. Average length of the worn out particles was The tensile strength was supposed to follow equation-1,
found to be larger than the wornout particles of other copper but the experimental results has shown a deviation ranging
content specimen. Therefore, coefficient of friction was from a minimum of 15% to a maximum of 26% for
88 V. K. Srivastava et al.: Mechanical Behaviour of Copper and Aluminium
Particles Reinforced Epoxy Resin Composites

aluminium filled polymer matrix composite and from 2% to average value is almost remained same. But the wear loss
a maximum of 10% for copper filled polymer matrix affected with change of weight percentage of fillers. For 5%
composite (as shown in Figs. 2 and 3). This variation can be aluminium filled polymer matrix composite, SEM images
justified by the presence of voids in the samples as the (Figs. 13 &14) shows sign of plowing due to three body
formation of voids and air bubbles being practically abrasions and also the worn out particles had sharp edges
unavoidable and these voids can act as a third phase of (Fig. 13a) which could cause abrasion [15].
reinforcement. This degradation of tensile strength with
increasing filler content showed that the fillers acted as
potential stress raisers at higher weight percentages [11].
Fig. 12(a&b) shows that matrix debonded from the
particles and Al particles pull out from the matrix as can be
identified from Fig. 12(b). Fig. 12 (a) clearly shows the
agglomeration of copper particles at higher filler
concentration.
(a) (b)
Figure 13. SEM micrograph shows (a) plowing of particle and (b) thin
debries coated in Al/epoxy resin composite after wear test

(a) (b)
Figure 12. SEM micrograph shows that (a) aggolomaration of Cu particles
and (b) microcracks appeared in the Cu/epoxy resin compressive
(a) (b)
It can also be noticed that the trend observed for
Figure 14. SEM micrograph shows (a) plowing of particle and (b) patches
compressive strength (Fig.4) was quite different from those
removed in Cu/epoxy resin composite after wear test
observed for tensile strength (Fig. 1). In the case of copper, it
could be assumed that the brittleness was retained by the With increase in aluminium weight percentage to 8%,
matrix when weight percentage was 1%. Initial compressive more three body abrasions was found in the SEM images
strength was thus high for copper filled polymer matrix (Fig. 13b) and also sharp edges justified the abrasive wear
composite with 1% particles by weight. But it decreased behavior. This counter surface adhesion could be the reason
when the weight percentage was increased to 5%. The for reduction in the value of friction coefficient. For copper
ductility of copper particles caused the overall compressive filled polymer matrix composite, marks of plowing were
strength to decrease. Because of the agglomeration of copper shown by all the SEM images in Figs. 14 (a&b). For 10%
particles (Fig.12a), matrix again gained its brittleness with copper filled polymer matrix composite, a lot of asperities
increasing weight percentage of copper to 10%. For were shown by SEM images (Fig. 14a) and due to these
aluminium particles, the initial compressive strength was asperities, a large wear loss and a higher value of friction
low but increased with increase in its weight percentage coefficient was found to exist for this sample.
because of the agglomeration of aluminium particles in the
matrix.
This increase in compressive strength was estimated as the 5. Conclusions
favorable deformation process facilitated by the presence of
fillers in the matrix. Thus under compressive loading, fillers Based on the experiments, following results can be drawn;
act as the load bearing capability of the composite, rather i. Tensile strength of the particles filled composites
than being a stress raiser as was in the case of tensile loading. degraded with increase of filler content. Al reinforced
Similar results were shown by Singha [12] in which the epoxy resin showed better tensile properties, in the
compressive strength was increased with the particle comparison to Cu reinforced epoxy resin composites,
reinforcement. with a maximum tensile strength of 104.5 MPa (23%
Vickers hardness obtained from the experiment is shown greater than neat epoxy resin) at a weight percentage
in Fig. 5. Hardness values for aluminium filled polymer of 1%.
matrix composite remained close to 21 Kgf/mm2, same as ii. With increasing filler content, though Al filled epoxy
that of epoxy. For copper, hardness increased with increase resin composites gained compressive strength, Cu
in filler weight percentage but further increment ceased at filled epoxy resin composites on the other hand
8% copper by weight, beyond which it decreased. showed the best results throughout with a maximum at
The results of friction coefficient suggested that the 10% by weight.
American Journal of Materials Science 2015, 5(4): 84-89 89

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