Solution blending, casting, thermo-mechanical properties and surface morphology of epoxy resin–polycarbonate blends

Purpose This research aims to explore the effects of varying polycarbonate concentrations on the mechanical and thermal properties of epoxy resin–polycarbonate blends. It investigates solution blending, casting methodologies and surface morphology to understand microstructural changes. The study identifies optimal polycarbonate ratios (7.5–10%) for enhancing tensile strength, impact resistance and thermal stability. Design/methodology/approach The study used solution blending to create epoxy resin-polycarbonate blends (2.5–15%), followed by film casting. Thermo-mechanical properties were tested via tensile strength, impact resistance and TGA. Surface morphology was examined to assess microstructural changes across blend ratios. Findings The research revealed that epoxy resin-polycarbonate blends exhibit enhanced mechanical and thermal properties at specific polycarbonate concentrations. Optimal performance was observed at 7.5 and 10% polycarbonate, showing significant improvements in tensile strength, impact resistance and thermal stability as confirmed by TGA. Surface morphology analysis highlighted microstructural changes corresponding to different blend ratios, underscoring the critical role of polycarbonate proportions in achieving superior material characteristics. Originality/value The research found that incorporating polycarbonate into epoxy resin significantly enhances mechanical and thermal properties, with the best results observed at 7.5 and 10% polycarbonate concentrations. These blends demonstrated improved tensile strength, impact resistance and thermal stability. Surface morphology analysis revealed notable microstructural changes, highlighting the importance of precise polycarbonate ratios in optimizing the performance of the blends.