Effect of Nano Ferrochrome Slag-Infused Polymer Matrix on Mechanical Properties of Bidirectional Carbon Fiber-Reinforced Polymer Composite

Polymeric nanocomposites have been extensively investigated due to their potential for enhancing the mechanical and tribological properties of polymer composites. In this study, the mechanical performance of carbon fiber-reinforced epoxy composites modified with nano-sized ferrochrome slag particles, an industrial by-product from stainless steel manufacturing, was evaluated. Composite laminates were fabricated using a vacuum-assisted hand lay-up process, with consistent carbon fiber reinforcement and uniformly dispersed nanofillers in the epoxy matrix. Mechanical properties such as tensile, flexural, impact, and Shore D hardness were evaluated as per ASTM and ISO standards. At 2 wt.% nanofiller loading, enhanced tensile strength and hardness by 33.02% and 8.92%, respectively, were achieved, while flexural strength and impact strength increased by 3.70% and 3.62% at 1 wt.% compared to the neat composite. Higher filler contents (>3 wt.%) resulted in reduced performance due to particle agglomeration and microstructural inhomogeneity. A scanning electron microscope was used to determine the uniform dispersion and agglomeration of nanofillers. The results demonstrated the potential of ferrochrome slag as a sustainable and cost-effective nanofiller for advanced composite applications.