Optimization of multifunctional mechanical, thermo-mechanical, dielectric, and moisture resistance properties of Margosa gum reinforced epoxy composites for sustainable engineering applications

Environmental concerns related to synthetic filler reinforced polymer composites have led to rapid advances in sustainable bio-based materials. The originality of this research is in crafting Margosa gum reinforced epoxy composites and determining the ideal filler loading for multi-functionality. The composites with effects from 0 to 25 vol% of Margosa gum were produced through vacuum-assisted casting and tested for their mechanical, thermo-mechanical, dielectric, and moisture resistance properties. The hydroxyl-rich functional groups which facilitate strong interfacial bonding between filler and matrix were identified by FTIR analysis. Tensile strength rose from 32.5 MPa for neat epoxy to 45.6 MPa at a filler loading of 15 vol%, whereas flexural strength was increased from 72.4 MPa to 97.8 MPa. The highest impact strength (5.8 kJ/m 2 ), storage modulus (3.02 GPa), and dielectric strength (33.5 kV/mm) corresponded to the MG–20 composite. At 15 vol% filler loading, the water absorption dropped a lot to 17.8% from 31.4%. Increasing filler content led to an improvement in thermo-mechanical stiffness and thermal stability. Still, an overfilled situation (25 vol%) caused filler agglomeration and microvoid formation, thereby lowering the performance. Overall, MG–15 and MG–20 composites show the best-balanced multifunctional features suitable for lightweight structural and electrical insulation uses.