Flexural, viscoelastic, and wear behavior of fly ash cenosphere filled polyester resin composites

The current study deals with the comprehensive analysis of flexural, viscoelastic, and wear properties of industrial waste fly ash cenosphere (FAC). The average particle size (D 50 ) of FAC is 63 µm. Fly ash cenosphere content is varied from 0, 5, 10, 20, and 40% by weight. Ball-on-disc tribometer is used for evaluating friction and wear properties of the composites at a speed of 200 rpm with an applied normal load of 15 N. Flexural modulus increased with an increase in the filler content by 50% at 40 wt%. Improved FAC dispersion in the polymer matrix was seen through flexural fractured scanning electron micrographs. A 54% increase is also seen in the storage modulus. Matrix-filler compatibility has been studied through dynamic mechanical thermal analysis parameters. No direct correlation between friction and wear was observed. The coefficient of friction of neat resin stands at 0.33, reaching 0.58 for 40 wt% FAC content and the specific wear rate (W s ) decreased up to 20 wt% of FAC content. At 40 wt% FAC loading, specific wear rate increased due to accumulation of FAC particles at the wear interface leading to increased particle-particle interaction resulting in particle-matrix debonding. Abrasive wear is the dominating wear mechanism as per worn surface morphology analyzed through SEM.