Statistical Methods in the Analysis of the Effect of Carbonisate on the Hardness of Epoxy-Resin-Based Composites

This research concerns the manufacture and characterisation of epoxy composites with the addition of carbonisate, obtained by the pyrolysis of MDF (medium-density fibreboard) furniture board waste. The laminated composites were made by hand lamination, with the carbonisate used as a filler to improve the mechanical properties of the composite. The carbonisate was obtained by the thermal decomposition of MDF waste in an anaerobic environment by pyrolysis, which is an efficient method of waste management and material recycling. The resulting carbonisate was integrated into an epoxy resin matrix to investigate its potential as a reinforcing agent. The article describes a study on the hardness of epoxy-resin-based composites to which carbonisate was added in different fractions and percentages. The aim of the research was to test the possibility of using char as a component in improving the mechanical properties of epoxy composites with a view towards creating a durable recycled material with optimal parameters. As part of the study, a statistical analysis of the results of hardness measurements was carried out to accurately assess the effect of the quantity and size of the carbonate particles on the mechanical properties of the materials. The analysis identified significant differences between samples and verified the repeatability of the results. It was found that the addition of carbonisate to the A0 base sample (without the addition of carbonisate) leads to a significant hardening of the material. This was confirmed by the higher medians of samples A01 (carbonisate 5% with a 0.5 mm fraction), A02 (carbonisate 7.5% with a 0.5 mm fraction), and A03 (carbonisate 5% with a 1.0 mm fraction) compared to the base sample. The most homogeneous hardness was shown in sample A02, with the highest concentration of results and the lowest values of standard deviation and spread. The results indicated that the addition of carbonate significantly increased the hardness of the composite materials, with optimal stability achieved at 7.5% (by weight) of carbonate with a 0.5 mm fraction. The conducted research precisely determined the influence of the amount and characteristics of carbonisate particles on the mechanical properties of the materials, which enables the more effective designing of future composites. The statistical results provide a reliable basis for evaluating the potential applications of these materials in various industrial sectors, such as construction, automotive and aerospace, where high hardness and durability are important.