Epoxy Composites Reinforced with Sol-Gel Synthesized Alumina-Silica, Alumina, and Natural Silica Fillers: Comparative...

Epoxy resins are widely used thermosetting polymers, but their limited toughness and flexural resilience restrict broader applications. In this study, diglycidyl ether of bisphenol A (DGEBA) epoxy was reinforced with 5 wt.% ceramic fillers of different origins: sol-gel alumina calcined at 550 °C (γ-Al₂O₃) and 1000 °C (α-Al₂O₃), silica derived from rice husk, silica from diatomaceous earth, and a hybrid alumina-silica mixture prepared by sol-gel and calcined at 1000 °C. Fillers were structurally characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and field-emission scanning electron microscopy (FESEM). Mechanical properties were evaluated through tensile (ASTM D638) and flexural (ASTM D790) testing. All reinforcements enhanced the performance of neat epoxy. γ-Al₂O₃ provided superior tensile reinforcement compared to α-Al₂O₃, underscoring the importance of particle morphology and surface reactivity. The hybrid alumina-silica filler achieved the highest flexural strength of 50.6 MPa, compared to 9.91 MPa for the neat epoxy. Bio-derived silica showed improved flexural properties, although its tensile reinforcement was less pronounced compared to the sol-gel derived fillers. These results establish clear structure-property relationships and confirm that filler phase, morphology, and calcination temperature critically govern the mechanical performance of epoxy composites.