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<p>Carbonization of fly ash mitigates rising CO<sub>2</sub> levels by enabling mineral carbonation, a key carbon sequestration and storage (CSS) strategy. However, the indirect carbonation process for producing carbonated fly ash (CFA) and its use as a sustainable filler in glass fiber-reinforced polymer composites (GFRPCs) remain underexplored. This study investigates the comprehensive characterization and erosion resistance of GFRPCs incorporating in-house synthesized CFA. The morphological, physical, mechanical, acoustic, and thermal properties were analyzed across CFA loadings (0–20 wt.%). At 10 wt.% CFA, the density increased by 4.1%, while tensile strength, flexural strength, flexural modulus, and interlaminar shear strength (ILSS) improved by 38.9%, 83.2%, 51%, and 83.7%, respectively. Impact strength, microhardness, and tensile modulus were 4.4, 2.9, and 4.7 times higher than those of unfilled GFRPC. The CFA-filled GFRPCs also exhibit excellent resistance to water absorption and are classified as Class D-type sound absorbers. This is likely due to strong interfacial bonding between the matrix and ceramic-rich CFA at 10 wt.% filler loading. Erosion wear was assessed using the central composite design (CCD) based on response surface methodology (RSM), considering composite type, impingement angle, erodent size, velocity, and mass flow rate. Optimal conditions (20 wt.% CFA, 300&#xa0;µm erodent size, 82&#xa0;m/s velocity, 90° impact angle, and 10&#xa0;g/min mass flow rate) reduced 68.8% erosion rate. RSM predictions closely matched experimental results with a 6.4% deviation, confirming model accuracy. These findings promote sustainable composite design with improved durability, soundproofing, and thermal stability, ideal for walls, partitions, and enclosures in industrial and architectural applications.</p> Graphical Abstract <p></p>

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Improved erosion resistance of glass fiber-reinforced polymer composites with carbonated fly ash: synthesis, characterization, and performance evaluation

  • 期刊论文

  • 发表日期：

    2025年7月9日

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  • Anisha Ekka,
  • Srimant Kumar Mishra,
  • Trupti Ranjan Mahapatra,
  • Punyapriya Mishra,
  • Amruta Panda,
  • Debadutta Mishra

摘要

Carbonization of fly ash mitigates rising CO2 levels by enabling mineral carbonation, a key carbon sequestration and storage (CSS) strategy. However, the indirect carbonation process for producing carbonated fly ash (CFA) and its use as a sustainable filler in glass fiber-reinforced polymer composites (GFRPCs) remain underexplored. This study investigates the comprehensive characterization and erosion resistance of GFRPCs incorporating in-house synthesized CFA. The morphological, physical, mechanical, acoustic, and thermal properties were analyzed across CFA loadings (0–20 wt.%). At 10 wt.% CFA, the density increased by 4.1%, while tensile strength, flexural strength, flexural modulus, and interlaminar shear strength (ILSS) improved by 38.9%, 83.2%, 51%, and 83.7%, respectively. Impact strength, microhardness, and tensile modulus were 4.4, 2.9, and 4.7 times higher than those of unfilled GFRPC. The CFA-filled GFRPCs also exhibit excellent resistance to water absorption and are classified as Class D-type sound absorbers. This is likely due to strong interfacial bonding between the matrix and ceramic-rich CFA at 10 wt.% filler loading. Erosion wear was assessed using the central composite design (CCD) based on response surface methodology (RSM), considering composite type, impingement angle, erodent size, velocity, and mass flow rate. Optimal conditions (20 wt.% CFA, 300 µm erodent size, 82 m/s velocity, 90° impact angle, and 10 g/min mass flow rate) reduced 68.8% erosion rate. RSM predictions closely matched experimental results with a 6.4% deviation, confirming model accuracy. These findings promote sustainable composite design with improved durability, soundproofing, and thermal stability, ideal for walls, partitions, and enclosures in industrial and architectural applications.

Graphical Abstract