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<p>This study presents an innovative approach to improving the fracture toughness and sustainability of hybrid epoxy composites by synergistically reinforcing Gossypium (cotton) and E-glass fibers with silicon carbide (SiC) microfillers (20–50&#xa0;μm, 0–15 wt%). Unlike conventional natural fiber composites limited by poor interfacial bonding, this work optimizes the hybrid laminate architecture and filler dispersion to achieve enhanced crack resistance. Composite laminates were fabricated via a controlled hand lay-up and compression molding process, followed by Mode I fracture toughness (GIC) and compact fracture toughness (KIC) testing per ASTM D5528 and D5045 standards using a 30 kN Instron 3365 frame. Results demonstrated that 15 wt% SiC composites attained the highest GIC = 0.82&#xa0;kJ/m², while 10 wt% SiC achieved the maximum KIC = 1.52&#xa0;MPa√m, confirming optimal energy dissipation through crack deflection, bridging, and fiber pull-out suppression. SEM fractography revealed uniform filler dispersion and strong interfacial adhesion with minimal voids, validating the improved load transfer and reduced delamination. Compared to unfilled controls, SiC-filled hybrids exhibited a 47% increase in GIC and 38% improvement in KIC, aligning with literature benchmarks for automotive-grade composites. The innovative combination of renewable cotton fibers with high-strength glass and ceramic fillers offers a sustainable, high-toughness material suitable for automotive body panels, undertrays, and interior structures where lightweight and damage tolerance are essential.</p>

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Fracture behavior and interfacial toughening mechanisms of SiC microfiller–reinforced gossypium/glass–epoxy hybrid composites for automotive structural applications

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年4月21日

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  • M. Arul,
  • Dinesh Subbiah,
  • A. Ganeshkumar,
  • K. Poyyathappan,
  • D. Manikandan,
  • Krishnaraj Ramaswamy

摘要

This study presents an innovative approach to improving the fracture toughness and sustainability of hybrid epoxy composites by synergistically reinforcing Gossypium (cotton) and E-glass fibers with silicon carbide (SiC) microfillers (20–50 μm, 0–15 wt%). Unlike conventional natural fiber composites limited by poor interfacial bonding, this work optimizes the hybrid laminate architecture and filler dispersion to achieve enhanced crack resistance. Composite laminates were fabricated via a controlled hand lay-up and compression molding process, followed by Mode I fracture toughness (GIC) and compact fracture toughness (KIC) testing per ASTM D5528 and D5045 standards using a 30 kN Instron 3365 frame. Results demonstrated that 15 wt% SiC composites attained the highest GIC = 0.82 kJ/m², while 10 wt% SiC achieved the maximum KIC = 1.52 MPa√m, confirming optimal energy dissipation through crack deflection, bridging, and fiber pull-out suppression. SEM fractography revealed uniform filler dispersion and strong interfacial adhesion with minimal voids, validating the improved load transfer and reduced delamination. Compared to unfilled controls, SiC-filled hybrids exhibited a 47% increase in GIC and 38% improvement in KIC, aligning with literature benchmarks for automotive-grade composites. The innovative combination of renewable cotton fibers with high-strength glass and ceramic fillers offers a sustainable, high-toughness material suitable for automotive body panels, undertrays, and interior structures where lightweight and damage tolerance are essential.