Fabrication of Waste Ceramic Reinforced Polymer for Electrical Insulation Application and Characterization of the Mechanical and Physical Properties

Abstract

Composite materials continue to be the forefront materials for many manufacturing industries. Due to their superior mechanical and physical properties, composite materials play a significant role in modern manufacturing technology. However, the cost of composite materials is seen to be a major challenge. In this thesis, waste floor tile ceramic particles are used as a reinforcement, so that a problem related to cost can be solved and sees a new way to manage construction ceramic waste materials. The main goal of this research is to propose a new composite material with an optimal physical and mechanical response for a low-voltage pin-type insulator. The ceramic reinforcement is prepared by crushing waste tiles with a stone crusher machine and sieving the powder under an average particle size of Ø<0.5,0.5< Ø <1, and 1< Ø <2mm diameter. Characterization of major and minor oxides- concentration in the ceramic powder is determined using a complete silicate analysis. Then the reinforcement ceramic is added to a general- purpose epoxy resin-1003 with 30%,35%, and 40% by weight. Experimental test samples are fabricated using a stir-casting technique. Taguchi L9 OA design of experiment is used for designing each experimental sample. Experimental analysis of physical properties such as water absorption and electrical resistance, specifically dielectric strength is investigated. Further mechanical responses such as flexural strength, and compressive strength are investigated. Finally, Minitab software is used to optimize process parameters. The research shows reinforcing 0.5<Ø<1 mm ceramic particles with 30%wt, exhibit an optimum flexural strength of 142.788 Mpa, compressive strength of 85.64Mpa, water absorption of 0.3% along with dielectric strength of 5.92Kv/mm. The research findings show a promising leap in the way waste ceramic tiles can be recycled and utilized for electrical insulation applications.