Fracture and toughening mechanisms of silica- and core–shell rubber-toughened epoxy at ambient and low temperature

The highly cross-linked thermosetting polymers used as adhesives and as the matrices of fibre composites for the construction of lightweight vehicles are very brittle, and finding effective toughening solutions for such engineering applications is a long-standing problem. An anhydride-cured thermosetting epoxy polymer has been modified by the addition of different wt% of silica nanoparticles, core–shell rubber particles and hybrids with equal wt% of both. The fracture energy was measured at ambient and low temperature (− 40 °C and − 80 °C) to understand the brittle fracture behaviour. The fracture and toughening mechanisms were identified by scanning electron microscopy of the fracture surfaces. Analytical models were used to predict the modulus and fracture energy; the predictions agreed very well with the measured values. Toughening using silica nanoparticles is especially efficient at low particle contents. This shows how epoxies can be toughened successfully for use in industrial and transport applications.