Mechanical and ballistic performance of individual and synergistic filler reinforced glass fiber epoxy composites

Abstract This study examines the influence of individual (Graphene) and synergistic fillers (Graphene + Boron Carbide (B₄C)) on the mechanical and ballistic performance of glass fiber epoxy‐reinforced composites (GFERCs). The different filler‐reinforced GFERCs were processed using the compression molding technique and cut as per testing standards. The results showed that the sample GF3 which had both the graphene and B₄C filler together had significantly enhanced the tensile, flexural, hardness, and impact properties. The properties showed an improvement of 23.3%, 34%, 7%, and 13%, respectively when compared with the unfilled GF1 sample. The ballistic test results also revealed this synergistically filled GF3 sample had the least back‐face signature (BFS) value of 23.5 mm after impact. Fractographic studies showed that the synergistic effect of graphene and B₄C also improved the bonding between the epoxy resin and glass fiber. The high toughness required for energy absorption is provided by matrix hardening, strong interfacial bonding, and fiber pullouts. Mainly the hard strike face created by the B₄C particles and the energy transfer provided by the graphene particles proved pivotal in ensuring energy dissipation in the composite. Finally, it was observed that the synergistic fillers played the most important role in improving the performance of GFERCs by enhancing the energy dissipation mechanisms. Highlights Multiple fillers (Graphene+B₄C) enhanced the mechanical and ballistic properties. Synergistic toughening provided by the B₄C and graphene particles. Hybrid fillers exhibited strong interfacial bonding.