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Epoxy matrix composites reinforced with fine clay particles were developed by hand lay-up open mould casting technique. The clay used in this study was pulverized and processed into fine particles through sedimentation process. The composites were developed by mixing the epoxy matrix and hardener with various weight fractions of fine clay particles (2, 4, 6, 8 and 10 wt%) in an open test moulds. In order to accomplish a uniform blend of the constituents; manual mixing of the blend was carried out for 3 min. The test specimens were left to cure for 24 hours in the moulds and for additional 30 days at room temperature of 25 ± 2 °C and were thereafter detached from the moulds. The developed composites test specimens were subjected to mechanical tests (flexural, tensile and impact) in accordance with ASTM standards and performed at room temperature. Structural characteristics of the clay particles were determined using X-ray diffractometer (XRD). The morphologies of the composites were determined utilizing scanning electron microscope (SEM). There was progressive enhancement in the mechanical properties of epoxy composites containing 2-6 wt.% fine clay particles while drastic decrease in the mechanical properties were noticed in the epoxy/clay composites reinforced with 8-10 wt.% fine clay particles. The SEM images revealed homogeneous particles distributions within the epoxy matrix at lower fine clay particles weight fractions (2 wt. % and 6 wt.%).
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