Effect of Waste Brass Wire Particulate Content on the Mechanical Properties of Epoxy Reinforced with Woven E Glass Fiber Composites

Abstract

Glass fiber reinforced epoxy (GFRE) composites are widely used in structural applications; however, their inherent brittleness and limited impact resistance restrict performance under dynamic loading conditions. To address these limitations while promoting material sustainability, this study investigates the mechanical behavior of GFRE hybrid composites reinforced with waste brass wire particulates generated from electrical discharge machining (EDM) processes. Hybrid laminates were fabricated using a hand lay‑up method, incorporating brass particulate contents ranging from 10 wt% to 90 wt% relative to glass fiber reinforcement, alongside neat epoxy (EP), glass‑only (GFRE), and brass‑only (WW) reference samples. Tensile, flexural, and Charpy impact tests were conducted in accordance with ASTM D3039, ASTM D790, and ASTM D256 standards, respectively, and failure morphology was examined using optical microscopy. The results indicate that mechanical performance improves with increasing brass content up to an optimal level of 50 wt%. At this composition, the hybrid composite achieved a tensile strength of 287.55 MPa, flexural strength of 229.19 MPa, and impact energy absorption of 352.45 kJ/m², representing improvements of approximately 25% and 29% in tensile and flexural strength, respectively, compared to GFRE. Beyond this threshold, higher brass contents resulted in reduced performance due to particulate agglomeration and weakened interfacial bonding. These findings demonstrate that recycled waste brass particulates can effectively enhance the mechanical performance of GFRE composites when optimally incorporated, offering a viable approach for developing high‑performance, sustainable hybrid composite materials.