Fabrication and Characterization of ZnO-Enhanced Kevlar Fiber/Epoxy Composites for Advanced Lightweight Structural and Engineering Applications

This research investigates the influence of zinc oxide (ZnO) nanoparticles on the mechanical properties, fatigue behavior, and microstructural characteristics of Kevlar fiber reinforced epoxy matrix composites for lightweight Innovation. The study aims to optimize the ZnO nanoparticle content to enhance the composite’s performance while maintaining its lightweight nature. Five composite samples with varying ZnO nanoparticle concentrations (2 g to 10 g) were fabricated using the hand layup method and subjected to comprehensive mechanical testing, including tensile, compression, and impact tests, in accordance with ASTM standards. The results demonstrated that the incorporation of ZnO nanoparticles significantly improved the composites’ tensile and compressive strengths, with sample C (6 g ZnO) achieving the highest tensile strength of 182.98 MPa and compressive strength of 187.43 MPa. Impact strength tests revealed that sample C also exhibited superior energy absorption capacity, reaching 34 kJ/m2. Fatigue testing showed enhanced durability under cyclic loading, with sample C maintaining a stress level of 20 MPa after 60,000 cycles, indicating optimal nanoparticle reinforcement. SEM micrographs revealed uniform dispersion of ZnO nanoparticles, strong fiber-matrix interfacial bonding, and minimal void content, contributing to the sustainable composites’ enhanced mechanical performance and fatigue resistance.