Experimental Investigation and RSM-Based Optimization of Phenolic/PTFE/SiC Composites

Articles in Press

Document Type : Research Article

Authors

1 Faculty of Materials and Manufacturing Technologies, Malek Ashtar University of Technology, Tehran, Iran

2 Faculty of Materials & Manufacturing Technologies, Malek Ashtar University of Technology, Lavizan, Tehran, Iran.Iran

Abstract

Resole phenolic resin, valued for its excellent heat resistance, strong adhesion, and chemical stability, has long been utilized in aerospace, automotive, and protective material applications. However, its relatively low toughness and brittleness limit broader use. In this study, the thermal and mechanical characteristics of phenolic composites were improved by incorporating Polytetrafluoroethylene (PTFE) powder, Silicon carbide (SiC) particles, carbon, and high-silica fibers. A D-optimal response surface methodology (RSM) design was employed to evaluate the effects of fiber type, curing temperature, and particle loading. Scanning electron microscopy (SEM) analysis revealed that the addition of reinforcing particles altered fracture morphology by promoting crack deflection and improving resin–fiber interaction. Differential scanning calorimetry (DSC) results confirmed a 7% increase in glass transition temperature (Tg) with 10% particle loading, indicating enhanced thermal stability. Mechanical testing demonstrated that the addition of 10 wt% reinforcing particles enhanced both tensile and flexural properties, regardless of the fiber type; however, the fiber type itself had a significant influence on performance. Carbon fiber composites achieved the highest tensile strength (264.8 MPa), which was 13% above hybrid laminates (235.2 MPa) and 185% above high-silica composites (93.0 MPa). Conversely, hybrid laminates exhibited the best flexural strength (219.9 MPa), exceeding carbon by 72% and high-silica by 150%. Quantitative ANOVA validation confirmed the reliability of the developed models for both tensile and flexural strength. Optimal parameters—10% particle loading, 180°C curing with carbon fibers for tensile strength, and hybrid fibers for flexural strength—offer clear, actionable guidance for industrial applications.

Keywords

Main Subjects

Mechanics of Advanced Composite Structures

Articles in Press, Accepted Manuscript
Available Online from 15 February 2026

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