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<p>With the increasing focus on utilizing industrial waste as reinforcement in composite materials, hybrid filler systems have gained attention due to their synergistic ability to overcome the limitations of polymer composites. In the present study, marble dust and fly ash were simultaneously incorporated into a basalt chopped fiber–reinforced epoxy composite. The composites were fabricated using a hand lay-up technique followed by autoclave curing, while NaOH treatment was applied to improve fiber–matrix bonding. The basalt fiber content (40 wt%) and total filler content (12 wt%) were kept constant, while the proportions of fly ash and marble dust were varied. Three-body abrasive wear tests were conducted under steady-state conditions and Taguchi L16 design. SEM analysis was performed to examine wear mechanisms. Results revealed that hybrid filler composites exhibited superior wear resistance compared to single-filler systems due to improved load sharing and interfacial integrity. The optimum performance was observed for the B40F8M4PC composite. Machine learning models further demonstrated high accuracy in predicting wear behavior, confirming the reliability of the proposed system for sustainable tribological applications.</p>

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Experimental and Machine Learning–Based Abrasive Wear Analysis of Basalt Fiber–Reinforced Epoxy Composites with Marble Dust/Fly Ash Fillers

  • 期刊论文

  • 发表日期：

    2026年4月17日

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  • Manmohan Meena,
  • Vikrant Sharma,
  • Mukul K. Paliwal

摘要

With the increasing focus on utilizing industrial waste as reinforcement in composite materials, hybrid filler systems have gained attention due to their synergistic ability to overcome the limitations of polymer composites. In the present study, marble dust and fly ash were simultaneously incorporated into a basalt chopped fiber–reinforced epoxy composite. The composites were fabricated using a hand lay-up technique followed by autoclave curing, while NaOH treatment was applied to improve fiber–matrix bonding. The basalt fiber content (40 wt%) and total filler content (12 wt%) were kept constant, while the proportions of fly ash and marble dust were varied. Three-body abrasive wear tests were conducted under steady-state conditions and Taguchi L16 design. SEM analysis was performed to examine wear mechanisms. Results revealed that hybrid filler composites exhibited superior wear resistance compared to single-filler systems due to improved load sharing and interfacial integrity. The optimum performance was observed for the B40F8M4PC composite. Machine learning models further demonstrated high accuracy in predicting wear behavior, confirming the reliability of the proposed system for sustainable tribological applications.