Silica fiber–polybenzoxazine–syntactic foams; Processing and properties

Polybenzoxazine filled with chopped silica fibers and their syntactic foams of varying composition and densities were processed. The composition and density variations were achieved by regulating the relative concentrations of silica fiber and glass microballoons (MB). The variation of tensile, compressive, and flexural properties with change in composition was investigated. For the silica‐fiber filled materials, the property attained a maximum at about 40% volume content of fiber, and thereafter, the properties showed a diminishing trend. The incorporation of microspheres significantly lowered the strength of silica filled materials. However, the decrease in the specific flexural strength was less pronounced and the strength was unaffected beyond a certain microsphere content. During processing and mechanical testing, a large quantity of fibers was fractured, which reduced the strength of silica filled systems. The diminution in material strength on embedding microspheres is attributed to the presence of stress concentrating loci as evidenced from SEM analysis. The various factors leading to the property variation with composition are discussed with microscopic analyses, like clustering of fibers, crack propagation, fiber pull out, and debonding of fibers from resin phase. Dynamic mechanical analysis revealed an improved damping property for the filled materials in contrast to the unfilled polymer. The T_g (deduced from tan δ maximum from DMTA) decreased in silica fiber containing materials and on incorporating the MB, the values reverted back to that of the neat polymer. Both silica and MB conferred better thermal and thermooxidative stabilities to the polybenzoxazine. However, the degradation mechanism is nonoxidative in nature. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008