High-Impact Performance Polymer Composite Structure Consisting of Construction Sand Particles

Recent research by Cornell University has led to the development of a novel polymer matrix composite reinforced with construction sand particles, primarily silica, for ballistic impact applications. Sand particles increase the rigidity and hardness of the composite at a lower cost. These particles, when tightly packed, can resist deformation and absorb kinetic energy from projectile impact, thereby reducing its velocity and penetration depth.

Manufacturing of sand particle-reinforced composites

This research utilized two types of epoxy resins, such as ER-099 and LY-556 based on bisphenol A, for observing the composite's mechanical performance on two matrix compositions. These composites were designed with graded layers, where the initial layer was dense and abrasive to erode the projectile, followed by less dense layers for tensile strength and energy absorption. The neat or minimally packed matrix areas act as a cushion and minimize backlash. Sand particles improve adhesion between inclusions and the matrix by increasing the surface area of the composite. By ensuring effective load transfer, this enhanced adhesion improves overall hardness.

Sand particles at a construction site.

Final composite results

The mechanical properties of these composites were evaluated by a variety of tests, including Shore-D hardness testing, Izod impact testing, and tensile testing. LY-556 composites with a sand particle size of 0.3 mm at 70% volume fraction displayed great impact performance in comparison to ER-099 composites. This research promises the future potential of sand particle-reinforced polymer composites as affordable and eco-friendly materials for ballistic impact applications.

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