Epoxy–melamine–cenosphere hybrid composites: complete analysis for engineering applications

Abstract In the present study, we explored the composition of an epoxy, melamine and cenosphere surface modified by using 3‐aminopropyltriethoxysilane (APTES) as a hybrid filler and improved interfacial bonding. We analysed the structure, morphology, mechanical and tribological, thermal conductivity. XRD confirmed a transition from amorphous to semicrystalline phases of the epoxy composite. The chemical structure observed by Fourier transform infrared spectroscopy exhibits a peak at 2930 cm −1 , indicating CH stretching and covalent bonding due to APTES, mutually supported by Raman spectroscopy. Improved filler distribution and reduced porosity were foreseen by SEM. A reduction in void content by 10%–12% was observed as a function of hybrid filler loading, confirmed by density measurements. There was a threefold increase in Shore D hardness (for 15 wt% hybrid filler) and increased tensile strength, 213 N (virgin epoxy) to 931 N (20 wt% hybrid filler). Increased thermal conductivity by 73%, with excellent heat diffusion, was confirmed by Lee's disc. A pin‐on‐disc tribometer demonstrated (67%) decreased specific wear rate compared to the virgin epoxy. This investigation may be deployable for the automotive and aviation domains as an emerging composite. © 2025 Society of Chemical Industry.