Implementation of the PECVD process to produce a novel range of filler-polymer-coated perlites for use in epoxy composites

[Display omitted] This study examines the use of expanded perlite powder (ExP), a natural rock, as reinforcement in bisphenol-A type epoxy resin. The surface of ExP has been coated using the PECVD method with different polymers such as poly(hexafluorobutyl acrylate) (PHFBA) and poly(glycidyl methacrylate) (PGMA). ExPs before and after the coating process underwent characterization using various techniques such as X-ray diffraction (XRD), thermogravimetric analysis (TGA), and Scanning Electron Microscopy (SEM). The effects of filler ratio and different polymer coatings on composite properties were investigated. The higher tensile strengths for uncoated, PHFBA-coated, and PGMA-coated ExP composites were determined as 109 MPa, 132 MPa, and 152 MPa, respectively. The surfaces of the polymer-coated ExP composites were found to be hydrophobic and water sorption was lower in these composites. ExPs have improved thermal stability and flammability properties. In addition, PHFBA-coated ExP composite was found more resistant to UV radiation and the hydrothermal environment.