Published Paper Details:

The large-scale generation of fly ash from coal-based thermal power plants presents serious environmental and land-use challenges. The present study investigates the development of fly ash reinforced polymer composites aimed at converting industrial waste into value-added engineering materials. Composite specimens were fabricated using a compaction-based technique followed by room-temperature curing, with fly ash content varied at 75 wt.%, 80 wt.%, and 85 wt.%. Mechanical properties were evaluated through hardness and compressive strength tests, while tribological performance was assessed under dry sliding conditions. Thermal conductivity measurements were conducted to examine insulation capability, and microstructural analysis was performed using scanning electron microscopy. The results demonstrate that hardness and wear resistance increase consistently with increasing fly ash content due to the ceramic nature of fly ash particles and improved load-sharing mechanisms. Compressive strength exhibited an optimum value at intermediate fly ash content, indicating a balance between reinforcement loading and matrix continuity. Thermal conductivity decreased significantly with higher fly ash content owing to hollow cenospheres, increased porosity, and interfacial thermal resistance. Microstructural observations confirmed uniform particle dispersion and effective interfacial bonding at optimum compositions. The study establishes a clear structure-property relationship and highlights the potential of fly ash reinforced polymer composites for structural, tribological, and thermal insulation applications