Physico-Mechanical and Rheological Properties of Epoxy Adhesives Modified by Microsilica and Sonication Process

Industrial waste from the production of metallic silicon and silicon–iron alloys, which includes silica fumes (microsilica), is subject to numerous applications aiming at its reuse in concrete and polymeric composites. Recycling solves the problem of their storage and adverse environmental impact. Six different formulas of epoxy resins were tested, differing in the type of polymer, the mixing process (sonication or not) and the presence of microsilica. The study showed that microsilica added to the epoxy resin changes its viscosity and free surface energy, and these are the parameters that determine the adhesion of the polymer to the concrete surface. Strength tests and SEM analysis have determined how microsilica molecules can penetrate the structure of polymer macromolecules by filling and forming temporary chemical bonds. Mixing the fillers with the adhesive was achieved by using a sonication process. The analysis of the obtained results showed that, depending on the initial composition of the polymer, the addition of microsilica can change the chemical, physical and mechanical properties of the hardened adhesive to varying degrees. In the case of adhesives used in the construction industry to strengthen and glue structural elements, these changes significantly affect the durability of the adhesive joints.