Epoxy Flooring/Oil Fly Ash as a Multifunctional Composite with Enhanced Mechanical Performance for Neutron Shielding and Chemical-Resistance Applications

[Image: see text] Heavy-oil fly ash (HOFA) is a graphitic carbon powder extracted in vast amounts as a waste material from burning crude oil in power plants. This HOFA has attractive structural properties besides its high amount of pure carbon (∼90 wt %). This powder exists in spherical, highly porous micron-sized particles, which implies its great potential as a mechanical reinforcement for different polymers. In this work, HOFA has been utilized to enhance the mechanical properties of epoxy flooring at HOFA weight fractions of 0, 1, 1.6, and 3.2 wt %. The obtained results revealed that the prepared epoxy-flooring/HOFA composites at a HOFA content of 1.6 wt % showed significant mechanical improvements compared with the pristine polymer. The tensile strength and Young’s module values were enhanced by ∼17 and 11%, respectively. Furthermore, the neutron-shielding performance was investigated. The composite with 1.6 wt % showed better neutron attenuation and lower transmittance than the pristine epoxy. The chemical resistance was also extensively studied against sodium hydroxide, nitric acid, and sulfuric acid. The changes in morphology, chemical elements, mass, volume, and molecular structures were investigated rigorously for pristine epoxy and its composite with HOFA at 1.6 wt %. After exposure to these chemicals for 21 days, the tested properties of the epoxy-flooring/HOFA composite showed better chemical resistance than that of the pristine epoxy. Where the epoxy-flooring/HOFA composite showed a surface with low cracks and blistering, it showed lesser changes in mass and volume and fewer molecular structure changes. These results indicated that it is possible to use this multifunctional composite for several applications, including the petrochemical industry, radiation shielding, construction, and automobiles.