The influence of temperature and interface strength on the microstructure and performance of sol–gel silica–epoxy nanocomposites

A series of silica–epoxy nanocomposites were prepared by hydrolysis of tetraethoxysilane within the organic matrix at different processing temperatures, i.e., 25 and 60 °C. Epoxy matrices reinforced with 2.0–10.0 wt% silica were subsequently crosslinked with an aliphatic diamine hardener to give optically transparent nanocomposite films. Interphase connections between silica networks and organic matrix were established by in situ functionalization of silica with 2.0 wt% γ-aminopropyltriethoxysilane (APTS). The microstructure of silica–epoxy nanocomposites as studied by transmission electron microscopy indicated the formation of very well-matched nanocomposites with homogeneous distribution of silica at relatively higher temperatures and in the presence of APTS. Thermogravimetric and static mechanical analyses confirmed considerable increase in thermal stability, stiffness, and toughness of the modified composite materials as compared to neat epoxy polymer and unmodified silica–epoxy nanocomposites. A slight improvement in the glass transition temperatures was also recorded by differential scanning calorimetry measurements. High temperature of hydrolysis during the in situ sol–gel process not only improved reaction kinetics but also promoted mutual solubility of the two phases, and consequently enhanced the interface strength. In addition, APTS influenced the size and distribution of the inorganic domain and resulted in better performance of the modified silica–epoxy nanocomposites.