Abstract

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The increasing environmental burden caused by industrial wastes has prompted the development of sustainable alternatives to conventional engineering materials. This study utilized sawdust ash, waste glass powder, and polyester resin to develop composite gasket materials, aligning with the principles of sustainability and circular economy. Five composite formulations were prepared with constant polyester resin content (60 wt%) and varying filler ratios. Standard tests were conducted to evaluate density, porosity, Brinell hardness (BHN), tensile strength, impact strength, and thermal resistance. Results showed that filler composition significantly influenced the composite properties. The formulation containing 25% sawdust ash and 15% waste glass powder exhibited the best performance, with a tensile strength of 50.47 N/mm² and thermal resistance of 175°C. Density ranged from 2.05–5.03 g/cm³, porosity from 0.01–0.03%, and hardness from 6.70–14.63 BHN. All samples demonstrated zero impact strength, highlighting brittleness and limiting their application in dynamic environments. Compared with conventional rubber gaskets, which typically possess tensile strength of 16 N/mm², heat resistance of 150°C, density of 1.5 g/cm³, and hardness of 30 Shore A (≈ 4.8 BHN). The developed composites showed superior strength and thermal performance but lacked flexibility. To validate these results, advanced characterization was performed on the best sample. SEM analysis revealed uniform filler dispersion, strong matrix bonding, and minimal porosity, consistent with the improved mechanical properties. XRF analysis confirmed crystalline phases of silica (SiO₂) and alumina (Al₂O₃), which contributed to enhanced thermal stability and strength. This study demonstrates the potential of waste-derived fillers in producing cost-effective, high-performance gasket composites for static sealing applications, advancing eco-friendly polymer composite technologies.

Keywords: Hybrid Composite, Gasket, Sawdust Ash, Waste Glass Powder, Polyester Resin, Sustainability