The growing demand for passenger comfort and environmental protection, as well as reducing fuel consumption and exhaust emissions, drives the search for new, high-performance materials. Composite leaf springs, applied as part of elastic suspension systems and with the advantages of being strong and lightweight, with a high load-carrying capacity, are a possible method with which to achieve those goals. In this study, an epoxy thermoset was blended with 10–50 wt.% polysulfide rubber and reinforced with 10 wt.% alumina powder. The characteristics of the copolymer composite blend were studied by performing ASTM mechanical tests, including tensile strength, impact strength, hardness, and damping ratio tests. The experimental outcomes showed that increasing the proportion of polysulfide rubber caused a reduction in the maximum tensile strength, modulus at fracture, natural as well as damped frequency, and hardness, whereas a significant improvement was observed in impact strength, logarithmic decrement, and the damping ratio. Reinforcement with alumina powder caused a meaningful increase in the maximum tensile strength and natural frequency, with a good improvement in deformation strength. Impact strength and the damping ratio were maximized when alumina powder was increasingly added. This increase was contrary to what occurred for the hardness, which decreased upon reinforcement. Statistical methods, altering the design of the experiments, and linear regression were used to optimize the composite mixture for manufacturing leaf springs. Finally, the model was validated using analysis of variance and probability plots (normal distribution). The regression equations of tensile and impact strength, hardness, and damping ratio test results proved composite suitability for the application of leaf springs under representative loading and operating conditions. Finite element analysis of the composite material was performed using SolidWorks Simulation 22 Mechanical software. ANSYS 2022 R1 was used to study the mechanical properties of the leaf spring model fabricated from the proposed composite material. The finite element analysis results showed a significant reduction in the weight of leaf springs, with very good mechanical properties, including the tensile and impact strength, hardness, and damping ratio, when using the proposed copolymer-reinforced composite material.

The growing request regarding the comfort of passengers, saving the environment by using new materials to lower fuel consumption, as well as exhaust emissions of motor vehicles, is the main cause of searching for new and high-performance products in this area. Composite materials are the most promising technology. The composite leaf springs, applying as part of the elastic suspension system with high strength, load-carrying capacity, and lightweight, are one of the possible manners to achieve those goals inside of vehicles used for the carriage of goods. As an example, inside the manuscript, fabricated epoxy thermoset is blended with 10-50 wt.% of polysulfide rubber composites and reinforced with 10 wt.% of alumina powder. The characteristics of the copolymer composite blend were studied by performing ASTM mechanical tests, including tensile strength, impact strength, hardness, and damping ratio tests. Experimental test results showed that tensile strength, natural frequency, and damped ratio were decreased when the polysulfide rubber percent increase in contrast to tensile strength, which showed a noticeable decrement. From the second side, the reinforcement on the basis of alumina powder caused a weighty increase in tensile strength and natural frequency with a good improvement in deformation strength. Impact strength and damping ratio were maximized when alumina powder was added increasingly, while this increase was contrary to, causing a decrease in the hardness of reinforcement. The experimental results were optimized using the statistical methods. Design of the experiment and linear regression model used to select the most appropriate mixture inside the proposed composite material for leaf springs manufacturing. Finally, validation of the model was realized by application of the statistical method of analysis of variance and probability plots (normal distribution). The regression equations of tensile and impact strength, hardness, and damping ratio test results showed that the proposed composite material is suitable to be applied for manufacturing the leaf springs considering loadings and working conditions during exploitation of such vehicles in traffic. Finite element analysis on the basis of a finite element model of composite material was performed using SolidWorks Simulation 22. Mechanical software ANSYS 2022 R1 was used to study the mechanical properties of the leaf spring model fabricated of the proposed composite material. Finite element analysis results interpreted and showed significant reduction in leaf spring weight with very good mechanical properties considering tensile and impact strength, hardness, and damping ratio when using the proposed copolymer-reinforced composite material.

The advanced composite materials development for automotive power transmission system systems intentions to enhance performance, durability, and thermal stability while reducing weight and noise. Achieving this, hybrid composite materials offer an effective balance between mechanical strength and frictional efficiency. Polysulfide is the most used polymer for it’s easy to blend apply to surfaces, good corrosion and wear resistance making it a good choice for power transmission system. Polysulfide high ductility led to the need to be blended with other polymer and reinforcing it with fiber to increase strength. In this research, a polymer composite material was prepared from two polymers (Polysulfide resin- Resole resin) and reinforced by fiber glass, where was weight ratio for polysulfide (50 wt %) and for resole was (30 wt %) and the type of the fiber glass used was plain woven (E-Glass) fibers at angle direction (0˚/45˚) with volumetric fraction (20%) where a hand lay-up method was used for prepare. Mechanical properties (Tensile strength, Impact strength and Flexural strength) were evaluated for the blend (Polysulfide and Resole) only and for a polymer composite material reinforced by fiber glass to study the mechanical properties of the composite and its performance when power transmission system is manufactured. Experimental results showed that 74%, 745%, 191% enhancement in tensile strength, impact strength and flexural strength of the composite compared with the blend. These results showed that this composite is a good choice for power transmission system manufacturing.

The advanced composite materials development for automotive clutch systems intentions to enhance performance, durability, and thermal stability while reducing weight and noise. Achieving this, hybrid composite materials offer an effective balance between mechanical strength and frictional efficiency. Polysulfide is the most used polymer for it’s easy to blend apply to surfaces, good corrosion and wear resistance making it a good choice for clutch system. Polysulfide high ductility led to the need to be blended with other polymer and reinforcing it with fiber to increase strength. In this research, a polymer composite material was prepared from two polymers (Polysulfide resin- Resole resin) and reinforced by fiber glass, where was weight ratio for epoxy (50 wt %) and for resole was (30 wt %) and the type of the fiber glass used was plain woven (EGlass) fibers at angle direction (0˚/45˚) with volumetric fraction (20%) where a hand lay-up method was used for prepare. Mechanical properties (Tensile strength, Impact strength and Flexural strength) were evaluated for the blend (Polysulfide and Resole) only and for a polymer composite material reinforced by fiber glass to study the mechanical properties of the composite and its performance when clutch system is manufactured. Experimental results showed that 74%, 745%, 191% enhancement in tensile strength, impact strength and flexural strength of the composite compared with the blend. These results showed that this composite is a good choice for clutch system manufacturing.