Epoxy resins exhibit remarkable mechanical properties, electrical insulation properties and chemical resistance. Epoxy resins have been widely used in construction, automotive, electronics, packaging, textiles, medical, and sports industries, owing to their advantages, such as low cost and simple processing and moulding procedures. Moreover, epoxy resin-based composites have gradually replaced traditional metal materials in some engineering applications due to their light weight, high strength, and workability, finding applications in a variety of fields such as aerospace, wind turbine blades, and watercrafts [1–4].
However, during the practical applications of epoxy-based composites, especially outdoor applications, such as offshore wind turbine blades and ship hulls, these materials inevitably undergo ageing due to the influences of environmental factors, such as temperature, humidity, salt mist, and ultraviolet light[5–8]. These factors lead to degradation of material performance or even failure, reducing the reliability and safety of the products and resulting in huge economic losses.
A series of studies have been conducted on the ageing behaviour of epoxy resin-based composites. It was found that the mechanical properties of composites were reduced in hygrothermal and salt mist environments, primarily due to moisture absorption[5, 8–10]. The materials showed reduced stiffness due to moisture absorption and plasticisation of the epoxy resin matrices[11–13]. Moreover, the thermal expansion coefficients of the epoxy resins and reinforcing materials were different. Consequently, this generated internal stress in the composites during ageing and formed microscopic defects within the material, resulting in inferior mechanical properties. The hygrothermal environment also influenced the glass transition temperature of epoxy resin-based composites [14–16], while the dielectric constant and dielectric loss of the composites changed with an increase in ageing time [17, 18]. The ageing properties of epoxy resin composites primarily result from the ageing of the resin matrix and the ageing of the composite interface; therefore, the ageing properties of epoxy resins and their composites need to be studied simultaneously.
Currently, many applications demand high performance from epoxy resins and their composites over long time periods, under relatively adverse conditions such as high temperature, high humidity, and salt mist. Therefore, examining the ageing behaviour of epoxy resins and their composites is crucial for safe and appropriate use and storage of the composites. At present, few studies present a concurrent investigation on the ageing of epoxy resins and epoxy resin-based composites. The research on the ageing performance of epoxy resins is mainly focused on coatings or other thin-layer products, lacking insight into the performance of comparatively thick epoxy resins across the thickness[2], especially epoxy/anhydride system. With the technological development of composite materials, epoxy resins and their composites have been transitioning into larger and thicker products. Hence, the study of ageing performance and ageing patterns of epoxy resins and relevant composite materials with certain thicknesses is critical to ensure the safety and promotion of composite products.
This research compared the moisture absorption behaviour of epoxy resins across the thickness and the changes in physical properties, thermal properties, chemical structure and microstructure under artificially accelerated hygrothermal and salt mist ageing conditions. We investigated the evolution of mechanical properties and microstructure of carbon fibre/glass fibre hybrid reinforced epoxy resin pultruded composites to explore the ageing pattern of epoxy resins and their composites, thereby laying a foundation for the manufacturing and safe applications of composite materials. It's important to note that besides humidity and salt studied in this research, other factors, such as temperature[19], pH[14], stress state[20], void contents[21], fiber orientation[22] and volume fraction[23], have a coupling effect on the aging properties of epoxy and its composites