Basalt fiber (BF) reinforced polymer composites (BFRPs) have promising applications in aerospace, chemical, automotive, and other advanced technologies. However, their mechanical properties are currently limited due to poor interfacial bonding between the smooth, inert, and low-energy surfaces of BF and the polymer matrix. To address this issue, in the present study, polydopamine (PDA) and polyethyleneimine (PEI) are grown in-situ on the BF surface and followed by grafting of carboxylic-functionalized, multi-walled carbon nanotubes (C-CNTs) on the PDA/PEI layer to construct an organic/inorganic hybrid interface between the fiber and polymer matrix (epoxy resin). Mechanical characterization of the resulting BF-PDA/PEI-C-CNTs/epoxy composites exhibit a 64.7 %, 34.4 %, 27.5 %, and 28.9 % increase in the interfacial shear strength (IFSS), interlaminar shear strength, flexural strength, and tensile strength of the modified BFRPs respectively. In addition, surface analysis of the modified BF shows an increase in surface roughness (Ra) from 9.80 nm to 43.46 nm. Finite element analysis (FEA) indicates that the maximum internal stress in the composite decreases with increasing thickness of the interfacial transition zone after BF modification, reaching a maximum reduction of 59.8 %. Overall, this construction of a hybrid interface between the two phases of the composite provides a simple, effective, and promising strategy to improve the mechanical performance of BFRPs.
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