Modern technology requires materials with distinctive combination of properties that is not possible to meet the requirements by conventional metal, alloys, ceramics and polymeric materials. Objectives: The point of this study is to utilize and compare mechanical properties of filler (burnt coal ash remains) and uni-directional E-Glass reinforced epoxy composites. Methods/Statistical Analysis: The composites of different proportions by percentage of matrix (50%, 45%, 40%, 35%), reinforcement (50%, 45%, 40%, 35%), and filler (5%, 10%, 15%) by mass is developed by hand layup method and compared for their mechanical properties. Finding: Mechanical properties of composite material having 50% matrix, 40% E-Glass and 10% burnt coal ash filler is found to have better mechanical property compared to other proportions except for the flexural and water absorption property. Maximum strength of 129.5MPa and 137.53kJ/m2 is observed for tensile and impact performance respectively. Higher Flexural strength was observed for composite with 50% matrix, 40% E-Glass and 5% filler. Higher flexural strength, smax of 187.92MPa is observed. A higher hardness value of range 72-73 RHN is observed with increase in filler percentage. Decrease in E-glass proportion showed a decrease in flexural strength. Lower water absorption percentage was observed with increase in filler proportion. At filler percentage above 10% a drop may observed in tensile, hardness and impact due to decrease in matrix/reinforcement. Application/Improvement: Coal ash which is a major environmental threat can be efficiently utilised to improve mechanical property of E-Glass/Epoxy composite. These reinforced composites have budding application due to low cost, superior characteristics and improved mechanical behaviour.
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