In this current study, high‐toughness epoxy bio‐composites were prepared and characterized for lightweight and low‐cost technological applications using novel palmyra sprout fiber (PSF) and red matta rice husk (RHA) biosilica. The principal aim of this research was to study how the alkali‐silane treatments on the fiber and particle influence the mechanical, wear, thermal and hydrophobic behavior of epoxy composites. The PSF was alkali‐silane treated whereas the biosilica was treated only with silane. The composites were prepared via a hand layup process and characterized. According to the results, the treated PSF with 3 vol.% RHA biosilica has the maximum tensile, impact, flexural strength, and hardness. The composite with the inclusion of 5 vol.% biosilica, and the palmyra sprout fiber has the lowest specific wear rate and COF of 0.007 mm3/Nm and 0.37. Moreover, these composites possess good thermal stability with the highest initial decomposition temperature of 342°C. Similarly, the composite designation ESP3 have the lowest contact angle of 75.7°, which is within the hydrophobic limit. These composites with improved mechanical, thermal and wear properties may be useful in a variety of engineering applications that can be used for high load‐bearing capacity and biodegradability, such as sporting goods, automobiles, home furniture, food packaging, transport, and aircrafts.
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