This paper investigates the mechanical performance and electrical resistivity of a structural adhesive epoxy enhanced using milled carbon fibre (MCF) as well as the bond performance of carbon fibre reinforced polymers (CFRP) and steel adhesively bonded joints using the enhanced epoxy. The epoxy was enhanced using such MCFs with different weight ratios of 1.5%, 3% and 5%. Tensile experiments were performed on the original and enhanced epoxy specimens according to ASTM D638. More ductile process failure was found for the epoxy after modification and significant improvements of E-modulus and tensile strength were evidenced when the MCF weight ratio was larger than 1.5%. Scanning electron microscopy (SEM) revealed that the failure mechanism of short MCFs pulled out from the epoxy matrix contributed to the enhancement of the mechanical performance of the epoxy. The electrical resistivity of the epoxy with MCF weight ratio of 5% was reduced by at least four orders of magnitude compared to the original epoxy, due to the conductive network formed by MCFs. Steel/CFRP double strap joints (with either CFRP sheets or CFRP laminates) were prepared using the enhanced epoxy and then tested in tension, however no obvious increase in joint stiffness or strength was observed.
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