Microwave Modification at Different Stages of Unsaturated Polyester/Brick Dust Composite Fabrication and Its Effect on Structural, Mechanical, Thermal and Moisture Properties

The growing volume of industrial waste and the need for sustainable material solutions drive the search for cost-effective fillers and energy-efficient processing methods for polymer composites. This study investigates the valorization of brick dust (BD), a fine ceramic waste, as a reinforcing filler for unsaturated polyester resin (UPR), combined with microwave (MW) treatment applied at different stages of composite fabrication. The brick dust was comprehensively characterized using laser diffraction, SEM, EDX, XRD, and FTIR, revealing an environmentally safe aluminosilicate powder with a mean particle size of 3–6 µm, plate-like morphology, and surface hydroxyl groups favorable for matrix interaction. The optimal filler content was found to be 50 phr, which increased flexural strength by 6.5%, flexural modulus by 134%, tensile strength by 11%, and impact strength by 40% compared to neat UPR. Among the MW strategies evaluated, post-curing of the fully polymerized composite for 120 s proved most effective, yielding further improvements in flexural strength (110 MPa, +34.1%), flexural modulus (8250 MPa, +49.7%), impact strength (13.8 kJ/m2, +119%), and Shore D hardness (88). MW post-curing also increased the gel fraction from 95.0% to 97.8%, raised the thermal stability index (THRI) from 150.6 to 165.8, and reduced equilibrium water absorption from 0.62% to 0.47% with a reversibility index of 87.5%. Fracture surface analysis confirmed a transition from interfacial debonding to cohesive matrix failure, with ultra-thin polymeric veils replicating the scaly filler structure. These results demonstrate that microwave post-curing synergistically enhances the mechanical, thermal, and moisture-resistant properties of brick dust-filled polyester composites.