Fabrication of three-dimensional hybrid composites and investigation of their mechanical properties

This study aims to investigate in detail the mechanical performance of composite materials produced from three-dimensional (3D) woven hybrid fabrics using tensile, flexural and shear tests. For engineering applications where high strength, deformation tolerance and multi-directional load carrying capacity are critical, the effect of weave structure types and filament combinations on performance was investigated. In the study, mechanical tests were performed on samples produced using three different types of weave structures and three different filament combinations, and the material properties were comprehensively analyzed. Type I (basic structure with regular and symmetrical layout), Type II (densely bonded and z-directional fiber reinforced structure) and Type III (hybrid structure with angled fiber layout) weave types used in this study were designed to analyze the structural responses of composites under different loading scenarios. Glass-Glass (CC), Polyester-Glass (PC), Glass-Carbon (CK) and Polyester-Carbon (PK) filament combinations were selected to optimize the strength, deformation capacity and energy absorption behavior of the respective weave types for target applications. The results of the tensile tests showed that weave structures and filament combinations significantly affected the tensile strength of the composites. Type I webbing exhibited a consistent performance in terms of tensile strength by providing homogeneous load distribution. Type II webbing achieved the highest tensile strength due to its interlayer layout strategy; however, its limited elasticity reduced its deformation tolerance. Type III webbing offered the most balanced and superior performance in tensile tests with high energy absorption and load carrying capacity. The glass-glass fiber combination provided the highest tensile strength, while the glass-polyester combination, with its greater deformation capacity, proved to be a suitable option for flexible structures. Bending tests revealed that the Type III woven structure exhibited the highest performance in terms of bending strength. This structure provided excellent resistance and deformation tolerance under bending loads due to its angled fiber arrangement. Type II webbing also showed high strength in bending tests but was limited in displacement capacity due to lack of flexibility. Type I webbing performed lower in terms of bending strength. Among the filament combinations, glass-glass fiber stood out as the most durable combination in terms of bending strength, while the glass-polyester fiber combination offered a profile suitable for applications requiring impact resistance with its high deformation capacity. Shear tests evaluated the effect of weave structures on the in-plane load carrying capacity of composite materials. Type III webbing provided high resistance to shear loads due to its angled fiber arrangement and provided a balanced load distribution. Type II webbing ranked second in terms of shear strength, but showed a loss of performance due to localized deformations under tension. Type I webbing performed the lowest in terms of shear strength, indicating a more limited potential for use in this type of application. In conclusion, this study reveals that the type of three-dimensional weave and filament combinations greatly shape the mechanical performance of composite materials in the light of the findings from tensile, flexural and shear tests.