Design of damage-resistant hybrid lay-up structures for fiber-reinforced composites based on interface properties.

• This paper proposes a damage-resistant Hybrid Fiber Reinforced Polymer Composites (HFRP) design method based on the interface properties. • The microscopic interface properties of composites are introduced into the investigation of interlayer interface properties. • The influence of different hybrid interlayer interfaces on the delamination damage behavior of composites is clarified. • The 3D printing technology was used to prepare specimens of the hybrid fiber-reinforced composites. In this work, the poor impact damage resistance of carbon fiber-reinforced plastic (CFRP) composites was improved by mixing carbon fibers with ductile fibers (glass fibers/Kevlar fibers). The damage behavior of five interfaces of the prepared hybrid fiber-reinforced plastic (HFRP) composites was investigated through mode-I and mode-II interlaminar fracture toughness tests and micro-droplet debonding tests. On this basis, a numerical model for predicting the impact damage of HFRP composites was established. Through a comprehensive evaluation of the impact damage resistance indexes obtained from the numerical simulations, the hybrid fiber type, hybrid ratio between different fibers, and hybrid lay-up sequence could be optimized. The specimens with optimized lay-ups were prepared by 3D printing, and the effectiveness of the numerical model was verified through low-velocity impact and compression after impact (CAI) tests. The results show that the introduction of glass fiber layers in CFRP composites can significantly improve the damage resistance of the composites. Compared with CFRP composites, when the volume fraction of the glass fibers is 25%, HFRP composites have a smaller delamination damage area (reduced by 74.08%), furthermore, the pit depth is reduced by 43.01%, the CAI is increased by 17.29%, and the strength retention rate is increased by 31.94%. [ABSTRACT FROM AUTHOR]