Enhancing mechanical and tribological performance of hybrid composites: An experimental study utilizing response surface methodology and firefly algorithm

Abstract This study emphasizes the significance of stacking sequence and hybridization of glass, carbon, kevlar and basalt fibers to enhance the mechanical characteristics and the overall wear response of polymer composites. The carbon layer on the outside of the composite exhibited higher ultimate tensile and flexural strengths. The abrasive wear of fabricated hybrid composites is also explored by performing experiments using Box–Behnken design approach. The pin‐on‐disc tester is utilized to do the wear test by varying composite type, sliding distance, and sliding velocity, with specific wear rate (SWR) serving as the response parameter. Regression analysis is performed to predict SWR using control and response parameters derived from experimentation. A novel firefly algorithm technique is adopted to determine the optimal process parameter combination. By utilizing optimized parameters (430 m, 10.5 m/s, and the CKBG4BKC stacking sequence), the SWR is considerably reduced to 16.82 × 10 −5 mm 3 /Nm. Scanning electron microscopy on the worn‐out wear surface reveals enhanced interfacial bonding, fiber breakage and plowing as the fundamental wear mechanism. This work provides insight into hybrid composites for constructing aircraft and automobile body structures, where they provide an optimal blend of strength, sustainability, and structural performance. Highlights Hybrid composite: Stacking sequence impacts on mechanical and abrasive wear. Box–Behnken design: Applied on stacking order, sliding distance and velocity. Utilizing metaheuristic firefly algorithm to enhance specific wear results. Optimal parameters: 430 m, 10.5 m/s, and CKBG4BKC stacking sequence. Lightweight, high‐strength, cost‐effective, and sustainable hybrid composites.