Understanding the Damage Mechanisms of Basalt/Carbon Fiber Hybrid Composites Under Quasi-Static and Dynamic Loadings

This work investigates the hybrid fiber sequence effect on the flexural and impact properties of basalt/carbon epoxy composites. In the present study, six configurations of composite laminates were fabricated by vacuum-assisted resin transfer method and tested in three-point bending and Charpy impact tests. The results show that hybrid composites outperform pure basalt or carbon laminates. The maximum flexural strength and modulus, such as in [C₂B₄C₂], were realized for the configurations with carbon fibers on the outer layers because of the rigidity of carbon. However, higher energy absorption was offered by the basalt-rich composites because of their ductility. Among the hybrids, a balanced stacking sequence like [C₄B₄] and [B₂C₄B₂] showed an optimum between stiffness and toughness. Flexural modulus was maximum at 12.1 GPa for carbon-dominant layers, whereas impact resistance was maximum for alternating hybrid layers at 120 kJ/m². SEM analysis revealed that the dominant mechanisms of failure were delamination at the fiber-matrix interface and fiber pull-out, while the stacking order was critical regarding stress distribution. Hybridization also increased cost-performance metrics by a factor of 40%, as basalt fibers reduced the cost while maintaining acceptable mechanical properties. These results prove the potential of basalt-carbon hybrid for applications requiring high strength, impact resistance, and economic efficiency.