Impact Resistance Performance of Hybrid Nano-Fiber Composites Reinforced with Carbon, Glass, and Kevlar Fibers with Duralumin Sheets: Effects of Indenter Geometry and Environmental Conditions

Natural fiber-reinforced composites are gaining attention for lightweight and durable engineering applications due to the increasing demand for sustainable and shock-absorbent materials. This study evaluates the impact resistance performance of hybrid Nano-fiber composites reinforced with carbon, glass, and Kevlar, combined with duralumin sheets, under various indenter geometries (flat, cone, and ball) and environmental conditions. Load-strain analysis reveals distinct mechanical behaviours among the configurations. The carbon-aluminium laminate composite demonstrates the lowest ultimate load (2500 N) and minimal strain capacity due to brittle failure mechanisms and poor interfacial bonding. In contrast, the woven glass-carbon hybrid composite achieves an improved ultimate load of 4000 N, attributed to enhanced load distribution and energy dissipation facilitated by glass. The woven Kevlar-carbon hybrid composite stands out for exhibiting the highest ultimate load (5000 N) and superior strain capacity, leveraging the remarkable toughness and energy-absorbing properties of Kevlar in synergy with the inherent stiffness of carbon. Indenter geometry significantly influences performance, with larger ball indenters producing higher peak loads due to increased contact area and deformation. These findings not only experimentally validate the superior mechanical properties and impact resistance of Kevlar-reinforced hybrids but also provide valuable insights into the complementary effects of hybridization and indenter geometry, positioning these materials as promising candidates for advanced engineering applications requiring exceptional durability and impact resistance The microstructural analysis also confirmed that the inclusion of Kevlar fiber not only improved toughness but also helped mitigate crack propagation, thus improving the overall impact resistance. Major Findings: The woven Kevlar-carbon composite achieved the highest ultimate load of 5000N, offering excellent energy absorption and toughness. Microstructural analysis confirms Kevlar’s role in enhancing crack resistance, making these composites suitable for aero and automobile industries.