Enhanced mechanical performance and failure mechanisms of woven glass fiber‐reinforced polymer composites with optimized multi‐walled carbon nanotube reinforcement

Abstract This study investigates the mechanical enhancement of woven glass fiber‐reinforced polymer (WGFRP) composites through incorporating multi‐walled carbon nanotubes (MWCNTs). The composite matrix comprises LY556 epoxy resin and HY951 hardener in a 10:1 ratio, with MWCNTs incorporated at varying weight percentages (0, 0.5, 1, 1.5, and 2 wt%). The effect of MWCNT concentration on ultimate tensile strength (UTS), elongation, peak load, flexural strength, and modulus of elasticity was systematically analyzed. Scanning electron microscopy (SEM) examined fracture morphology, fiber‐matrix interfacial adhesion, and failure mechanisms. The results indicate that the optimal MWCNT concentration of 1 wt% yields superior mechanical properties with UTS of 135 MPa, flexural strength of 178.09 MPa, and flexural modulus of 20,299.16 MPa. The improvements were attributed to the uniform dispersion of MWCNTs, enhancing interfacial bonding and stress transfer. However, at higher concentrations (≥ 1.5 wt%), MWCNT agglomeration leads to stress concentration points, reduced interfacial adhesion, and decreased mechanical performance. SEM analysis revealed failure modes of fiber pullout, delamination, void formation, and brittle fracture, particularly at higher MWCNT loadings. These findings highlight the potential of MWCNT‐reinforced WGFRP composites in aerospace, automotive, and sports industries, where high strength, stiffness, and lightweight characteristics are critical. Highlights Optimal MWCNT (1 wt%): UTS 135 MPa, flexural 178.09 MPa, modulus 20,299 MPa. High MWCNT (>1 wt%): Agglomeration reduces adhesion, weakening properties. Failure Modes: Fiber pullout, delamination, voids, brittle fracture observed. Fabrication: Hand layup, sonication, ASTM D3039 (tensile), ASTM D790 (flexural). Applications: High strength, lightweight, ideal for aerospace, auto, sports.