Real‐Time Structural Monitoring and Effective Interlaminar Reinforcement of Carbon Fiber Composites Hybrid With Surface Modified Non‐Woven Silk Fabric

ABSTRACT Carbon fiber reinforced polymer (CFRP) composites are widely used in aerospace applications, necessitating advanced structural health monitoring (SHM) techniques to ensure their integrity and safe operational performance. This study specifically introduces an innovative SHM approach using fiber hybrid reinforcement for CFRP composites during flexural deformation. MXene and carbon nanotubes modified non‐woven silk fabric (MC‐nSF) was prepared by the surface micro‐dissolution and adhesion (SMDA) process. The resultant MC‐nSF has demonstrated exceptional strain sensitivity, making it suitable for SHM applications. The MC‐nSF layer was strategically positioned within CFRP composites via the vacuum‐assisted resin transfer molding (VARTM) process to evaluate their interlaminar properties and responsiveness. Notably, the resistance change rate (Δ R/R 0 %) of CFRP composites incorporating the MC‐nSF layer experienced significant increases of 10.95% in the interlaminar shear (ILS) test and 5.17% in the end‐notch flexure (ENF) test before damage. The analysis of Δ R/R 0 % trends allowed for precise identification of crack initiation, facilitating effective monitoring of crack propagation. Additionally, integrating the MC‐nSF layer significantly improved the interlaminar properties of the CFRP composites, with ILS strength and Mode II interlaminar fracture toughness increased by 7% and 54%, respectively. This research highlights the potential of hybrid reinforcement in advancing SHM capabilities for CFRP composites, thus paving the way for safer and more reliable structures.