Dual-Modified GFRP Composites: Synergistic Self-Healing and Toughening via HDPE Powder and Electrospun PAN Nanofiber Interleaves

To improve the reliability of glass-fiber/epoxy-reinforced polymer (GFRP) composites, four laminates were manufactured by vacuum bagging: (i) a virgin baseline, (ii) an epoxy system modified with 15 wt% high-density polyethylene (PE) powder, (iii) a laminate interleaved with electrospun polyacrylonitrile (PAN)-based nanofiber mats, and (iv) a hybrid combining both modifiers. The specimens were subjected to low-velocity impacts; half were then heated at 150 °C for 30 min and re-impacted. PE caused peak-load loss up to 30% compared to virgin specimens but recovered 25% after heating by filling cracks. PAN interleaves limited the loss to 5%, and the hybrid laminate merged the benefits: it showed the highest first-impact load, retained 96% on re-impact, and gained a further 10% after heating while keeping the smallest permanent indentation. SEM confirmed molten PE migrating along the nanofiber mat to repair delamination fronts, explaining the laminate’s bell-shaped, oscillation-free force response and demonstrating a practical, synergistic self-healing mechanism. Collectively, the results demonstrate a clear structure–property connection: PAN nanofibers capture crack growth, while PE provides temperature-triggered self-healing, and their synergy offers a practical pathway to lightweight GFRP structures with enhanced impact resilience and restoration of mechanical integrity.