A review of fabrication techniques surface treatments and mechanical performance of stainless steel wire mesh reinforced polymer composites

Abstract Stainless-steel wire mesh (SSWM)-reinforced glass fiber-reinforced polymer (GFRP) composites represent a transformative advancement in aerospace materials, addressing critical limitations of conventional GFRP such as poor impact resistance and delamination susceptibility. This review paper comprehensively examines fabrication techniques, mechanical performance improvements, and surface treatment strategies in SSWM-GFRP composites. Reported studies show significant mechanical gains—tensile and flexural strengths increased by 25–30%, impact resistance enhanced by 20–35%, and fatigue life extended by 30% compared to unreinforced GFRP. Advanced fabrication methods such as hand lay-up, compression molding, and VARTM achieve these performance enhancements, though processing challenges like void formation and mesh misalignment persist. Surface treatments, including chemical, mechanical, and electrical modifications, further improve interfacial bonding and shear strength by up to 35%, enhancing load transfer efficiency and delamination resistance. The improved vibration damping and corrosion resistance make these composites suitable for high-performance aerospace components such as wing skins, fuselage panels, and radomes. Existing studies primarily address fabrication techniques and broad mechanical enhancements without systematically exploring the effects of mesh size variations on performance metrics like stress distribution, impact resistance, and fatigue life. Addressing this gap is crucial for optimizing composite designs tailored for aerospace applications. The novelty of this review lies in its focused assessment of the underexplored influence of SSWM geometry—specifically wire diameter, mesh density, and weave pattern—on the stress distribution, impact response, and fatigue resistance of GFRP composites. By synthesizing advancements in fabrication and surface-treatment processes while emphasizing systematic investigation of mesh size effects, this review identifies research directions for developing next-generation lightweight, damage-tolerant, and sustainable SSWM-GFRP composites tailored for aerospace applications.