Cut protective performance of woven fabrics made with metallic/glass yarn-reinforced hybrid yarns

Purpose This study aims to systematically evaluate the cut-resistant performance of woven fabrics engineered from novel dual-sheath single-core hybrid yarns. It specifically investigates the impact of core material (stainless steel [SS] vs glass), yarn twist architecture (S-S vs S-Z) and fabric construction (areal density and thread density) on the cut protection level. Design/methodology/approach Twelve different types of dual-sheath single-core hybrid yarns were fabricated, with SS or glass as the core, PET as the middle sheath and UHMWPE as the outer sheath. The yarns were twisted in either S-S or S-Z directions. A power loom was used to produce 36 woven fabric samples with a satin weave structure at different areal densities (150, 200 and 250 g/m²). The cut resistance performance of fabrics was tested according to ASTM F2992M-15 using a tomodynamometer. Surface morphology of the fabrics and blades was also analyzed using optical and scanning electron microscopy. Findings The core material was the most significant factor influencing cut resistance. SS-core fabrics achieved a maximum protection level of A6 (rating force 3,173 gf), significantly outperforming glass-core fabrics, which reached a maximum of A5 (approximately 2,100 gf). Microscopy revealed distinct failure mechanisms such as the SS core causing blade blunting through metal-on-metal friction, while the glass core abraded the blade through scratching. Furthermore, fabrics with a higher thread density demonstrated superior performance by minimizing yarn distortion. The S-Z twist direction offered a marginal improvement in cut resistance over the S-S architecture. Practical implications The findings provide crucial insights for manufacturers of cut-resistant apparel and gear. The research demonstrates that selecting the appropriate core material and optimizing fabric density and yarn linear density are essential for creating high-performance cut-protective clothing. The superior performance of SS-core fabrics suggests their potential use in high-risk applications, such as industrial workwear, law enforcement uniforms and military gear. Originality/value This research fills a critical gap in cut-resistant textile development by pioneering the use of dual-sheath single-core hybrid yarns in a woven fabric structure. Unlike previous studies focused on knits or composites, this work provides novel insights into the synergistic effects of core material properties, yarn architectural twist and woven fabric construction parameters on cut resistance. The detailed failure analysis linking blade wear morphology (blunting vs scratching) to the core material offers a new perspective on the mechanisms of cut protection.