Influence of Thermoplastic Matrix on the Mechanical Behavior of Hybrid Carbon–Kevlar Fiber Reinforced Composites for Aerospace Applications

The mechanical properties of two different thermoplastic matrices, polyethylene (PE) and thermoplastic polyurethane (TPU), containing hybrid carbon-Kevlar fiber-reinforced composites have been explored in order to determine useful material systems for aerospace structural components. Mechanical tests including tensile, flexure, low-velocity and high-velocity impact tests have been performed to assess the composite’s behavior. Laminates were prepared through compression molding with plain and twill woven hybrid carbon-Kevlar fabrics and mechanical characterization was carried out as per ASTM standards. Mechanical tests including tensile, flexure, low-velocity and high-velocity impact tests have been performed to assess the composite’s behavior. The mechanical performance comparison revealed that TPU-based composites, particularly the twill hybrid TPU, outperformed PE-based variants across most tests. In tensile tests, twill hybrid TPU laminates showed superior ultimate tensile strength of 63.54 MPa. Hybrid fiber reinforcement takes advantage of the high tensile strength of carbon fibers and Kevlar ductility with a balanced performance profile over matrix systems. In flexure test, the same composite achieved the highest flexural strength of 80.54 MPa. Both the low-velocity as well as high velocity impact test showcased that, twill hybrid TPU laminates withstood 3248 N and the residual velocity was reduced by 49% which signifies the high impact resistance and greater energy dissipation of TPU matrix. Overall, TPU-based composites exhibited superior impact resistance and energy absorption capability because of the inherent elasticity and toughness of the matrix, whereas PE-based composites showed relatively greater stiffness and weight efficiency. These results highlight the importance of matrix choice in optimizing composite properties for aerospace applications that require structural integrity as well as damage tolerance. The understanding derived from this study supports the knowledge-based design of lightweight, high-performance composite materials for future aerospace components.