Influence of Warp Tension on the Mesostructural Configuration and Compressive Performance of 2.5 Dimensional Angle‐Interlock Woven Composites

ABSTRACT The warp tension applied during the preform fabrication is a critical process parameter that significantly governs the final mechanical performance of the resulting composites. In this work, an integrated experimental and finite‐element approach was employed to systematically investigate the effects of warp tension on the compressive behavior of 2.5 dimensional angle‐interlock woven composites (2.5DAWCs). The results reveal that variations in warp tension essentially alter the crimp level of the yarns and the filament‐breakage rate, thereby giving rise to distinct compressive response trends in the warp and weft directions. By incorporating tension‐induced yarn crimp and filament breakage defects into the finite‐element models, it is confirmed that the peak mechanical performance of the composites arises from a subtle balance between reduced yarn crimp and minimized filament breakage rate. Finally, based on response surface methodology, the quantitative contributions of weft density and warp tension to composite properties were established, allowing for the optimal design of processing tension parameters. The findings reported herein provide a reliable theoretical framework for the precise tailoring of high‐performance textile composites via synergistic process parameter regulation.