Synergistic Optimization of Hot Molding Process and Lay‐Up Design of CFRP ‐Steel Composite Load Wheel

ABSTRACT Thermoplastic CFRP composites offer great potential for lightweight rail vehicle wheels due to high specific strength and fatigue resistance. However, poor molding parameters and stacking designs cause resin defects, while PEEK matrices lack wear resistance. This work fabricated CFRP‐steel hybrid wheels via precision hot molding with three laminate configurations. Single‐factor experiments evaluated how curing temperature, dwell time, and ply orientation affect flexural behavior. Results show ply orientation impacts performance most significantly: the [0°] 20s lay‐up reached 1225 MPa flexural strength, 28.3% higher than the 90° configuration. The 45° lay‐up provided optimal dimensional stability and fracture toughness, with minimal degradation in complex flange regions. Optimal processing parameters were heating to 370°C at 3°C/min, holding for 30 min, and demolding below 60°C, balancing performance and efficiency. Integrating steel wear rings combined high load capacity with enhanced wear resistance, achieving a 15.33% mass reduction versus aluminum alloy wheels. This study provides a viable manufacturing pathway for high‐performance lightweight composite wheels in demanding industrial applications.