Novel zone-based hybrid laminate structures for high-velocity impact (HVI) in carbon fibre-reinforced polymer (CFRP) composites

We propose novel zone-based hybrid laminate concepts for improving the high-velocity impact (HVI) response of baseline carbon fibre-reinforced polymer (CFRP) composites while maintaining similar areal weights and retaining substantial in-plane mechanical properties by requiring that about 80% (by mass) of the baseline CFRP is kept in the hybrid concepts. We identify three zones along the thickness of the laminate according to their role during HVI and implemented tailored materials in these zones to improve the HVI response. We studied a wide range of materials, including: fibre reinforcements of carbon (thin- and thick-plies), glass, Zylon and ultra-high molecular weight polyethylene (UHMWPE); a shape memory alloy/carbon fabric; and ceramic, alumina and titanium sheets. All laminate concepts have similar areal weights for a meaningful comparison. After defining the various concepts, we manufactured and measured their specific dissipated energy under HVI, and finally carried out post-mortem analysis (including C-scan and microscopy). The results show up to 95% improvement in energy dissipation over the baseline quasi-isotropic (QI) CFRP configuration.