Studying the effect of polycarbonate sheet integration on glass fiber‐epoxy hybrid composite performance for automotive applications

Abstract Thermoplastic polycarbonate provides minimal structural weight and ductility and is a recyclable material. However, investigation of the characteristics of hybrid composites reinforced with woven glass and polycarbonate sheets is limited. This current study investigated the effect of integration of polycarbonate sheets on glass fiber‐epoxy hybrid composite performance. Non hybrid laminate was fabricated from eight layers of woven glass fiber impregnated with epoxy resin (NG). However, the hybrid samples utilized various symmetric stacking patterns which were made by alternating two processed polycarbonate (PC) sheets with six layers of woven glass fiber embedded with epoxy matrix. The manufacturing was made using the hand layup procedure. Mechanical testing includes compressive, tensile, bearing, and hardness was performed on hybrid and non‐hybrid composites. The results showed that employing PC sheets instead of fibers affect the laminate's strength, ductility, bearing capacity, and hardness. Utilization of PC sheets reduces both compressive and tensile strength. However, an enhancement in tensile, compressive, and bearing failure strain was achieved by 2.5%, 31.25% and 31.7%, respectively with hybrid composite having PC in the skin layers as compared with NG. The extent of failure damage is correlated with the position of the PC sheets in the tested samples. Highlights Novel hybrid composites of woven glass fiber and polycarbonate sheet as reinforcement with various stacking orders were successfully prepared by the hand lay‐up method. The compressive strain of hybrid PC samples are higher than NG sample. The hybrid PC composites showed an improved bearing strength and strain performance. The influence of sample configuration on the damage mechanisms has been investigated.