Architectural Hybridization of Natural Fibers With SS304 Wire Mesh for Superior Interlaminar Integrity

ABSTRACT Delamination is a critical failure mode in laminated polymer composites, where interlaminar crack growth under out of plane loading causes rapid stiffness and strength loss. This study investigates flax fiber hybrid laminates reinforced with SS304 stainless steel wire mesh to enhance interlaminar performance, with and without a novel weaving architecture. Two laminates were fabricated by hand lay‐up: a nonwoven hybrid laminate (F0) and a woven hybrid laminate (F2), in which flax and hemp yarns were interlaced through mesh openings to create a mechanically anchored interphase. Fibers were alkali‐treated with 5% NaOH to improve fiber‐matrix adhesion. Interlaminar shear strength (ILSS) was measured using short‐beam shear tests, and Mode‐I fracture toughness was determined by double cantilever beam (DCB) testing. The woven laminate (F2) showed higher ILSS (11.02 MPa) than F0 (7.39 MPa), indicating better interfacial bonding and through‐thickness load transfer. Mode‐I fracture toughness also improved from 583 J/m 2 (F0) to 838 J/m 2 (F2), a 30% increase, demonstrating greater resistance to delamination. Fractography revealed matrix cracking and fiber pullout in F0, while F2 exhibited crack deflection, yarn bridging, and higher frictional energy dissipation. Weaving‐assisted metal‐natural fiber hybridization effectively enhances delamination resistance and shear performance in sustainable composite laminates.