A combined FEA and experimental approach to characterize hybrid composite of E-glass/Carbon/Kevlar fibers under tensile loading

This study presents a combined numerical–experimental approach to identify hybrid composite laminates with superior resistance to tensile deformation. Using the Taguchi L27 design, three optimal stacking sequences comprising E-glass, carbon and Kevlar-29 fibers were identified: H1 (CF–EG–CF–K29–EG–CF), H2 (CF–K29–EG–CF–EG–CF), and H3 (CF–K29–EG–CF–CF–K29). These hybrids exhibited the lowest deformation at the 0° fiber orientation, with values closely approaching those of pure carbon/epoxy laminates. Finite Element Analysis performed according to ASTM D3039-14 provided ply-level strain distribution, revealing that the hybrids demonstrated strain patterns similar to carbon-rich laminates, confirming the dominant role of carbon plies in load sharing. Experimental tensile tests validated the simulation results with an R 2 exceeding 0.95 and deformation deviations within ±10%, establishing strong agreement between predicted and measured behavior. The findings confirm that strategic hybridization of carbon with Kevlar and E-glass can produce lightweight laminates with high stiffness and low deformation, offering a competitive alternative to single-fiber composites for high-performance structural applications.