A novel design of three‐dimensional/unidirectional hybrid composites to balance in‐plane and interlaminar mechanical properties

The working condition of the rail transit components such as bogies is complicated, so the high comprehensive performance of composite parts is desperately required. However, existing pure three‐dimensional braided or laminated composites have been unable to satisfy the cooperative demand of in‐plane and interlaminar properties. In this paper, a novel design of three‐dimensional braided/unidirectional (3D/UD) hybrid composite is proposed to balance the in‐plane (tensile, compression, bending), interlaminar (interlaminar shear, low‐speed impact) properties of the composite. The effects of different 3D/UD mixing ratio and layup sequence on the mechanical properties and damage mechanism of hybrid composites were studied by the parametric analysis of the experimental test results, and the comprehensive mechanical properties of the hybrid structure were optimized by COPRAS evaluation method. The results show that the larger the proportion of unidirectional layer, the better the mechanical property in‐plane, but the worse interlayer property. In addition, the change of layup sequence induces a complex nonlinear relationship between 3D/UD mixing ratio and mechanical properties. Combined with microscopic failure characterization results, it is found that the sandwich structure and the addition of uniformly distributed interfacial layer can improve the mechanical properties of the hybrid composite. The optimization results show that the sandwich structure hybrid composite UD₆/3D/UD₆ with the best balance between in‐plane and interlaminar properties was selected by COPRAS. Compared with pure 3D composites, the comprehensive mechanical properties of UD₆/3D/UD₆ are increased by 53.9%, which provides a reference for the structural design of hybrid composites in the future.