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In the field of hybrid natural fiber polymer composites, there has been a recent surge in research and innovation for structural applications. To expand the strengths and applications of this category of materials, significant effort was put into improving their mechanical properties. Hybridization is a designed technique for fiber-reinforced composite materials that involves combining two or more fibers of different groups within a single matrix to manipulate the desired properties. They may be made from a mix of natural and synthetic fibers, synthetic and synthetic fibers, or natural fiber and carbonaceous materials. Owing to their diverse properties, hybrid natural fiber composite materials are manufactured from a variety of materials, including rubber, elastomer, metal, ceramics, glasses, and plants, which come in composite, sandwich laminate, lattice, and segmented shapes. Hybrid composites have a wide range of uses, including in aerospace interiors, naval, civil building, industrial, and sporting goods. This study intends to provide a summary of the factors that contribute to natural fiber-reinforced polymer composites’ mechanical and structural failure as well as overview the details and developments that have been achieved with the composites.

Increasing scientific interest has occurred concerning the utilization of natural fiber-enhanced hybrid composites that incorporate one or more types of natural enhancement. Annual natural fiber production is estimated to be 1,783,965 × 103 tons/year. Extensive studies have been conducted in the domains of natural/synthetic as well as natural/natural hybrid composites. As synthetic fibers have better rigidity and strength than natural fibers, natural/synthetic hybrid composites have superior qualities via hybridization compared to natural composites in fibers. In general, natural fiber compounds have lower characteristics, limiting the use of natural composites reinforced by fiber. Significant effort was spent in enhancing the mechanical characteristics of this group of materials to increase their strengths and applications, especially via the hybridization process, by manipulating the characteristics of fiber-reinforced composite materials. Current studies concentrate on enhancing the understanding of natural fiber-matrix adhesion, enhancing processing methods, and natural fiber compatibility. The optimal and resilient conceptions have also been addressed due to the inherently more significant variabilities. Moreover, much research has tackled natural fiber reinforced hybrid composite costs. In addition, this review article aims to offer a review of the variables that lead to the mechanical and structural failure of natural fiber reinforced polymer composites, as well as an overview of the details and costings of the composites.

In recent years, most boat fabrication companies use 100% synthetic fiber-reinforced composite materials, due to their high performance of mechanical properties. In the new trend of research on the fabrication of boat structure using natural fiber hybrid with kevlar/fiberglass-reinforced composite, the result of tensile, bending, and impact strength showed that glass fiber-reinforced polyester composite gave high strength with increasing glass fiber contents. At some point, realizing the cost of synthetic fiber is getting higher, researchers today have started to use natural fibers that are seen as a more cost-effective option. Natural fibers, however, have some disadvantages, such as high moisture absorption, due to repelling nature; low wettability; low thermal stability; and quality variation, which lead to the degradation of composite properties. In recent times, hybridization is recommended by most researchers as a solution to natural fiber’s weaknesses and to reduce the use of synthetic fibers that are not environmentally friendly. In addition, hybrid composite has its own special advantages, i.e., balanced strength and stiffness, reduced weight and cost, improved fatigue resistance and fracture toughness, and improved impact resistance. The synthetic–nature fiber hybrid composites are used in a variety of applications as a modern material that has attracted most manufacturing industries’ attention to shift to using the hybrid composite. Some of the previous studies stated that delamination and manufacturing had influenced the performance of the hybrid composites. In order to expand the use of natural fiber as a successful reinforcement in hybrid composite, the factor that affects the manufacturing defects needs to be investigated. In this review paper, a compilation of the reviews on the delamination and a few common manufacturing defect types illustrating the overview of the impact on the mechanical properties encountered by most of the composite manufacturing industries are presented.

Natural fiber‐reinforced composites have emerged as a promising alternative in various industries, including automotive, aerospace, construction, and civil engineering, owing to their eco‐friendly nature and favorable mechanical properties. However, challenges such as low thermal stability and high moisture absorption limit their widespread use. To overcome these limitations, surface modifications such as mercerization, benzoylation, silane treatment, and acetylation have been extensively explored. Hybrid composites (HCs), combining natural and synthetic fibers, offer a compelling solution by harnessing the unique properties of both materials. This review comprehensively examines the types of fibers and polymers utilized in HCs, along with various chemical treatments to enhance their properties. Additionally, a detailed analysis of different manufacturing processes for HCs is provided, including hand lay‐up, vacuum‐assisted resin transfer molding, autoclave molding, injection molding, and compression molding. Furthermore, this review highlights recent advancements in HCs and their applications. Significant outcomes include a deeper understanding of the synergistic effects between natural and synthetic fibers, improved mechanical and thermal properties, and enhanced applications in diverse industries. The potential of HCs as a sustainable and high‐performance material solution emphasizes the importance of ongoing research and innovation in this field to overcome existing challenges and unlock new possibilities for composite engineering. Highlights Surface modifications such as mercerization, benzoylation, and silane treatment enhance the properties of natural fibers in composite materials. Hybrid composites (HCs) offer unique advantages by combining natural and synthetic fibers, including improved thermal, mechanical, and damping properties. Various chemical treatments and manufacturing processes contribute to enhancing the properties and applications of HCs. Recent advancements in HCs have led to an improved understanding and utilization of composite engineering across multiple industries. The review discusses challenges, opportunities, and future prospects for HCs, emphasizing the need for ongoing research and innovation in this field. Natural fiber‐reinforced hybrid composites are emerging as eco‐friendly alternatives in different industrial applications for their favorable mechanical and thermal properties.

In this study, the mechanical properties of basalt/ramie/polyester hybrid composite laminates were investigated. A matrix of 45% polyester was used, as it has good bonding properties between fibers. The composite laminates were fabricated using a hand layup technique, with seven layers stacked in different sequences and impregnated in the polyester matrix to create a hybrid configuration. Tensile, flexural, impact, compression, and hardness tests were conducted according to ASTM standards for mechanical characterization. The results showed that the overall stacking sequence of sample number seven (BRBRBRB) had the highest tensile strength at 120 MPa, impact energy at 8 J, flexural strength at 115 MPa, compression strength at 70 MPa, and hardness of 77. Natural fiber-reinforced composites are being used in current automotive industry applications, such as in electric vehicles.

Kevlar and carbon fibres and fabrics have won a leading place in the structure market, although such materials are not cheap, and are increasingly used for reinforcing and strengthening structural elements in the civil engineering, automotive, aerospace and military industries, due to their superior mechanical properties, especially in terms of strength. The mechanical characteristics of such composite materials must be known in order to numerically simulate the mechanical behaviour of such structures in terms of the distribution of stresses and strains. It has also become a necessity to understand the effects of reinforcement with both types of fibres (carbon fibres and Kevlar fibres) on the mechanical properties, especially on the impact properties of such composites. This review aims to expose the main advantages and disadvantages of the hybridization of carbon and Kevlar fibres. For this reason, an overview is presented concerning the main characteristics (tensile strength, flexural strength, impact strength, coefficient of thermal expansion and so on) for carbon and Kevlar fibres and also for hybrid Kevlar–carbon composite materials to aid in the design of such hybrid composite materials. Finally, some civil construction rehabilitation and consolidation applications of the composites reinforced with carbon fibre, Kevlar fibre or with hybrid Kevlar–carbon fabrics are highlighted in the last part of the paper.

Natural filler/fiber based composites are material focusing on the use of natural reinforcement material for fabrication process. In present research two different composites are developed using (i) pine needle fiber and epoxy (ii) pistachio shell filler and epoxy. Impact strength of developed composites is studied which shows that with addition of pistachio shell filler and pine needle fibers in composites, there is increase in impact strength as compared to neat epoxy sample. In addition, hybrid composite with natural filler and pine needle fiber has shown the highest impact strength of 23.33 kJ/m2. Investigating samples further in different conditions (petrol, kerosene, water) for impact strength, research shows that there is substantial decrease in strength in comparison to the samples subjected to ambient conditions.

Natural fibers are gaining too much attention and researchers are shifting their interest due to environmental concern and ecological benefits. The present experimental study is focused on the investigation of thermo-mechanical properties of aggro–waste pineapple leaf fiber (PALF) reinforced polymer composite under the influence of pineapple micro-particulate inclusion. For developing the hybrid composites, constant weight fraction (30%) of PALF and five different weight fractions (2.5%, 5%, 7.5% and 10%) of particulates are taken. The study involves preparation, chemical treatment (with 5% NaOH solution) and characterization (XRD, FTIR and TGA) of micro particulate and results revealed that the treatment of particulate has a better crystalline index and thermal stability which improved their material characterization as well as mechanical and thermal properties. The addition of chemically treated particulates in PALF reinforced polymer composites showed better interfacial bonding between fibers and matrix that enhanced the mechanical and thermal properties of the developed composite. The experimental results showed that 7.5% of particulates inclusion has highest tensile, flexural, compressive and hardness properties with higher plane strain fracture toughness and thermogravimetric analysis while 2.5% of particulate inclusion has highest impact strength. The water absorption and biodegradability tests were also performed and revealed that the addition of particulates has greater water absorption and better biodegradability. The scanning electron microscopy was used to study the morphology behaviour with different weight fraction of particulates and also analyzed the fracture behaviour of developed hybrid composites.

The printing industry provides flex banners as a noteworthy product. Flex banners find widespread use in promotions while serving multiple events since they demonstrate greater durability and sun protection compared to other fabric banners. The banners originate from distinct regions as the China Flex Banner (FC) and Korean Flex Banner (FK). Flex banner advertisements with promotional content receive their length of use from permitting specifications issued for advertising purposes. Flex banner wastes degrade slowly since these plastic products make up the banner materials. Once flex banners become unnecessary for use they generate significant waste which demands proper sustainable waste management solutions. The reduction of Flex banner waste needs a solution that includes glass fiber reinforcement for its use in hybrid composite materials. Each type of flex banner has its own characteristics in the shape of the fiber surface which can have an impact on strength when used as a composite material. The research showed that fiberglass would boost the composite mechanical properties. The FC type of reinforcement achieved maximum impact and flexural strength according to this research.

This study investigates the mechanical, thermal, and chemical properties of basalt/woven glass fiber reinforced polymer (BGRP) hybrid polyester composites. The Fourier transform infrared spectroscopy (FTIR) was used to explore the chemical aspect, whereas the dynamic mechanical analysis (DMA) and thermomechanical analysis (TMA) were performed to determine the mechanical and thermal properties. The dynamic mechanical properties were evaluated in terms of the storage modulus, loss modulus, and damping factor. The FTIR results showed that incorporating single and hybrid fibers in the matrix did not change the chemical properties. The DMA findings revealed that the B7.5/G22.5 composite with 7.5 wt% of basalt fiber (B) and 22.5 wt% of glass fiber (G) exhibited the highest elastic and viscous properties, as it exhibited the higher storage modulus (8.04 × 109 MPa) and loss modulus (1.32 × 109 MPa) compared to the other samples. All the reinforced composites had better damping behavior than the neat matrix, but no further enhancement was obtained upon hybridization. The analysis also revealed that the B22.5/G7.5 composite with 22.5 wt% of basalt fiber and 7.5 wt% of glass fiber had the highest Tg at 70.80 °C, and increased by 15 °C compared to the neat matrix. TMA data suggested that the reinforced composites had relatively low dimensional stabilities than the neat matrix, particularly between 50 to 80 °C. Overall, the hybridization of basalt and glass fibers in unsaturated polyester formed composites with higher mechanical and thermal properties than single reinforced composites.