Nylon/large‐tow carbon fiber‐wrapped yarn composites with improved interfacial shear and impact strength

Abstract Hybrid fiber‐reinforced composites uniquely address the performance limitations of carbon fiber‐reinforced polymers (CFRPs). In this study, continuously wrapping large tow CF (48 K) with low‐cost nylon was proposed to create nylon‐CF core‐spun yarns (NCCYs). Unidirectional nylon‐CF/epoxy composites (NCFECs) were successfully fabricated using NCCYs as hybrid fiber reinforcement. The nylon wrapping on the CF significantly enhanced the energy absorption and dispersion of the CFRPs, thereby improving the impact strength. The measured impact strength of the NCFECs was 108.7 kJ/m 2 , which was 70.4% greater than that of the corresponding CF/epoxy composite (63.8 kJ/m 2 ) with the same CF content. Additionally, NCCYs exhibited an excellent interfacial shear strength of 35.3 MPa, representing a 73.9% increase compared to that of the large tow CF (20.3 MPa). This study developed NCFECs using a simple and low‐cost process to produce advanced composites, providing an innovative manufacturing strategy for CFRPs with high impact resistance. Highlights The NCCYs are prepared by using the wrapping technology. The structure of the wrapped yarns endows the NCCYs with high interfacial shear. The nylon fiber layer gives NCFECs higher impact strength.