Hybrid structure design of expanded steel mesh to enhance the tensile performance of fiber‐reinforced composites

Abstract Metal hybrid structures with fiber‐reinforced composites optimize strength, weight, toughness, and durability while minimizing cracks and retaining structural integrity. The present investigation evaluates the tensile performance of hybrid composites manufactured from expanded steel wire meshes and fiber‐reinforced epoxy versus pure glass fiber (GE). Hybrid specimens were fabricated with steel mesh of varying pattern sizes inserted at two different positions within the composites and exposed to two loading layouts. The results indicated that replacing GE layers with steel mesh decreased specimen density by 6.25% while increasing ductility and energy absorption. Medium‐size mesh provided the most effective performance, enhancing tensile strength, peak load, energy absorption, and stiffness by an average of 18.9% over other sizes. The outer layer configuration was superior to the inner layer, improving peak strength, failure strain, stiffness, and absorbed energy by up to 25.6%. Moreover, vertical loading boosted overall performance by an average of 28.5% compared with horizontal loading. The SO2 configuration was selected via Grey Relational Analysis to be the most effective arrangement. Highlights Insight into the impact of using expanded steel mesh in GE composites. Analyzing the effect of mesh size and laminating order on tensile performance. Effect of loading layouts on the overall performance of the hybrid composites. Examining damage morphologies to assess the interlayers interaction. Superior results in terms of peak load, failure strain, and toughness.