Abstract
This study investigates the effect of stainless-steel wire mesh (SSWM) size on the mechanical performance of glass fiber-SSWM hybrid composites for aerospace application. Laminates were fabricated by embedding AISI 304 steel meshes (10 to 120 openings per inch) and bi-directional glass fibers in epoxy using hand layup and compression molding. Mechanical tests showed mesh size strongly affects properties: Mesh 120 achieved the highest tensile strength (539.19 MPa) with low void content (0.49%), suitable for tensile-critical parts; Mesh 20 had the highest flexural strength (487.97 MPa) due to its heavier mesh weight and low voids (0.53%), ideal for load-bearing panels; Mesh 40 offered the best balance of impact resistance (1.715 J), tensile (409.10 MPa), and flexural (339.78 MPa) strengths, supporting multifunctional structures. Finer meshes (80, 120) exhibited improved ductility and damping for vibration-sensitive applications. SEM analysis revealed strong interfacial bonding and crack-bridging in Mesh 40, while Mesh 120 showed microcracking and fiber pull-out, indicating trade-offs between tensile and impact performance. Void content ranged from 0.49% to 1.93%, confirming high manufacturing quality. These findings emphasize the critical role of mesh geometry in optimizing hybrid composite performance and suggest further work on advanced fabrication methods and durability testing.