Abstract
This study experimentally evaluates the mechanical and microstructural performance of single- and double-layer intraply hybrid composite (IRC) laminates produced using the hand lay-up method, focusing on Glass-Aramid (GA), Aramid-Carbon (AC), and Carbon-Glass (CG) configurations. Tensile, flexural, compressive, and density tests were conducted in accordance with relevant ASTM standards to assess the influence of hybrid type and layer number under field-representative manufacturing conditions. Microstructural investigations were performed using optical microscopy and scanning electron microscopy (SEM) to identify fabrication-induced imperfections and their relationship to mechanical behavior. The results demonstrate that increasing the laminate configuration from single to double layer significantly enhances mechanical performance across all hybrid types. Double-layer AC laminates exhibited the highest tensile strength (330.4 MPa) and Young's modulus (11.93 GPa), corresponding to improvements of approximately 85% and 59%, respectively, compared to single-layer counterparts. In flexural loading, the highest strength was observed in double-layer CG laminates (97.14 MPa), while compressive strength was maximized in double-layer AC laminates (34.01 MPa), indicating improved stability and resistance to compression-driven failure. Statistical analysis confirmed that layer number is the dominant parameter governing mechanical response, exceeding the influence of hybrid configuration alone. Microstructural observations revealed fiber misorientation, incomplete resin impregnation, and localized voids inherent to manual fabrication. However, these imperfections were consistently distributed across all specimens and did not obscure comparative mechanical trends. Coefficients of variation generally remained below 10%, indicating acceptable repeatability despite non-ideal manufacturing conditions.