Sustainable Innovations: Mechanical and Tribological Advancements in Carbon and Kevlar Reinforced Epoxy Composites

The study of technical textiles and their composites is crucial for material selection in performance-driven applications. This research investigates the mechanical and abrasion behavior of plain-woven Kevlar and carbon fiber fabrics and their epoxy-based composites under various environmental conditions. Tensile tests and Martindale abrasion tests were performed in warp and weft directions, following ASTM D3039, ISO 105-E04:2013, and ISO 12947-3:1998 standards. Samples were tested in dry conditions, after immersion in water, and in a salt solution simulating human sweat. Dry fabrics exhibited the highest tensile strength, with Kevlar fabric outperforming carbon fabric due to its denser weave and resistance to moisture-induced degradation. However, carbon/epoxy composites showed superior mechanical properties, owing to better fiber–matrix adhesion and stiffness. Hybrid Kevlar-carbon composites offered a balanced mechanical response, particularly in the warp direction. Abrasion tests revealed lower mass loss in Kevlar fabrics compared to carbon, with damage intensifying under wet conditions especially in sweat simulations due to salt-induced weakening. This behavior is linked to fiber structure, fiber–matrix bonding, and abrasive wear mechanisms. Sweat simulation testing reflects realistic service conditions found in protective clothing and aerospace applications. The results support the development of durable, lightweight composites for environments involving moisture or salt exposure. While statistical consistency was ensured using sample averaging, future studies will include detailed statistical analyses. To mitigate wet-condition degradation, future work will explore the use of surface treatments or coatings. This study contributes to sustainable material design by enabling longer service life, reduced material waste, and optimized hybrid fiber configurations. Further research will explore bio-based matrices and nano-enhanced hybrids to expand eco-friendly performance solutions.