Effect of stacking sequence on banana-aramid hybrid laminate propertiesAbstract
Growing demand for lightweight, durable, and sustainable materials has increased interest in hybrid natural-synthetic fiber composites for structural and wear-critical applications. Research and industrial adoption are strong in Europe, North America, and the Asia-Pacific region, with Europe leading automotive and construction sectors due to sustainability-driven policies. This study examined the effect of stacking sequence on the mechanical, tribological, and hygroscopic performance of banana-aramid hybrid epoxy laminates fabricated by compression moulding. Four configurations were evaluated: all-banana (A), aramid-skinned banana core (B), alternating banana-aramid layers (C), and aramid-dominated laminates (D). Tensile, compressive, impact, hardness, water absorption, and wear properties were assessed. Sample C showed the highest tensile strength (36.80 MPa), while Sample D exhibited superior compressive strength (45.56 MPa), hardness (77 Shore D), impact resistance (13.89 kJ/m2), lowest water absorption (0.0712%), and best wear resistance (0.0006 mm). These results confirm that optimized stacking sequences enable high-performance, sustainable hybrid composites.
Keywords:
aramid fiber; banana fiber; epoxy composites; mechanical properties
1. Introduction
Growing environmental concerns and the depletion of fossil resources have accelerated the development of natural fiber-reinforced and hybrid polymer composites as sustainable alternatives to petroleum-based materials[1]. Natural fibers such as banana, jute, sisal, hemp, coir, flax, vetiver, and luffa are increasingly utilized due to their renewability, low density, biodegradability, and cost-effectiveness[2-4]. Recent studies on lignocellulosic fibers derived from asparagus bean stem, Zanthoxylum acanthopodium, and Mimosa pudica have demonstrated that fiber type, chemical composition, and surface treatment significantly influence mechanical performance, water resistance, and interfacial bonding in polymer composites[5,6]. Despite these advantages, natural fibers generally exhibit moderate strength, hydrophilicity, and environmental sensitivity, limiting their use in demanding applications[7].
Banana fiber, extracted from the plant pseudo-stem, offers low density and renewability but suffers from moisture sensitivity and limited tensile strength. To overcome these drawbacks, hybridization with high-performance synthetic fibers has emerged as an effective strategy. Aramid fibers (e.g., Kevlar) provide high tensile strength, impact resistance, thermal stability, and superior tribological performance, although their cost and non-biodegradability restrict standalone applications[8]. Banana-aramid hybridization thus enables a balance between sustainability and mechanical reliability, making such composites attractive for structural and wear-critical applications.
Composite performance is strongly influenced by stacking sequence and interfacial architecture, which govern stress transfer, moisture diffusion, and wear behavior[9]. Epoxy resin is widely used due to its excellent adhesion and dimensional stability, while compression moulding ensures uniform laminate consolidation[10]. Previous studies on flax-vetiver-Luffa cylindrica, Parthenium hysterophorus–Ipomoea pes-caprae, and areca sheath–palm leaf sheath hybrid composites have confirmed that optimized stacking sequences significantly enhance mechanical performance and reduce water absorption, supporting applications in automotive interiors, structural panels, and acoustic components[11,12]. However, systematic investigations on banana–aramid hybrid epoxy laminates remain limited, particularly regarding stacking-sequence effects on mechanical, tribological, and hygroscopic properties[13].
Accordingly, the present study investigates banana–aramid hybrid epoxy laminates with distinct stacking sequences fabricated by compression moulding[14]. Mechanical, tribological, and water absorption behaviors were evaluated to establish structure–property relationships and demonstrate the potential of stacking-sequence engineering for sustainable, high-performance composite applications.
The novelty of this work lies in the systematic evaluation of stacking-sequence effects in banana–aramid hybrid epoxy laminates, linking aramid layer placement with mechanical, tribological, and hygroscopic performance. The study uniquely demonstrates that alternating banana–aramid layers optimize tensile strength, while aramid-dominated sequences enhance compressive strength, impact resistance, moisture resistance, and wear durability, providing clear design guidelines for sustainable hybrid composites.
2. Materials
The composite laminates were developed using epoxy resin, banana fibers, and aramid fabric as the primary constituents.
2.1 Matrix
Epoxy resin (LY556) and hardener (HY951) from Covai Seenu & Seenu Co., Coimbatore, India, were used in a 10:1 weight ratio. Epoxy was chosen for its strong adhesion, dimensional stability, and compatibility with both natural and synthetic fibers[15].
2.2 Natural fiber
Banana fibers, obtained from Amman Impex, Coimbatore, were extracted from pseudo-stems, washed, sun-dried for 48 h, cut to size, and aligned during lay-up. Pretreatment improved fiber–matrix bonding and minimized voids[16].
2.3 Synthetic fiber
Woven aramid fabric (Kevlar-type) was used as the synthetic reinforcement. Aramid fibers were selected owing to their high tensile strength, excellent impact resistance, low density, and outstanding wear properties, which complement the eco-friendly but relatively weaker banana fibers. The fabric was cut into sheets of uniform size to match the mold dimensions[17].
3. Methods
3.1 Composite fabrication
Laminates were fabricated using the hand lay-up process in a flat mould of 300 mm × 300 mm × 5 mm[18]. The mould surface was cleaned and coated with a polyvinyl alcohol (PVA) release agent to facilitate easy demoulding. Epoxy resin (LY556) and hardener (HY951) were mixed in a ratio of 10:1 by weight[19-21]. Banana fibers were cleaned, dried, and cut to uniform size, while aramid fabrics were trimmed to match the mould dimensions. Fibers were stacked in four configurations and are shown in Table 1.
Each fiber layer was placed in the mould and manually impregnated with the resin–hardener mixture using a brush and roller to ensure proper wetting and removal of entrapped air. After lay-up, the laminate was covered with a release film and a weighted plate was placed on top to maintain uniform thickness during curing[22]. The Figure 1 shows the hand lay-up process.
3.2 Curing process
Specimens were cured at room temperature for 24 h, followed by post-curing in a hot-air oven at 60 °C for 2 h, then cut to ASTM standard dimensions for testing[23,24]. The four laminate stacking sequences developed in this study are illustrated in Figure 2
(a) Sample A (Ba Ba Ba Ba); (b) Sample B (Ar Ba Ba Ba Ar); (c) Sample C (Ba Ar Ba Ar Ba); (d) Sample D (Ar Ba Ar Ba Ar).
4. Testing Procedures
To evaluate the influence of stacking sequence on the performance of banana–aramid hybrid epoxy laminates, a comprehensive set of experimental tests was conducted in accordance with standard ASTM procedures[25]. The specimens prepared for these evaluations are shown in Figure 3. The tests covered tensile, compression, hardness, impact, water absorption, and wear performance, each designed to assess specific mechanical, physical, and tribological characteristics of the composites. For each test, five specimens per stacking sequence were evaluated, and the mean values were reported.
Specimens for Various Tests, (a) Tensile Test; (b) Compression Test; (c) Hardness Test; (d) Impact Test; (e) Water Absorption Test; (f) Wear Test.
4.1 Tensile and flexural test
Tensile and flexural tests were performed using a universal testing machine (UTM). Tensile strength was measured in accordance with ASTM D3039, while flexural strength was evaluated following ASTM D7264 at a crosshead speed of 2 mm/min[26].
4.2 Compression test
Compressive strength and modulus were evaluated as per ASTM D695. Specimens with a length-to-diameter ratio of 2:1 were subjected to axial compressive loading until failure[27].
4.3 Hardness test
Surface hardness was measured with a Shore D tester following ASTM D2240. Multiple readings were taken across each specimen and averaged[28].
4.4 Impact test
Impact strength was obtained by the Charpy method in compliance with ASTM D256, using notched specimens to record absorbed fracture energy[29].
4.5 Water absorption test
Moisture uptake was evaluated using ASTM D570. Specimens were dried, weighed, immersed in water for 24 h at room temperature, and reweighed to calculate weight gain[30].
4.6 Wear test
Tribological performance was studied on a pin-on-disc tribometer per ASTM G99. Cylindrical pins of the laminates were tested against a hardened steel disc under controlled load and sliding distance, with wear loss and coefficient of friction recorded[31].
4.7 Scanning Electron Microscopy (SEM) analysis
Fracture surface morphology of the tested specimens was examined using Scanning Electron Microscopy (SEM). Samples from tensile, impact, and wear-tested laminates were sputter-coated with a thin layer of gold to enhance conductivity before imaging. SEM analysis provided detailed insights into fiber–matrix interfacial adhesion, fiber pull-out, crack propagation, matrix fragmentation, and microvoid formation. These observations were correlated with the mechanical and tribological test results to better understand the underlying failure mechanisms and performance differences between stacking sequences[32-34].
5. Results and Discussions
5.1 Tensile and flexural strength
As observed in Figure 4a, The tensile strength of banana–aramid hybrid epoxy laminates strongly depended on stacking sequence, increasing from 16.60 MPa for the banana-only laminate (Sample A) to 38.18 MPa for the aramid-dominated laminate (Sample D). The low strength of Sample A resulted from the limited stiffness of banana fibers, their heterogeneous composition, and weak fiber–matrix adhesion, which promoted fiber pull-out and matrix cracking. Introducing aramid surface plies in Sample B improved strength to 24.48 MPa by enhancing load bearing, though the banana-rich core limited performance. A significant increase was observed in Sample C (36.80 MPa), where alternating banana–aramid layers improved stress transfer and delayed crack propagation. The highest strength in Sample D was achieved through aramid-dominated load sharing, with banana fibers contributing to toughness and sustainability[35].
The stacking sequence thus plays a decisive role in tensile behavior, with aramid-rich and alternating designs outperforming banana-dominated laminates[36]. This trend is consistent with earlier studies on banana–aramid and other natural–synthetic hybrid laminates, where alternating or aramid-skinned configurations exhibited enhanced tensile strength due to improved interfacial stress transfer and delayed crack initiation (e.g., reported ranges of 30-42 MPa depending on stacking architecture)[36,37]. SEM analysis is expected to validate these results: Sample A should show fiber pull-out and poor adhesion, while Samples C and D are likely to display stronger bonding, fewer voids, and enhanced stress transfer. Figure 5a represents the tensile stress–strain curves of all the samples, while Figure 5b represents the flexural stress–strain curves of all the samples.
As observed in Figure 4b, Sample A exhibited the lowest flexural strength of 21.5 MPa, while a progressive increase was observed for Samples B (32.5 MPa) and C (50 MPa). The significant improvement in flexural performance indicates enhanced load transfer and bending resistance with modified reinforcement. Sample D achieved the highest flexural strength of 54 MPa, demonstrating the most effective stress distribution and structural integrity under flexural loading.
Tensile and flexural stress–strain responses improved progressively from Sample A to Sample D. Samples C and D exhibited higher stress at comparable strain, indicating delayed failure and better load transfer. Sample A showed lower stress at lower strain, reflecting inferior mechanical performance.
5.2 Compression strength results
The compressive strength of the laminates strongly depended on fiber type and stacking configuration. As observed in Figure 6, The banana-only laminate (Sample A) showed the lowest strength of 34.59 MPa due to low fiber stiffness, lumen collapse, micro-buckling, and weak fiber–matrix adhesion. Introducing aramid surface plies in Sample B increased strength to 40.02 MPa (≈16% improvement) by enhancing compressive resistance and delaying matrix cracking. Sample C, with alternating banana–aramid layers, exhibited slightly lower strength (39.56 MPa) because banana fibers on the outer surfaces were prone to localized crushing. The highest compressive strength was achieved by Sample D (45.56 MPa), representing a 32% improvement, owing to aramid-dominated outer layers that reduced micro-buckling, constrained matrix deformation, and ensured uniform stress distribution.
Overall, these findings confirm that aramid-rich stacking, particularly with aramid at the surfaces, provides the most effective reinforcement strategy for maximizing compressive strength in hybrid laminates[38]. Similar improvements in compressive strength have been reported for natural–aramid hybrid epoxy systems, where high-modulus aramid outer plies suppressed fiber micro-buckling and matrix kinking, resulting in compressive strength gains of 25–35% over natural-fiber-only laminates[38,39].
5.3 Shore D hardness
Hardness values reflected the contribution of aramid layers to surface stiffness which is shown in Figure 7. The banana-only laminate (Sample A) showed the lowest value of 57.25 due to lumen structure and weak adhesion. Adding aramid in Sample B raised hardness to 66.63, while Sample C was slightly lower (65.63) because banana occupied outer layers. The maximum hardness of 77 was achieved by Sample D, where aramid-dominated surfaces minimized micro-voids and improved stress transfer. This trend demonstrates that aramid placement at outer plies effectively improves surface rigidity and abrasion resistance[40]. Comparable hardness enhancement has been observed in aramid- and glass-fiber–modified natural fiber composites, where Shore D values increased with synthetic fiber surface dominance due to reduced porosity and improved load-bearing capability of the surface layers[40,41].
5.4 Impact strength results
Impact strength also improved with aramid reinforcement. As we observe Figure 8, Sample A recorded the lowest value of 10.58 kJ/m2 due to brittle banana fracture and weak adhesion. Sample B increased to 12.92 kJ/m2, aided by aramid fibrillation and energy dissipation. Sample C showed an intermediate strength (11.73 kJ/m2) as banana outer layers were more prone to cracking. The best performance was achieved by Sample D (13.89 kJ/m2), which absorbed 31% more energy than Sample A through crack deflection and stress redistribution. These results highlight the superior toughness of aramid-rich hybrids[42]. The observed impact strength enhancement aligns well with previous studies on banana–aramid and jute–aramid hybrids, which attribute higher energy absorption to aramid fibrillation, crack deflection, and fiber bridging mechanisms under dynamic loading[42,43].
5.5 Water absorption results
From the observation from Figure 9, we can tell that moisture uptake decreased markedly with aramid incorporation. The banana-only laminate absorbed 0.1587% water, while Sample B dropped to 0.0872% due to hydrophobic aramid barriers. Sample C absorbed slightly more (0.1025%) because banana plies were exposed at the surface. Sample D showed the lowest uptake (0.0712%), demonstrating that aramid-rich outer layers act as effective shields against water ingress and improve dimensional stability[44]. This behavior is in agreement with reported literature, where hydrophobic synthetic fiber skins significantly reduced moisture diffusion pathways in natural fiber composites, leading to reductions in water absorption of up to 40-60% compared to fully natural laminates[44,45].
5.6 Wear test results
Wear tests revealed significant improvements in tribological resistance with aramid reinforcement. In Figure 10, The banana-only laminate (Sample A) suffered the highest material loss (0.002875 g), while Sample B reduced wear to 0.00105 g owing to aramid’s superior abrasion resistance. Sample C (0.001275 g) performed better than A but worse than B due to banana on the surface. Sample D showed the least wear (0.0006 g), nearly 80% lower than Sample A, confirming the protective effect of aramid outer plies[46]. Similar reductions in wear loss have been documented in aramid-reinforced hybrid composites, where hard, wear-resistant aramid fibers at the sliding interface limited matrix removal and fiber fracture, thereby enhancing tribological durability[46,47].
5.7 Scanning Electron Microscopy (SEM) analysis
SEM micrographs of the fractured surfaces provided insight into interfacial adhesion, fiber distribution, and failure mechanisms of the laminates. The banana-only laminate (Sample A, Figure 11) exhibited extensive fiber pull-out, matrix cracking, and micro-voids, indicating weak fiber–matrix bonding. Elongated voids around pulled-out fibers suggest inefficient stress transfer, consistent with its low tensile strength (16.60 MPa), high wear loss (0.002875 g), and higher water absorption (0.1587%). Hybrid laminates with aramid fibers showed marked improvements. Sample B (Figure 12), with aramid outer plies, displayed dense fracture surfaces with minimal voids and limited fiber pull-out, reflecting strong adhesion and effective load transfer, supporting higher tensile strength (24.48 MPa) and reduced wear loss (0.00105 g). Sample C (Figure 13), with alternating banana and aramid layers, exhibited mixed fracture features—banana-rich regions showed partial debonding, while aramid zones had cohesive failure, explaining intermediate performance. Sample D (Figure 14) had the most refined fracture morphology, with strong adhesion, restricted crack propagation, and aramid layers arresting cracks while banana fibers contributed stiffness, resulting in superior mechanical properties and wear resistance.
6. Conclusion
This study assessed banana–aramid hybrid epoxy laminates with different stacking sequences, focusing on mechanical, tribological, and hygroscopic performance. Incorporating aramid fibers consistently enhanced properties over banana-only laminates. Aramid-rich laminates (Sample D) showed the highest tensile and compressive strength, superior hardness, improved impact resistance, lower water absorption, and enhanced wear resistance. SEM analysis confirmed stronger fiber–matrix adhesion and fewer voids in aramid-dominated laminates. Stacking-sequence design enables tailoring composites for specific applications, making aramid-rich hybrids ideal for lightweight, semi-structural uses. They offer a sustainable balance of strength, durability, and environmental resistance for automotive interior panels and engine covers, aerospace cabin panels, protective sports gear, machine casings, and electrical enclosures.
Industrial challenges include the high cost of aramid fibers, moisture sensitivity of banana fibers, and complex layered fabrication. These can be mitigated through optimized fiber ratios, surface treatments, and automated layup or quality-control methods.
Future work can focus on optimizing stacking sequences, incorporating nano-reinforcements, enhancing thermal and environmental durability, and scaling up production to expand practical applications while maintaining sustainability.
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Data Availability:
All data supporting the findings of this study are included in this article and its supplementary materials.
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How to cite:
Natarajan, R., Rangasamy, R., & Karuppusamy, M. (2026). Effect of stacking sequence on banana-aramid hybrid laminate properties. Polímeros: Ciência e Tecnologia, 36(3), e20260025. https://doi.org/10.1590/0104-1428.20250088
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Edited by
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Associate Editor:
José A. C. G. Covas
All data supporting the findings of this study are included in this article and its supplementary materials.
