Development of an Innovative Glass/Stainless Steel/Polyamide Commingled Yarn for Fiber–Metal Hybrid Composites

Fiber–metal hybrid composites are widely used in high-tech industries due to their unique combination of mechanical, toughness and ductile properties. Currently, hybrid materials made of metals and high-performance fibers have been limited to layer-by-layer hybridization (fiber–metal laminates). However, layer-by-layer hybridization lacks in fiber to fiber mixing, resulting in poor inter-laminar interfaces. The objective of this paper was to establish the fundamental knowledge and application-related technological principles for the development and fabrication of air-textured commingled yarn composed of glass (GF), stainless steel (SS) and polyamide-6 (PA-6) filaments for fiber–metal hybrid composites. For this purpose, extensive conceptual, design and technological developments were carried out to develop a novel air-texturing nozzle that can produce an innovative metallic commingled yarn. The results show that an innovative metallic commingled yarn was developed using fiber–metal hybrid composites with a composite tensile strength of 700 ± 39 MPa and an E-modulus of 55 ± 7. This shows that the developed metallic commingled yarn is a suitable candidate for producing metal–fiber hybrid composites.