Nano-Engineered Sandwich Interlayers for Simultaneous Functionalization and Delamination Resistance in CFRPs

Carbon fiber-reinforced polymers (CFRP) are widely employed in advanced manufacturing sectors such as aerospace, wind energy, and new energy vehicles owing to their high specific strength and stiffness. The growing demand for lightweight, high-performance, and multifunctional materials has accelerated the development of structurally and functionally integrated CFRP. Introducing functional interlayers between composite laminates is an effective strategy to impart additional functionalities; however, such interlayers are often multi-component and structurally complex. A critical challenge remains to integrate functionality without compromising, and preferably enhancing, the load-bearing capability of CFRP, particularly their resistance to interlaminar delamination. In this study, electrically heated CFRP incorporating a sandwich-structured interlayer composed of glass fiber mesh fabric/CNT veils doped with carbon nanotubes/glass fiber mesh fabric (GF/CNTs-CNTv/GF) was investigated. The effects of interlayer architecture and CNT loading on the Mode II interlaminar fracture toughness were systematically examined. Delamination failure modes and interlaminar toughening mechanisms were analyzed using scanning electron microscopy and ultra-depth-of-field three-dimensional microscopy. The results demonstrate that an optimal CNT pre-impregnation concentration of 1.0 wt% yielded a maximum G_IIC of 1644.8 J/m², corresponding to a 103.06% increase relative to the reference laminate. The enhanced performance is attributed to simultaneous optimization of interfacial "nano-engineering" effects, including matrix toughening and a pronounced "nano-anchoring" mechanism induced by CNT. These effects promote a transition in failure mode from weak interfacial debonding to a mesh-block composite delamination pattern, thereby activating multiple energy-dissipation mechanisms such as crack deflection, fiber pull-out, rupture, and bridging. This work highlights the effectiveness of CNT-modified sandwich interlayers in improving delamination resistance and provides both theoretical insight and experimental validation for the design of multifunctional CFRP with superior interlaminar fracture toughness.