Effect of stacking order on the properties of hybrid palm sheath/polyester fiber felt‐reinforced polymer composite laminates

Abstract Natural fiber‐reinforced composites exhibit excellent mechanical properties. However, achieving a balance between excellent mechanical properties and optimal acoustic performance remains a challenge. In this study, four composite laminates with different stacking orders were fabricated using polyester fiber mats (WFs) and palm sheaths (WPs) through a hot‐press process. Moreover, the effects of different stacking orders on the mechanical and acoustic properties of the composite were investigated. The results revealed that the incorporation of polyester fiber felts and the modification of the layup sequence of WP and polyester fiber felts significantly improved the mechanical and acoustic properties of the composites. Scanning electron microscopy images revealed a strong bonding between palm fibers and polyester fibers at the epoxy resin interface. Compared with pure palm fiber composites, the alternately stacked palm fibers and polyester fibers (WP/WP/WF/WP/WF) exhibited the highest mechanical properties, with a significant enhancement of 142.67% and 16.90% in flexural and tensile strengths, respectively. Additionally, the peak absorption coefficient of polyester fiber felts, positioned in the surface layer of the composite material, within the 2580–3400 Hz frequency band significantly increased from 0.07 to 0.44. Therefore, this study indicates that modifying the stacking order improves the mechanical and acoustic properties of the composites, making them suitable for use in acoustic engineering materials for buildings and decorative panels for furniture, including perforated panels and acoustic screens. Highlights The fabric‐like textured structure significantly enhanced the overall performance of the composites. The stacking order significantly influenced the overall properties of the composite. Alternately stacked polyester fiber felts and palm fibers exhibited excellent mechanical performance. The polyester fiber felts positioned on the surface layer of the composites exhibited superior mechanical performance. A laminate with “green” attributes and good acoustic properties was fabricated.