Surface engineering of textile structural composites with ZnO nanorods and graphene nanofillers for aircrew helmet applications

Abstract This research aimed to augment the properties of interfibre interfaces through surface treatment with ZnO nanorods while simultaneously modifying the matrix with graphene nanoplatelets. The strategic approach of this research focused on synergizing these interventions to enhance the mesomechanical, and macromechanical properties, which are specifically targeted at improving the performance of aircrew helmets. This study investigated the effectiveness of these enhancements in improving the mechanical performance of aircrew helmets. The synergy of integrating ZnO nanorods and doped GNPs into Kevlar fabric resulted in a 29% increase in impact energy absorption compared to that of the standard Kevlar composite. Furthermore, the composite samples underwent thorough analysis through techniques such as thermogravimetric analysis (TGA), Raman spectroscopy, Fourier‐transform infrared spectroscopy (FTIR), dynamic mechanical analysis (DMA), and scanning electron microscopy (SEM) imaging. The findings indicate that incorporating 1% graphene nanofillers into Kevlar during the fourth seed cycle of ZnO treatment yields favorable mechanical performance characteristics. SEM at 50 KX magnification provided detailed visualization of the ZnO nanorods grafted onto the fabric substrates, with subsequent evaluation of the morphological damage and fractography of the impacted composites. The findings of this research hold significance for advancing the understanding of composite material behavior under impact loads and contribute to ongoing efforts to enhance the durability and performance of structural composites in diverse applications. Highlights Synergistic treatment with ZnO nanorods and graphene nanoplatelets boosted Kevlar composite properties for aircrew helmets. Adding 1% graphene during ZnO treatment increased impact energy absorption by 29%. Comprehensive analysis validated treatment efficacy, showing substantial mechanical improvements. The research advances composite understanding, paving the way for durable, high‐performance materials for applications like aircrew helmets.