Sustainable Basalt Fiber Hybrid Composites for Enhanced Fatigue Resistance in Lightweight Marine Structural Applications

Abstract

Basalt fiber hybrid composites are promising lightweight materials for marine structures; however, conventional laminates exhibit limited long-term durability due to moisture absorption, weak fiber–matrix adhesion, corrosion, and fatigue degradation. To overcome these limitations, this research developed basalt/carbon hybrid epoxy composites reinforced with nano SiO₂. Seven laminates (S1–S7) containing 0–3.0 wt.% nano SiO₂ were created by hand-laying down and then carefully cured. Mechanical, durability, chemical, and microstructural performance were comprehensively evaluated using tensile, water absorption, cyclic fatigue, Fourier Transform Infrared Spectroscopy (FTIR), Electrochemical Impedance Spectroscopy (EIS), and Scanning Electron Microscopy (SEM). The optimum S5 laminate (2.0 wt.% nano SiO₂) achieved 308 MPa tensile strength, 0.84% water absorption, 151,900 fatigue cycles, and 8.5 × 10⁵ Ω cm² charge transfer resistance, confirming superior interfacial bonding and corrosion resistance. The developed nano SiO₂-modified basalt/carbon hybrid composite demonstrates significant potential as a durable, lightweight material for advanced marine engineering applications.