Ballistic and drop-weight impact response of SS304 metal mesh embedded woven flax/hemp fiber hybrid composites R. Elayaraja, G. Rajamurugan Scientific Reports, 2026 This research looks over the way hybrid natural fiber composites reinforced with woven SS304 wire mesh and flax-hemp yarns behave under low and high speed impacts. The hand lay-up approach was used to create hybrid laminates with alkali-treated flax fibers serving as the main reinforcement and epoxy resin serving as the matrix. The interlaminar strength and energy absorption capability of the stainless-steel mesh were enhanced by weaving it with hemp and flax strands. S1 (Flax/SS304/Flax) and S2 (Flax/SS304/Flax with woven hemp-flax yarns) are the two stacking sequences that were developed. Drop heights of 0.5 m and 1 m were used for low-velocity impact examinations, while a gas-gun apparatus was used for high-velocity ballistic evaluations. Based on the results, the woven hybrid structure (S2) outperformed the non-woven design (S1) in impact and ballistic performance, with energy absorption rates up to 25% higher and specific energy absorption rates 20% higher. The incorporation of SS304 mesh enhanced delamination resistance and localized load redistribution, while the utilization of hemp fibers permitted ductile deformation and delayed fracture development. Metal mesh and natural fibers worked together to improve crashworthiness and damage tolerance through a controlled, gradual failure mechanism. The results show that hybrid composites made of wire mesh and natural fibers can be a viable, lightweight alternative to traditional structural and ballistic protection materials.
Weaving Architecture-Driven Changes in Mechanical, Vibration and Acoustic Behaviour of Metal Mesh Embedded Natural Fiber Hybrid Composite R. Elayaraja, G. Rajamurugan Polymers for Advanced Technologies, 2026 This research aims to develop an innovative fiber‐reinforced polymer composite that integrates the advantages of flax fibers using a unique flax yarn‐weaving technique on a stainless‐steel 304 wire mesh (FSS 304). Although flax fibers offer advantageous reinforcement characteristics, their intrinsic mechanical constraints have prompted the investigation of hybrid composite designs with enhanced performance. This paper describes the fabrication and characterization of a novel hybrid composite that uses the synergistic reimbursement of FSS 304 and flax fibers, yielding a lightweight yet durable material appropriate for diverse engineering applications. Four distinct configurations (F30°, F45°, F60°, and F90°) were fabricated to examine the effects of the reinforcement orientation. The experimental findings indicate that the integration of FSS 304 markedly improves the composite hardness (F90°‐23.8 VHN), impact resistance (F30°—8.4 J), flexural strength (F90°—106.58 MPa), and tensile strength (F90°—49.2 MPa). Furthermore, acoustic analysis demonstrated that the fiber orientation substantially influences sound absorption and transmission loss, with the F90° orientation exhibiting the most effective noise reduction, especially in the 600–2000 Hz frequency range. The composite F45°‐oriented FSS 304 enhanced the natural frequency by 22%. Microstructural analysis by SEM and EDX confirmed the elemental composition. The resulting lightweight and eco‐friendly composites exhibit enhanced performance for diverse engineering applications.
Architectural Hybridization of Natural Fibers With SS304 Wire Mesh for Superior Interlaminar Integrity R. Elayaraja, G. Rajamurugan Polymer Composites, 2026 Delamination is a critical failure mode in laminated polymer composites, where interlaminar crack growth under out of plane loading causes rapid stiffness and strength loss. This study investigates flax fiber hybrid laminates reinforced with SS304 stainless steel wire mesh to enhance interlaminar performance, with and without a novel weaving architecture. Two laminates were fabricated by hand lay‐up: a nonwoven hybrid laminate (F0) and a woven hybrid laminate (F2), in which flax and hemp yarns were interlaced through mesh openings to create a mechanically anchored interphase. Fibers were alkali‐treated with 5% NaOH to improve fiber‐matrix adhesion. Interlaminar shear strength (ILSS) was measured using short‐beam shear tests, and Mode‐I fracture toughness was determined by double cantilever beam (DCB) testing. The woven laminate (F2) showed higher ILSS (11.02 MPa) than F0 (7.39 MPa), indicating better interfacial bonding and through‐thickness load transfer. Mode‐I fracture toughness also improved from 583 J/m 2 (F0) to 838 J/m 2 (F2), a 30% increase, demonstrating greater resistance to delamination. Fractography revealed matrix cracking and fiber pullout in F0, while F2 exhibited crack deflection, yarn bridging, and higher frictional energy dissipation. Weaving‐assisted metal‐natural fiber hybridization effectively enhances delamination resistance and shear performance in sustainable composite laminates.
Mechanical and dynamic performance of stainless steel and nylon mesh reinforced hybrid kevlar/glass fiber composites G Rajamurugan, R Elayaraja, Amod Paba, Samarjeet Singh, Vinayak Vir Singh, M Arul Murugan Engineering Research Express, 2025 This research details an extensive experimental examination of the mechanical and dynamic properties of hybrid composites strengthened with E-glass and Kevlar fibers, and further improved with SS 304 stainless steel and nylon mesh. Four laminate configurations were fabricated via hand lay-up techniques, with variations in stacking sequences like C1- Glass fiber 2 layer/Nylon mesh/Glass fiber 2 layer/SS 304 wire mesh/Glass fiber 2 layer, C2- Kevlar fiber 2 layer/Nylon mesh/Kevlar fiber 2 layer/SS 304 wire mesh/Kevlar fiber 2 layer, C3- Glass fiber 2 layer/Nylon mesh/Kevlar fiber 2 layer/SS 304 wire mesh/Glass fiber 2 layer, C4- Kevlar fiber 2 layer/Nylon mesh/Glass fiber 2 layer/SS 304 wire mesh/Kevlar fiber 2 layer. Composite C1, outperforming all other specimens tested, had impressive flexural strength (505.89 MPa), Vickers hardness (24.76 HRM), and tensile strength (199.67 MPa). The composite with the greatest impact energy absorption was C3, which measured 4.76 J. Data from DMA showed that C1 had better viscoelastic characteristics than other materials. It was very stiff and thermally stable, with a storage modulus of up to 5000 MPa and a glass transition temperature close to 80 °C. Microstructural analyses with field emission scanning electron microscopy and energy dispersive x-ray spectroscopy verified the homogeneity of the reinforcement phases and the durability of the fiber-matrix adhesion. These results demonstrate the promise of mesh-reinforced Kevlar-glass hybrid composites for structural uses requiring extreme heat resistance, toughness, and strength.
Utilizing woven flax/hemp yarn on SS304 wiremesh reinforced flax fiber composites for tribological applications R. Elayaraja, G. Rajamurugan Results in Engineering, 2025 The rising demand for lightweight and sustainable materials across multiple industries, such as automotive and construction has propelled the advancement of natural fiber-reinforced composites. Nonetheless, obstacles persist in enhancing their tribological performance for rigorous applications. This research utilized a central composite design to enhance the wear and friction characteristics of flax fiber reinforced integrating flax and hemp yarns with the stainless steel 304 wire mesh (FSS 304). Different loads and fiber orientations (45°, 60°, and 90°) demonstrated that a 90° orientation reduced the wear rate to 1.37 × 10⁻⁷ g/m, whereas a the 45° orientation generally yielded a lower coefficient of friction at higher loads, achieving the overall minimum CoF of 0.2721, although at 10 N, its CoF was highest among the orientations. This underscores the impact of fiber orientation on wear and friction processes. The predictive model, which used response surface methodology (RSM), accurately captured the trends in the experiments with high R² values. This showed that it was strong enough to predict wear and friction behavior. Erosion tests revealed that the 60° orientation exhibited the greatest erosion resistance, with a mass loss of 0.0186 g. These findings highlight the significance of fiber orientation in the design of natural fiber composites for specific tribological performance.
Investigating the Moisture Absorption Characteristics of a Composite Material Produced from Waste Plastic Filled with Pineapple Fibre Reinforcement M. Babu, R. Elayaraja, S. Suresh, V. Sugan International Journal of Advanced Science and Engineering, 2025 This study focuses on addressing the issue of moisture ingress in polymer composites, a factor that often compromises structural performance and limits service life, especially in humid or outdoor conditions.A hybrid composite was fabricated using pineapple fibre as reinforcement and waste plastic particles as filler, aiming to improve resistance to water absorption.Composites with varying fibre and filler proportions were prepared and tested in accordance with ASTM standards.Statistical evaluation using analysis of variance (ANOVA) indicated that pineapple fibre content exerted the most significant influence on water absorption (p < 0.001), followed by waste plastic content (p = 0.005), whereas the chemical surface treatment showed minimal impact (p = 0.083).The combination of 5% pineapple fibre, 15% waste plastic, and sodium hydroxide treatment yielded the lowest water uptake over both 4 hr and 24 hr immersion periods.These results highlight the potential of incorporating recycled plastic as effective filler for producing moisture-resistant, sustainable composites.The findings can guide the development of eco-friendly materials for use in applications such as construction panels, automotive parts, and other components requiring enhanced durability in moist environments.
Autonomous UAV Swarms: Innovations and Applications S. Suresh, D. Velmurugan, N. Vasudevan, D. Surekha Rathi Samundi, R. Elayaraja Innovations and Developments in Unmanned Aerial Vehicles, 2025 Autonomous UAV swarms are transforming automation, collaboration, and data-driven decision-making in Industry 5.0. This chapter explores their innovative applications, underscoring their impact on efficiency, adaptability, and safety across sectors. In manufacturing, UAV swarms streamline inventory management, conduct inspections, and optimize supply chains, boosting productivity. In agriculture, they enable precision farming through real-time crop monitoring, soil analysis, and pest control. In construction, UAV swarms facilitate site mapping, progress tracking, and safety inspections. In logistics, they enhance last-mile delivery, warehouse operations, and traffic monitoring. These applications illustrate how UAV swarms advance Industry 5.0's vision of seamless, intelligent systems, fostering interconnected and adaptive industrial ecosystems.
Wear and erosion performance of metal mesh-reinforced natural fiber hybrid composites—a critical review Elayaraja R, Rajamurugan G Materials Research Express, 2025 Composites made of natural fibers and polymers are a new, environmentally friendly option for many industrial and construction processes, including those in the transportation, aerospace, marine, and civil engineering industries. They are attractive options for lightweight structural components due to their intrinsic qualities, which include low density, biodegradability, and cost-effectiveness. The development of micro-cracks, moisture sensitivity, and weak fiber-matrix adhesion limit their practical use in situations prone to wear and erosion because these factors decrease their durability and reliability. Mesh reinforcements made of metals like stainless steel, copper, or aluminum are becoming more popular as a solution to these problems. Mechanical and tribological properties are improved when metallic meshes are embedded in the composite matrix. This occurs because the meshes improve interfacial bonding, promote uniform stress transfer, and effectively control fracture propagation. Adding nanoscale reinforcements, which have self-lubricating and crack-arresting properties, can further improve the material by creating synergistic strengthening at different sizes. Important design aspects, including as the mesh arrangement, fiber orientation, stacking sequence, and hierarchical interaction amongst reinforcements, determine the extent to which performance is improved. Recent advances in the study of fiber-metal mesh hybrid composites’ tribological and erosional behavior are examined in this review, which aims to shed light on the main processes involved, including fiber pull-out, matrix cracking, crack bridging, and load transfer over metallic networks. The study also details future directions involving hybrid multi-scale designs, engineered fiber-mesh interfaces, and predictive modeling strategies to achieve superior and long-lasting tribological performance, and it highlights their potential applications in high-performance sectors like braking systems, marine components, protective coatings, and structural reinforcements.
Effect of thermal treatment on the mechanical behaviour of 3D-printed carbon fiber-reinforced PLA bioplastic S Suresh, D Velmurugan, J Balaji, PM Gopal, R Elayaraja, S Sudhagar Journal of Elastomers and Plastics 58 (4), 746-766 , 2026 2026 Citations: 1
Ballistic and drop-weight impact response of SS304 metal mesh embedded woven flax/hemp fiber hybrid composites R Elayaraja, G Rajamurugan Scientific Reports 16, 15835 , 2026 2026 Citations: 1
Reinforcement of a novel woven pineapple yarn and wire mesh on natural fiber hybrid composite E Radhakrishnan, R Govindasamy Textile Research Journal 96 (3-4), 369-378 , 2026 2026 Citations: 10
Sustainable Recycling of EDM Wire Waste on Nylon Mesh in Carbon Fiber Composites for a Circular Economy G Rajamurugan, R Elayaraja, P Krishnasamy, GS Sur, A Paba Fibers and Polymers, 1-13 , 2026 2026 Citations: 1
Architectural Hybridization of Natural Fibers With SS304 Wire Mesh for Superior Interlaminar Integrity R Elayaraja, G Rajamurugan Polymer Composites , 2026 2026
Weaving Architecture‐Driven Changes in Mechanical, Vibration and Acoustic Behaviour of Metal Mesh Embedded Natural Fiber Hybrid Composite R Elayaraja, G Rajamurugan Polymers for Advanced Technologies 37 (1), e70489 , 2026 2026 Citations: 3
Wear and Erosion Performance of Metal Mesh-Reinforced Natural Fiber Hybrid Composites-A Critical Review R Elayaraja, G Rajamurugan Materials Research Express , 2025 2025 Citations: 2
Precision Agriculture with Unmanned Aerial Vehicles S Suresh, S Boopathi, R Elayaraja, D Velmurugan, R Selvapriya Optimizing AI Applications for Sustainable Agriculture, 513-534 , 2025 2025
Mechanical and dynamic performance of stainless steel and nylon mesh reinforced hybrid kevlar/glass fiber composites G Rajamurugan, R Elayaraja, A Paba, S Singh, VV Singh, MA Murugan Engineering Research Express 7 (3), 035541 , 2025 2025 Citations: 5
Utilizing woven flax/hemp yarn on SS304 wiremesh reinforced flax fiber composites for tribological applications R Elayaraja, G Rajamurugan Results in Engineering 27, 105909 , 2025 2025 Citations: 8
Metal additive manufacturing: revolutionizing production in the digital age R Elayaraja Machining and Tribology of Advanced Materials: From Coatings, Lubrications … , 2025 2025
The Integration of Augmented and Virtual Reality in Modern Manufacturing S Subramanian, B Sampath, DPE Loganathan, E Natarajan, ... Manufacturing Strategies and Systems, 156-173 , 2025 2025 Citations: 6
Strategic enhancement of joint strength in dissimilar Al/Mg alloys: a workable approach for aerospace application S Suresh, E Natarajan, K Markandan, S Sudhagar, G Anbuchezhiyan, ... Discover Materials 5 (1), 23 , 2025 2025 Citations: 11
Improving Composite Joints with Nanoparticles Through Friction Stir S Suresh, J Balaji, D Velmurugan, E Natarajan Advances in Materials and Manufacturing Processes for Composite Applications … , 2025 2025
Autonomous uav swarms: Innovations and applications S Suresh, D Velmurugan, N Vasudevan, DSR Samundi, R Elayaraja Innovations and Developments in Unmanned Aerial Vehicles, 95-128 , 2025 2025 Citations: 4
Investigating the Moisture Absorption Characteristics of a Composite Material Produced from Waste Plastic Filled with Pineapple Fibre Reinforcement M Babu, R Elayaraja, S Suresh, V Sugan 2025 Citations: 4
Mechanical and dynamic response of epoxy based pineapple/flax fiber composites reinforced with steel and nylon wire meshes G Rajamurugan, P Raja, Ramakrishnan, P Krishna, J Raj, R Elayaraja Engineering Research Express 6 (4), 045557 , 2024 2024 Citations: 10
Recent development and efficacy of wire mesh embedded natural fiber composite-a review R Elayaraja, G Rajamurugan Results in Engineering 24, 103141 , 2024 2024 Citations: 16
Performance of hybrid composites fabricated by flax/hemp fibers using wire mesh plain weaving techniques R Elayaraja, G Rajamurugan Fibers and Polymers 25 (12), 4873-4883 , 2024 2024 Citations: 19
Mechanical and tribological performance of ramie composite reinforced with perforated Al/Cu foils G Rajamurugan, R Athithya, P Krishnasamy, A Nadeem, L Kavinkumar, ... Engineering Research Express 6 (3), 032501 , 2024 2024 Citations: 16
MOST CITED SCHOLAR PUBLICATIONS
Performance of hybrid composites fabricated by flax/hemp fibers using wire mesh plain weaving techniques R Elayaraja, G Rajamurugan Fibers and Polymers 25 (12), 4873-4883 , 2024 2024 Citations: 19
Recent development and efficacy of wire mesh embedded natural fiber composite-a review R Elayaraja, G Rajamurugan Results in Engineering 24, 103141 , 2024 2024 Citations: 16
Mechanical and tribological performance of ramie composite reinforced with perforated Al/Cu foils G Rajamurugan, R Athithya, P Krishnasamy, A Nadeem, L Kavinkumar, ... Engineering Research Express 6 (3), 032501 , 2024 2024 Citations: 16
Characteristics, applications and processing of aluminium foams–A review J Dineshkumar, T Jesudas, R Elayaraja Materials Today: Proceedings 42, 1773-1776 , 2021 2021 Citations: 14
Strategic enhancement of joint strength in dissimilar Al/Mg alloys: a workable approach for aerospace application S Suresh, E Natarajan, K Markandan, S Sudhagar, G Anbuchezhiyan, ... Discover Materials 5 (1), 23 , 2025 2025 Citations: 11
Experimental investigation of prosopis juliflora and mango tree with epoxy resin R Elayaraja, R Sasikumar, M Gokul, T Gowrisankar IOP Conference Series: Materials Science and Engineering 923 (1), 012050 , 2020 2020 Citations: 11
Reinforcement of a novel woven pineapple yarn and wire mesh on natural fiber hybrid composite E Radhakrishnan, R Govindasamy Textile Research Journal 96 (3-4), 369-378 , 2026 2026 Citations: 10
Mechanical and dynamic response of epoxy based pineapple/flax fiber composites reinforced with steel and nylon wire meshes G Rajamurugan, P Raja, Ramakrishnan, P Krishna, J Raj, R Elayaraja Engineering Research Express 6 (4), 045557 , 2024 2024 Citations: 10
Utilizing woven flax/hemp yarn on SS304 wiremesh reinforced flax fiber composites for tribological applications R Elayaraja, G Rajamurugan Results in Engineering 27, 105909 , 2025 2025 Citations: 8
Performance and emission characteristics of a naturally aspirated direct injection diesel engine fuelled with Calophyllum Inophyllum (Punnai) methyl ester L Periyannan, D Subramaniam, P Saravanan, R Elayaraja, A Murugesan International Journal of Ambient Energy 43 (1), 3638-3644 , 2022 2022 Citations: 8
Performance analysis of EDM parameters on silicon nitride-titanium nitride composite for improving geometrical tolerances: An integrated GRA-RSM approach L Selvarajan, R Sasikumar, R Elayaraja, TS Senthilkumar, R Rajavel, ... Journal of the Chinese Institute of Engineers 47 (4), 430-441 , 2024 2024 Citations: 7
The Integration of Augmented and Virtual Reality in Modern Manufacturing S Subramanian, B Sampath, DPE Loganathan, E Natarajan, ... Manufacturing Strategies and Systems, 156-173 , 2025 2025 Citations: 6
Mechanical and dynamic performance of stainless steel and nylon mesh reinforced hybrid kevlar/glass fiber composites G Rajamurugan, R Elayaraja, A Paba, S Singh, VV Singh, MA Murugan Engineering Research Express 7 (3), 035541 , 2025 2025 Citations: 5
Additive Manufacturing for a Sustainable Production: Materials, Processes, and Impact S Suresh, E Natarajan, S Sudhagar, S Boopathi, R Elayaraja Futuristic Technology for Sustainable Manufacturing, 1-16 , 2024 2024 Citations: 5
Autonomous uav swarms: Innovations and applications S Suresh, D Velmurugan, N Vasudevan, DSR Samundi, R Elayaraja Innovations and Developments in Unmanned Aerial Vehicles, 95-128 , 2025 2025 Citations: 4
Investigating the Moisture Absorption Characteristics of a Composite Material Produced from Waste Plastic Filled with Pineapple Fibre Reinforcement M Babu, R Elayaraja, S Suresh, V Sugan 2025 Citations: 4
Weaving Architecture‐Driven Changes in Mechanical, Vibration and Acoustic Behaviour of Metal Mesh Embedded Natural Fiber Hybrid Composite R Elayaraja, G Rajamurugan Polymers for Advanced Technologies 37 (1), e70489 , 2026 2026 Citations: 3
Wear and Erosion Performance of Metal Mesh-Reinforced Natural Fiber Hybrid Composites-A Critical Review R Elayaraja, G Rajamurugan Materials Research Express , 2025 2025 Citations: 2
Advanced Joining Methods for Lightweight Materials in Sustainable Manufacturing S Suresh, D Velmurugan, J Balaji, S Sudhagar, R Elayaraja Futuristic Technology for Sustainable Manufacturing, 17-36 , 2024 2024 Citations: 2
Effect of thermal treatment on the mechanical behaviour of 3D-printed carbon fiber-reinforced PLA bioplastic S Suresh, D Velmurugan, J Balaji, PM Gopal, R Elayaraja, S Sudhagar Journal of Elastomers and Plastics 58 (4), 746-766 , 2026 2026 Citations: 1