Perforation Energy Research Articles

Failure analysis of additively manufactured AuxHex and hierarchical honeycomb-core sandwich panels subjected to projectile impact

Honeycomb sandwich panels (HSPs) are extensively employed across various industries owing to their outstanding strength and capacity for energy absorption. Despite their widespread use, the potential of additively manufactured (AM) honeycombs in ballistic protection remains relatively unexplored. This study aims to comprehensively assess the energy absorption performance of two distinct HSP configurations, namely AuxHex and Hierarchical, through high-velocity impact tests spanning velocities ranging from 220 to 270 m/s. The high-velocity impact experiments are conducted using a single-stage pneumatic gun, complemented by simulations executed via Abaqus/Explicit. Our findings reveal that the hierarchical HSP demonstrated a notable 9.6 % enhancement in energy absorption compared to panels featuring an AuxHex honeycomb. Interestingly, the hierarchical panels also necessitated 4.8 % more energy for perforation. In terms of failure mechanisms, both sheets of the HSPs experienced ductile shearing, with the formation of characteristic petal-like structures. Concurrently, the honeycomb core underwent fragmentation on the side facing the projectile, while plugs were ejected from the back sheet. Moreover, our analysis indicates that the residual deflection of the back sheet surpassed that of the striking sheet by 15–20 %. This disparity can be attributed to prolonged contact duration and variations in interaction forces between the sheets. Overall, this investigation provides valuable insights into the energy absorption capabilities of AM honeycomb-based HSPs under high-velocity impact conditions, shedding light on their potential for enhanced ballistic protection in various applications.

A comprehensive analysis of low velocity impact response of [0/±45/90]s thin woven GFRP composites at room temperature

This study is motivated by the need to explore the low-velocity impact behavior of angle-ply thin woven GFRP composites with stacking sequence of [0/±45/90]s, especially the lack of literature concerning damage analysis correlation with a comprehensive range of measurements. The damage diameter, area, and perimeter length are characterized in this study by a novel AutoCAD image processing technique. The test results revealed that specimens subjected to impact energies in the range of 2–30 J are free from edge delamination compared to those tested at 40–50 J. Decreasing the contact duration at impact energy of 60 J is due to perforation accompanied with damage propagation toward the specimen edges and thus, the contact force is sharply dropped from its maximum value of about 4.48kN to 1.3kN. Consequently, both rebound speed and coefficient of restitution dropped to zero. The direct measurement of the energy threshold is increased in the following order: energy threshold at Fmax (2.3–14.9 J), first penetration (load drop) after peak load (23.9–25.6 J), penetration energy threshold (37.9 J), perforation energy threshold (31.1 J), and perforation and crack propagation energies (43.3 J). The perimeter length represents a novel damage parameter, exhibiting a strong correlation with impact energy, as evidenced by a high coefficient of determination of 0.97.

Improving the impact performance of natural fiber reinforced laminate through hybridization and layup design

There is growing interest in Natural Fiber Reinforced Polymer (NFRP) composites for structural components despite their lower mechanical performance than synthetic composites such as Glass Fiber Reinforced Polymer (GFRP) composite. This study demonstrates significant improvement in impact resistance of NFRP-GFRP hybrid laminates can be achieved through the integration of laminate layup design with interlaminar hybridization. By placing more GFRP plies near the top and bottom of the hybrid laminate while reducing the occurrence of neighbouring GFRP-GFRP plies and neighbouring NFRP-NFRP plies around the centre of the laminate, the impact resistance of the hybrid laminate can be significantly improved and even surpass GFRP laminates. On top of stacking sequence of plies, the impact resistance of the hybrid laminates can be further improved by introducing a bio-inspired helicoidal layup. The result shows that with 30 wt% GFRP plies and 70 wt% NFRP plies, the perforation energy of NFRP-GFRP hybrid helicoidal laminate outperforms both the plain GFRP and plain NFRP laminates by 11.7% and 143.8%, respectively, whereas the peak load of the hybrid helicoidal laminate subjected to impact is also comparable to the plain GFRP laminate.

Mechanical Properties of Luffa Fiber Reinforced Recycled Polymer Composite

Environmental issues over the eventual fate of post-consumer polymers can be dealt with in two separate ways which is recycling or using biodegradable polymers. However, it is evident that recycling polymers from post-consumer polymers can decrease the mechanical properties over time. Hence, to strengthen the recycled polymers, integrating fibers, such as luffa, into the High-Density Polyethylene (HDPE) matrix, was carried out to produce a fiber reinforced recycled polymer (FRrP) composite. The tensile testing of the FRrP composite shows that the 10% fiber volume fraction (FVF) composite exhibits a higher tensile strength of 3.9% than the neat recycled HDPE (RHDPE). In terms of Young’s Modulus, the 5% FVF of FRrP is shown to have a higher value than the neat RHDPE by 54%. The low density of luffa fibers also contributes to the composites lightweight character. The impact testing shows that the FRrP enhances the impact properties when compared to the neat RHDPE. The peak load, perforation energy, and the total energy absorbed by the FRrP indicate an increasing trend when luffa, of up to 15% FVF, is added as the reinforcement. Thus, the addition of luffa as reinforcement in RHDPE shows significant potential as a high-performance, sustainable, and environmentally friendly material, such as automotive parts and protective gear.

Ballistic resistance of a novel re-entrant auxetic honeycomb under in-plane high-velocity impact

Due to their high load-bearing capacity and excellent energy dissipation properties, metal honeycomb lightweight sandwich panels are commonly utilized as highly efficient weight-saving components in the automotive, aerospace, and military industries. Especially the auxetic honeycomb sandwich panels have higher yield strength, more robust shear modulus, fracture toughness, less fatigue expansion, and higher vibration and energy absorption. In this paper, the ballistic resistance and energy absorption mechanisms of a novel re-entrant auxetic honeycomb (RSH) sandwich panel are investigated. The ballistic limits and energy absorption of the re-entrant star-shaped honeycomb (RSH), star-shaped honeycomb (SSH), and re-entrant star-shaped honeycomb (RH) sandwich panels are compared and analyzed, as well as the deformation mechanism during projectile penetration. The results show that the RSH sandwich panel has the best in-plane ballistic performance among the three types of honeycomb sandwich panels. For the same relative density, the ballistic limit of the RSH sandwich panel is 17.4% and 7.1% higher than that of the SSH and RH sandwich panels respectively. In addition, the effects of different design parameters on the ballistic resistance of RSH sandwich panels are investigated by changing the panel thickness, the relative density of the core layer, the cell angle and the cell size. It can be concluded that increasing the thickness of the face sheet is more effective in improving the ballistic limit (perforation energy) of the RSH with a thinner core layer. However, increasing the relative density of the core layer is more effective in enhancing the ballistic limit (perforation energy) for thicker core layers. Cell size has a significant effect on the ballistic resistance of RSH sandwich panels compared to cell angle, especially at impact velocities close to the ballistic limit.

High‐velocity ballistic response of AA 1100‐H14 based carbon‐fiber metal laminates: An experimental investigation

AbstractA detailed experimental investigation was carried out for the high‐velocity ballistic response of AA 1100‐H14 based carbon‐fiber metal laminates (FMLs). FMLs with different metal volume fractions and the same thickness of carbon‐epoxy fiber laminates were tested to examine the surface and internal damage. The ballistic performance parameters, namely % escalation in absorbed energy, specific energy absorbed, ballistic limit, specific perforation energy, first cracking energy, and global deformation profile, were studied and a comparison was drawn with pure carbons fiber reinforced epoxy composite laminates. Despite having greater thickness, pure carbon fiber‐reinforced epoxy composite laminates absorbed less impact energy than FMLs and failed catastrophically. For FMLs, the % escalation in the absorbed energy and the specific energy absorption kept increasing with the increasing impact velocity until the onset of perforation. Once the perforation started, both these parameters showed a decreasing trend. Thick FMLs absorbed a good amount of energy, leading to projectile recoil suffering minimal damage. The ballistic velocity, specific perforation energy, and first cracking energy on the front and rear face of FMLs layers showed an increasing trend. The minimum for the thinner and maximum for the thicker FMLs attributed to the large thickness and more metal volume fraction. Contrary to the large deformation of the impacting points, pure carbon fiber‐reinforced epoxy composite laminates showed very minimal deformation as compared to FMLs. The brittle nature of the epoxy resin resisted the deformation to a large extent leading to less energy absorption.Highlights High‐velocity ballistic response of AA 1100‐H14 based carbon‐FMLs was investigated. Ballistic performance parameters of FMLs were studied and was compared with carbons fiber reinforced composite laminates. The ballistic limit of FMLs showed a direct dependence its thickness and metal volume fraction. In the absence of any metallic layer, pure carbons fiber reinforced composite laminates absorbed less impact energy.

Experimental investigation on impact behavior of curved sandwich composites with chiral auxetic core

The purpose of this study is to evaluate and compare the capability of impact energy absorption of the sandwich panels with various chiral auxetic cores. To this end, flat and curved panels were subjected to impact testing at varying energy levels. Glass fiber-reinforced epoxy composites and PLA material were used as the skins and core of the examined sandwich panels, respectively. The face sheets were produced by the hand-layup method and the auxetic cores with tetrachiral, anti-tetrachiral, and hexachiral configurations were printed using a 3D printer. The wall thickness, node diameter, and ligament length of the cells, as well as the core thickness, were kept constant for all the studied core structures. Flat and curved sandwich panels were obtained by combining the skins and cores produced in flat, 100 mm, 125 mm, and 160 mm radii of curvature with the epoxy used in skin production. Drop weight tests were carried out at impact energies of 10, 25, and 80 J. The contribution of the auxetic core configuration and panel curvature to the impact behavior of the sandwich panel was evaluated by examining the relationships between contact forces and deflection and by the analysis of the energy absorption and failure mode. The comparative evaluations showed that the auxetic core structure and the curvature of the panel have a significant effect on the impact properties of the sandwich panels. It was also observed that the use of tetrachiral cores could be the ideal design option for flat panels loaded at the perforation energy level. For curved panels, it was determined that the use of a hexachiral core configuration was advantageous in terms of more energy absorption capability, while the use of an anti-tetrachiral core structure was more effective in terms of specific energy absorption.

Numerical investigation of projectile impact behavior of hybrid fiber-reinforced concrete slabs

In our earlier study, the impact resistance of slabs made up of concrete containing hybrid fibers (i.e., steel and synthetic fibers in various proportions) was evaluated through an experimental program. The test specimens, measuring 600 × 600 × 90 mm, were cast with varying amounts of fibers, while some were kept as control samples without any fibers. The high-velocity impact tests were conducted using a gas-gun system, where hemispherical steel projectiles were fired at the slabs. The craters’ sizes and penetration depths were measured. The hybrid fibers in the concrete reduced spalling and scabbing damage and reduced the size of craters. In the current study, the impact response of the hybrid fiber-reinforced concrete (HFRC) slabs was investigated numerically. LS-DYNA software was employed for this investigation, and crack sizes, areas of spalling and scabbing damages, and penetration depths were estimated. The numerical simulations provided an efficient and practical tool for analyzing the HFRC slabs’ response against impact load. The use of hybrid fibers decreased front surface damage and prevented concrete particles from flying out of the back face. The inclusion of fibers in concrete increased the perforation energy by 49%–203%. The numerical predictions of penetration depth were reasonably close, with absolute errors varying from 3.6%− 32.6%, and the error in the prediction of maximum rebar strain varied from 2.5% to 12.7%. The presented model thus has the capability to predict the local damages of various types of RC and HFRC slabs with acceptable accuracy.

Determination of Energy Absorption Capabilities of Shear Thickening Fluid Impregnated Aramid Fiber Fabrics for Ballistic Applications

Low velocity impact behavior of shear thickening fluid (STF) impregnated aramid fabric having different number of layers had been investigating throughout this study to determine a relationship between number of layers and perforation energy. Firstly, STF solutions including polyethylene glycol, silica nanoparticles and ethanol were prepared by mixing a homogenizer. Solutions containing 20% silica nanoparticles by weight were used in this study. Rheological analysis was performed to observe thickening behavior of solution. After thickening behavior and critical shear rate was determined from rheological analysis, solution was impregnated into aramid fabric. Then, specimens having different number of layers from 1 to 8 were prepared for low velocity impact experiments. A drop weight impact test was applied at different energy levels and perforation energy was determined. Finally, a curve fitting equation was found to use it for potential energy absorption applications such as ballistic impact.

The influence of composite core thickness on the perforation resistance of titanium-based FMLs

Fibre metal laminates (FMLs) have been widely used as structural materials in aerospace applications due to their superior properties compared to traditional fibre reinforced composites. FMLs are hybrid materials consisting of alternating sheets of metal and plain composite. The aim of this study is to investigate the impact response of FMLs that have potential applications in the next generation of aircraft. Here, the influence of the thickness of the composite core in a 2/1 (metal/composite/metal) titanium alloy-based fiber metal laminate were investigated under low velocity impact conditions. It is shown that increasing the thickness of the composite core resulting in higher values of impact force and absorbed energy. The FMLs offered a much higher specific perforation energy than that offered by the plain composite for a given thickness of composite core.Explicit finite element (FE) models were developed to predict the response of the laminates under low velocity impact loading, which were then validated by comparing the numerical predictions with the corresponding experimental results. The resulting FE predictions showed good agreement with the experimental data in terms of the load-displacement trace, peak impact force, absorbed energy and perforation mechanisms.

Effect of graphene oxide fibre surface modification on low-velocity impact and fatigue performance of flax fibre reinforced composites

Fatigue and impact resistance are essential performance indicators in structural biocomposites. Integrating multilayer and oxygen-rich graphene oxide (GO) crystals as a fibre surface modification or reinforcing agent in polymer matrix systems have been shown to enhance the interfacial strength and toughness of natural fibre composites. However, the state-of-the-art literature on the GO-modification of composites has focused mainly on their microscale and quasi-static mechanical performance. Here, the fatigue testing results showed that surface modification of flax fibres with GO reduces the slope of the S-N curve by 17% and promotes fibre pull-outs upon failure. Based on the in-situ impact damage analysis, the GO-modification delayed the impact damage initiation and prolonged the stable damage progression phase. The impact perforation energy was similar for modified and unmodified specimens. At kinetic energies below the perforation limit, the GO-modification suppressed the extent of fibre failure and endowed flax-epoxy specimens with better damping performance.

Ballistic impact response of elastomer-retrofitted corrugated core sandwich panels

The ballistic impact resistance of metallic corrugated sandwich panels retrofitted with elastomeric coating (polyurea) is investigated through combined experimental and numerical efforts. Dynamic penetration process, failure mechanisms, ballistic limit velocity, and perforation energy threshold of polyurea-coated sandwich panels are firstly elucidated via experiments and then compared with those of non-coated sandwich panels. Subsequently, based upon a user-defined compressible model of polyurea, three-dimensional finite element (FE) simulations of both non-coated and coated sandwich panels are carried out to analyze the ballistic impact response, interrogate the energy absorption mechanisms, and assess the influence of coating position/thickness and projectile rigidity on ballistic performance. Excellent agreement between experimental measurements and numerical predictions is achieved. It is demonstrated that the presence of a sufficiently thick (e.g., ∼15 mm) impact-side elastomeric coating helps to curtail the kinetic energy of flat-ended projectiles, thus enhancing the penetration resistance considerably. The use of a thicker and impact-side coating is favored owing to its superior energy absorption capability. It is also ascertained that the effectiveness of polyurea coating in resisting rigid, flat-ended projectiles is much more remarkable relative to deformable, conical ones. Further, retrofitting an all-metallic sandwich panel with elastomeric coating broadens its multifunctionality significantly, enabling it to simultaneously carry structural loads, mitigate impact and blast loadings, and resist projectile penetration, at a minimal increase in fabrication cost and structural mass. The insights of this study provide a potential new avenue for enhancing the ballistic impact resistance as well as multifunctional attributes of all-metallic sandwich construction.

Prediction of Ballistic Limit of Strengthened Reinforced Concrete Slabs Using Quasi-Static Punching Test

The formulas available in the literature for predicting the projectile impact response of reinforced concrete (RC) targets are generally developed based on the results of impact tests. Recently, however, in order to avoid performing involved and challenging projectile impact tests, the impact response of RC targets was predicted using the quasi-static punching response of RC slabs. In this paper, the concept is extended to concrete slabs strengthened with textile-reinforced mortar (TRM) or carbon fiber-reinforced polymer (CFRP) sheets externally bonded to the concrete surface. In 16 groups, 96 slabs of 600 × 600 × 90 mm size were cast and tested under quasi-static and impact loads. The slabs were reinforced with two types of reinforcement: ϕ8@100 mm and ϕ4@25 mm. The singly and doubly reinforced concrete slabs with rebar spacing of 100 mm were strengthened using externally bonded CFRP and TRM on the back side of the slab specimens. Two mixes of concrete, representing normal and high-strength concretes, were used. The results of the present study reveal that the CFRP and TRM strengthening of RC slabs enhanced the energy absorption in punching by 57–130% and 20–59%, respectively. The use of WWM in singly and doubly reinforced slabs also resulted in a 30–42% and 41–63% increase in energy absorption in punching, respectively. An earlier proposed model was modified to incorporate the influence of strengthening (CFRP and TRM) in the estimation of the projectile perforation energy of the strengthened RC slabs with the help of energy absorbed in their quasi-static punching. This perforation energy was then employed for predicting the ballistic limit of CFRP- and TRM-strengthened slabs. The predictions show good agreement with the experimentally observed ballistic limits.

Mechanics of ballistic impact with non-axisymmetric projectiles on thin aluminium targets. Part II: Energy considerations

In Part I of this study, the ballistic performance and failure mechanisms of a thin aluminium target impacted by plate-like, non-axisymmetric projectiles with three different geometries, were considered using the gas-gun experiments. Failure mechanisms of the target material were found to depend strongly on the projectile’s geometrical features. Also, the local target’s response was not a reliable predictor of the critical kinetic energy for perforation or penetration. In order to improve the prediction of ballistic performance of thin targets, a nonlocal target behaviour should also be accounted for. In this part of the study, the global target response is examined, and a heuristic approach is introduced for the energy balance. The approach involves a new factor that represents additional energy-dissipating mechanisms between the projectile’s critical energy and the local work in target defeat. The methodology is based on the identified strong correlation of the normalised impact-induced peak kinetic energy in the target, KE¯Tmax, and the normalised target impact-induced nonlocal internal energy, U¯TPL+KE, associated with plastic deformation and increase in kinetic energy. A physically-based semi-analytical formulation for KE¯Tmax is developed by decomposition of the contributions by the inclined and blunt projectile sections, succeeding statistical analysis of key projectile’s geometrical and impact parameters. The developed approach was assessed for 17 projectile geometries implementing a total of 119 finite-element simulations with experimentally validated numerical models at subcritical (50) and critical/supercritical (69) projectile velocities. The obtained predictions had an average absolute error of less than 6.5% for impact velocities at and above the ballistic limit, while at subcritical velocities a higher scatter was observed as a result of secondary interaction effects between the projectile and the target. Overall, the methodology yielded results for the ballistic limit with an error below 5%, improving the otherwise derived results nearly twofold. The method was proven to be a practical and accurate way to improve the projectile’s critical energy prediction for thin targets, and, even though developed for non-axisymmetric projectile cases, its framework is directly transferable to axisymmetric projectiles.

Fibre–Wood Laminate Biocomposites: Seawater Immersion Effects on Flexural and Low Energy Impact Properties

The present paper explores a new concept of a hybrid eco-composite by substituting the natural fibre plies with thin wood veneers. The new composite, named Fibre–Wood Laminate (FWL), is inspired by fibre–metal laminate materials. The studied FWL configuration consisted of a single thin pinewood veneer at each of the outer layers of a flax woven fabric reinforced bio-epoxy composite manufactured by infusion. Three-point bending results showed that wood veneer gives a highly anisotropic nature to the FWL. In the best case, with the grain of the wood at 0°, the stiffness and the strength increased by 28 and 41%, respectively, but reduced the strain-at-break by 27% compared to the flax fibre reinforced bio-epoxy (FFRB). The penetration and perforation energy thresholds and the peak force of the FWL obtained by falling weight impact tests were 32, 29, and 31% lower than those of the FFRB, respectively. This weakening was due to using single wood veneers, so the challenge for improving impact properties will be to explore thicker FWLs with different stacking sequences and orientations. The effect of immersing the FWL in seawater also showed considerable differences. The epoxy matrix filled the cellular structure of the wood veneers, creating a barrier effect and reducing the amount of water absorbed by the flax fibres.

Experimental study on the behaviour of grid-scored foam-cored sandwich composites under low-velocity and quasi-static punch shear loads

Grid-scored foams are core materials adapted to resin infusion systems used in marine vessels and aerofoil shell structures of wind turbine blades. Perforation resistance is critical in such constructions, and so the goal of this research is to analyse the energy absorption ability of sandwich composites with grid-scored foam core. Grid-scored foam contributed more to the energy absorption capacity of sandwich structures due to causing higher contact force compared with rigid foam under low-speed and quasi-static punch shear loads. At quasi-static punch shear tests, the energy absorption capability of grid-scored foams is more sensitive to test speed. Grid-scored foam improved the elastic energy absorption values of the sandwich structure under quasi-static punch shear tests. The perforation energy results obtained from the quasi-static tests of the grid-scored specimens showed a similar trend to the results obtained from the low-velocity impact tests. Compared with the damaged rigid-cored counterparts, grid-scored foam-cored sandwich specimens demonstrated higher damage tolerance in dynamic and static testing by limiting core crushing and face sheet-foam core delamination between resin channels.

Effect of Indenter Nose Shape and Layer Configuration on the Quasi-Static Perforation Behaviour of Metal-Plastic Laminates.

This study investigated the perforation resistance behaviour of metal–plastic laminates (MPLs) when they are indented by different nose shapes. Aluminium (Al) and HDPE (high-density polyethylene) layers were bonded with a suitable adhesive in an alternative manner to prepare bilayer and trilayer MPL configurations. Quasi-static perforation experiments were performed with hemispherical, conical and blunt indenters. The effects of nose shape, layer configuration and adhesive on the force–deformation profile, perforation resistance capacity and failure mechanisms were evaluated. The results indicate that for a monolithic layer, the blunt indenter showed the highest perforation energy capacity. The conical and blunt indenters facing Al backed by HDPE gave higher perforation energy. The hemispherical indenter facing HDPE backed by Al was found to be more effective in perforation resistance. Trilayer Al–HDPE–Al showed higher perforation resistance than HDPE–Al–HDPE. Circumferential cracking, radial symmetric cracking and shear plugging were the main failure modes for Al under hemispherical, conical and blunt indenters, respectively. The adhesive contributed to an increase in the perforation energy and peak force to failure in laminates. The adhesive was shown to detach from the Al surface after Al fracturing through crack propagation, and this effect was more pronounced when the indenter faced HDPE at the front of the laminate.

Impact and fatigue tolerant natural fibre reinforced thermoplastic composites by using non-dry fibres

This article introduces stiff and tough biocomposites with in-situ polymerisation of poly (methyl methacrylate) and ductile non-dry flax fibres. According to the results, composites processed with non-dry fibres (preconditioned at 50% RH) had comparable quasi-static in-plane shear strength but 42% higher elongation at failure and toughness than composites processed with oven-dried fibres. Interestingly, the perforation energy of flax–PMMA cross-ply composites subjected to low-velocity impact increased up to 100% with non-dry flax fibres. The in-situ impact damage progression on the rear surface of composites was evaluated based on strain and thermal field maps acquired by synchronised high-speed optical and thermal cameras. Impact-induced delamination lengths were investigated with tomography. Non-dry fibres also decreased the tension–tension fatigue life degradation rate of composites up to 21% and altered the brittle failure mode of flax–PMMA to ductile failure dominated by fibre pull-out.

Effect of ply blocking on the high-speed impact performance of thin-ply CFRP laminates

Although studies have shown ply blocking in carbon fiber reinforced polymers (CFRP) improves their resistance to fiber damage and affect their mechanical behavior under different loading conditions, the effect of ply blocking on high-speed impact of CFRP laminates is rarely investigated. Through a combined experimental and numerical study, it is shown that ply blocking significantly affects the ballistic limit and modes of damage of thin-ply CFRP laminates. Two competing mechanisms are observed - as the level of ply blocking increases, resistance to fiber damage increases but it becomes easier for projectiles to slip through between fibers of ply clusters at the back face of the laminates. Consequently, the perforation energy of laminates initially increases as the level of ply blocking increases. The increase in perforation energy peaks at 64%. With further increase in ply blocking, the perforation energy drops. Excessive ply blocking allows projectiles to slip through between the fibers without breaking them. A new laminate layup was designed to mitigate the effects of the various damage modes. Its perforation energy is measured to be twice that of laminates without ply blocking.

Melt-blown fiber mat interleaving enhances the performance of single-polypropylene composites

In this study, we demonstrate that integrating melt-blown fiber mat interleaves into single-polypropylene composites enhances several mechanical properties and influences the morphology positively. Polypropylene veils were generated by melt blowing. We then created single-polypropylene composites by film-stacking in which we applied a film as a matrix, a woven fabric as primary reinforcement, and the melt-blown fiber mats as interleaves. The tensile modulus was improved in the range of 20%–46%, and the interlaminar shear strength and the perforation energy at impact were increased by 17% and 14%, respectively, due to interleaving. Master curves were constructed from dynamic mechanical analysis frequency sweep tests based on the time–temperature superposition principle. The storage modulus significantly increased while the tanδ decreased. The interleaving considerably reduced the delamination by creating a net-like structure leading to superior interfacial adhesion. The interleaving demonstrated in this study can promote single-polymer composites’ utilization in various engineering applications where high toughness and impact resistance are required.