This study investigated the effect of the fusion-bonded dots of veil interleaves on the crack propagation path of the interlaminar fracture of continuous carbon fiber reinforced epoxy resin. Two thin fiber layers (i.e., nylon veil (NV) with fusion-bonded dots and Kevlar veil (KV) physically stacked by fibers) were used to toughen composites as interleaves. Result shows that the existence of fusion-bonded dots strongly influenced the crack propagation and changed the interlaminar fracture mechanism. The Mode I fracture path of the nylon veil interleaved composite (NVIC) could propagate in the plane where the dots were located, whereas the path of the Kevlar veil interleaved composite (KVIC) randomly deflected inside the interlayer without the pre-cracking of the dots. The improvement of Mode I toughness was mainly based on fiber bridging and the resulting fiber breakage and pull-out. Fiber breakage was often observed for NVIC, whereas fiber pull-out was the main mechanism for KVIC. For the Mode II fracture path, the fusion-bonded NV dots guided the fracture path largely deflected inside the interlayer, causing the breakage of tough nylon fibers. The fracture path of the physically stacked KVIC occurred at one carbon ply/interlayer interface and only slightly deflected at fiber overlapped regions. Moreover, the fiber pull-out was often observed.

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