Sandwich Panels Research Articles

High-temperature effect on continuous glass fiber reinforced polypropylene multilayer composite and corrugated sandwich panels

The high-temperature mechanical behaviors of Multi-Layer Composite Panels (MCP) and Corrugated Sandwich Panels (CSP) of Continuous Glass Fiber-Reinforced Polypropylene (CGFRPP) are critical for their application in aerospace fields, which have been rarely mentioned in previous studies. High-temperature quasi-static tensile and compression tests on CGFRPP MCP are conducted first. The results showed that the tensile and compression strength, stiffness, and tensile modulus of MCP decreased with increasing temperature. The Gibson model was found to be more suitable for predicting the high-temperature mechanical performance of MCP after comparing the calculated results of different theoretical models with experimental data. Secondly, high-temperature planar compression tests were conducted on the CGFRPP CSP, revealing that the main failure modes were corrugated core buckling and delamination between the face panel and core material, with delamination being intensified at higher temperatures. Therefore, we proposed a strength theoretical model that considers structural buckling failure and interface delamination failure, and introduced the influence factor to evaluate the effect of interface delamination on structural strength.

Analysis of composite honeycomb sandwich panels under blast loads

ABSTRACT This paper presents a novel isogeometric model to analyze the static bending, fre, and forced vibration characteristics of a sandwich of two-layer plates made of auxetic honeycomb core and laminated three-phase polymer/GNP/fiber skin subjected to a double blast load. The two layers are restricted from vertical movement by elastic pins but they can still move in the horizontal plane. The unique feature of the refined first-order shear plate theory with a distribution function g(z) is used to replace the shear correction factor, thereby allowing the shear stress at the top and bottom surfaces to be accurately calculated. The results are derived by the exact Navier solutions for rectangular plates and the IGA method with arbitrary boundary conditions for elliptical and rectangular plate structures. A comprehensive investigation was conducted to evaluate the influence of some parameters on the oscillation of sandwich two-layer plates subjected to double blast load.

Test methods for determination of shear properties of sandwich panels

This paper presents analysis and comparison of test methods for determining transverse shear strength and shear modulus of steel-faced sandwich panels commonly used in construction. The test methods are taken from the governing European standard EN 14509:2013. Two-point loading and four-point loading test methods as well as a full-scale test method are examined. Based on extensive experimental work on sandwich panels with varying core thickness, comprising mineral wool (MW) and polyisocyanurate (PIR) and encompassing both roof and wall panels, this study provides details of the test setup for the four-point loading and vacuum box methods with which a pure shear failure is obtained. Such details are missing from EN 14509. This paper highlights that the two-point loading method fails to consistently produce shear failure, especially in thicker panels, indicating it does not accurately measure transverse shear strength. The results of the experiments conducted in this study indicate that the four-point loading and full-scale test methods provide consistent shear failure for thicker panels while yielding greater transverse shear strength than the two-point loading test in general.

Enhancement of mechanical properties and machinability of aluminium composites by cupola slag reinforcements

AbstractRapid evolution in engineering and manufacturing demands light weight material with enhanced mechanical properties. Aluminium metal matrix composites with ceramic reinforcement particulates serve this demand due to their reduced density, improved strength and hardness along with higher resistance to wear and corrosion. However, the material cost and reduced machinability hinders the full potential of utilization. To overcome these challenges, in this work cupola slag, an industrial waste generated as by product of cast iron production, has been incorporated as reinforcement of aluminium composites using low cost stir casting method. The enhancement of material properties and machinability by cupola slag inclusion on base alloy has been investigated in detail. Moreover, introspection about the underlying mechanisms responsible for the improvement in material properties has been studied using detailed microstructure and fractographic analysis. The results show improvement of in material properties and machinability up to 7 wt.–% cupola slag inclusion, beyond which the reduced wettablity prohibits sound castings. The ultimate tensile strength and specific strength observed to be improved by 18.20 % and 33.23 % respectively for 7 wt.–% slag reinforced composites when compared with base alloy. This work can be a successful addition to the knowledge pool of ongoing research on low‐cost novel material with enhanced properties.

The Effect of Rubber-Metal Interactions on the Mechanical, Magneto-Mechanical, and Electrical Properties of Iron, Aluminum, and Hybrid Filler-Based Styrene-Butadiene Rubber Composites.

Multifunctional stretchable rubber composites are gaining attention due to their unique electrical, mechanical, and magnetic properties. However, their high production costs pose economic challenges. This study explores the use of cost-effective metal powders-iron, aluminum, and their 1:1 (vol/vol) hybrid filler-in styrene-butadiene rubber composites, varying from 10 to 20 vol%. The effects of these metal particles on the mechanical, electrical, morphological, and swelling properties were investigated. Metal particles generally act as non-reinforcing fillers but can significantly enhance the mechanical modulus, electrical, and magnetic properties based on the filler structure and the filler-rubber interactions. Iron-based composites exhibit significant electrical conductivity and excellent magnetic properties. Aluminum enhances the modulus, while the combination yields average mechanical properties with added magnetic characteristics. Iron demonstrates higher reactivity with sulfur-based crosslinking ingredients, adversely affecting the rubber matrix's crosslinks, as shown by swelling tests. This reactivity is attributed to iron's transition metal characteristics. At 20 vol%, iron-filled composites display the highest magnetic anisotropic effect on toughness (~25%) under a magnetic field by permanent magnets and excellent electrical conductivity (1.5 × 10-2 S/m). While iron significantly boosts the electrical and magnetic properties, higher filler amounts degrade the mechanical properties. These composites are currently suitable for electrical and smart mechanical applications, but incorporating reinforcing fillers could enhance their robustness for broader applications.

Topology optimization of adaptive sandwich plates with magnetorheological core layer for improved vibration attenuation.

In this study the optimum topology distribution of the magnetorheological elastomer (MRE) layer in an adaptive sandwich plate is investigated. The adaptive sandwich plate consists of an MR elastomer layer embedded between two thin elastic plates. A finite element model has been first formulated to derive the governing equations of motion. A design optimization methodology incorporating the developed finite element model has been subsequently developed to identify the optimum topology treatment of the MR layer to enhance the vibration control in wide-band frequency range. For this purpose, the dynamic compliance and density of each element are defined as the objective function and design variables in the optimization problem, respectively. The method of the solid isotropic material with penalization (SIMP), is extended for material properties interpolation leading to a new MRE-based penalization (MREP) model. Method of moving asymptotes (MMA) has been subsequently utilized to solve the optimization problem. The developed finite element model and design optimization method are first validated using benchmark problems. The proposed design optimization methodology is then effectively utilized to investigate the optimal topologies of the magnetorheological elastomer (MRE) core layer in MRE-based sandwich plates under various boundary and loading conditions. Results show the effectiveness of the proposed design optimization methodology for topology optimization of MRE-based sandwich panels to mitigate the vibration in wide range of frequencies.

Mineralogical Characterization and Geochemical Signatures of Supergene Kaolinitic Clay Deposits: Insight of Ropp Complex Kaolins, Northcentral Nigeria

This study presents the chemical and mineralogical composition of clay deposits and associated rock types within the Ropp Complex in order to assess the influence of parent lithology on the kaolinization, genesis, and utility of the deposit. Representative kaolin samples from E horizons of the weathering profiles and their bedrocks were collected from six sites in the Ropp Complex. Clay mineralogy was determined via the XRD technique, while a geochemical analysis was conducted using XRF, SEM coupled with EDS, and ICP-MS. The results showed that all kaolins dominantly contain kaolinite with a content of 77%–98% except for the AS1 kaolin with only minor kaolinite (20%) but mainly illite (65%). The notably lower crystallinity of kaolinite (HI value of 0.53–1.1) as well as its markedly small grain size is consistent with the formation of kaolinite from intensive chemical weathering of igneous rocks. The AS1 kaolin was probably formed from hydrothermal alteration in the burial stage due to the heating of groundwater by the late volcanism. Mobile trace elements (Sr, Ba, and Eu) exhibited a depletion trend, while immobile elements (Hf, Ta, Th) showed enrichment. The relatively more zirconium in kaolins implies the formation of low-temperature kaolinization. The notably high kaolinite content, accompanied by reasonable levels of Fe2O3 and TiO2, signifies a medium-grade quality. Furthermore, chondrite-normalized rare earth element (REE) patterns exhibit congruent trends in rocks and kaolin samples, indicating a relative enrichment in light rare earth elements (LREEs) alongside a discernible negative Eu anomaly. The abundant kaolinite and silicon–aluminum composition make the kaolins suitable for refractories, pharmaceutics, cosmetics, and supplementary cementitious material (SCM).

High Order Theory Approach for Debonded Sandwich Panels Part I: Formulation and Displacement Fields

High Order Theory Approach for Debonded Sandwich Panels Part I: Formulation and Displacement Fields

Structural performance of precast concrete sandwich panels with bolt-steel plate connection subjected to axial loading

A new precast concrete sandwich panel with glass fiber-reinforced polymer connectors was proposed, utilizing bolt-steel plate connections. A compressive experiment was carried out to investigate the performance. The main damage was concrete crushing in the bolt connection region, at the panel bottom, and above the joint. The connector type, solid concrete rib, slenderness ratio, and thickness affected the failure mode and bearing capacity. The use of GFRP connectors and solid concrete ribs enhanced the ultimate bearing capacity and stiffness of the panels while reducing the lateral deflection. Higher slenderness ratios leading to reduced axial bearing capacity and increased lateral deflection. Finally, the results of the existing empirical calculation formulae were compared with experimental ones, and they were overly conservative. A new formula for predicting the bearing capacity was proposed, and the difference percentages between the proposed formula and experimental results were −0.4 %–2.8 %, which was the most accurate prediction formula.

High Order Theory Approach for Debonded Sandwich Panels Part II: Energy Release Rate and Mode Mixity

High Order Theory Approach for Debonded Sandwich Panels Part II: Energy Release Rate and Mode Mixity

Low-velocity impact response of hybrid core sandwich panels with spring and strut cores filled with resin, silicone, and foam

Advancements in the load-bearing capacity of composite panels open doors to high-performance applications. The integration of additive manufacturing allows for the creation of intricate core designs effortlessly. Hybrid cores, combining structural elements with infill materials, play a crucial role in enhancing panel impact resistance while maintaining its low weight. This study compares sandwich panels incorporating spring and octet strut structural elements infused with different materials—silicon, foam, and epoxy resin—evaluating their energy absorption capabilities. Additive manufacturing is employed to produce these panels with structural elements then subsequently filled with infills. The drop tower test is utilized to experimentally assess panel behavior under low-velocity impact. Design of experiments and statistical analysis are used to examine the influence of core height, impact height, core geometry, and filling type on the damaged area and impactor penetration. Results showed that the strut-based structure performed better than other structures in preventing penetration, with a damaged area reduction from 501.45 to 301.58 m2 compared to the spring core. The addition of foam or silicon reduced the impact damage to the front and the back sheets, with silicon infills proving to be the most effective, reducing penetration by reducing penetration by about 60%. The depth of impact was measured, with results indicating that the truss core displayed the smallest specific depth of penetration. A decision tree model predicted that a sandwich panel with a spring core would have a 100% chance of perforation while a filled core showed a significantly reduced penetration risk.

Experimental and numerical investigation of shear strain and failure in sandwich panels with foam-core and jute/glass composite faces under 3-point bending

There is a growing demand for natural fibers related to cost and environmental issues. This work focuses on the influence of the stacking sequence and hybridization on the shear strain of sandwich panels with glass/jute composite faces and polyethylene terephthalate foam core. Behavior comparison followed analytical, experimental, and numerical approaches. Failure analyses of the panels were performed numerically using the finite element method, with progressive damage and Hashin failure criterion. Digital image correlation was used to examine total surface deformation. Results showed that the hybrids presented better overall mechanical properties.

Measurement of the water absorption on hybrid carbon fibre prepreg waste composite and its impact on flexural performance

Carbon fibre (CF) prepreg, essential to composites and aircraft, generates waste known as carbon fibre prepreg waste (CFW) due to its limited lifespan. This study investigates recycling CFW through hybridization, milling it into powder and mixing it with epoxy resin and alumina to form hybrid composites. Using Minitab software, optimal compositions were determined from 13 and 20 experimental designs for CFW-EP and CFW-EP-AL, respectively. Results identified 2.5 wt% CFW and 97.5 wt% epoxy resin as optimal for CFW-EP, and 2.5 wt% CFW, 2.5 wt% alumina, and 95 wt% epoxy resin as optimal for CFW-EP-AL. Samples of epoxy resin polymer (EP), carbon prepreg waste reinforced composite (CFW-EP), and carbon prepreg waste reinforced with alumina composite (CFW-EP-AL) were fabricated and tested for moisture absorption and flexural strength, revealing noticeable deterioration over time. These findings highlight the importance of compositional analysis in developing sustainable materials with optimal flexural strength for various applications.

Forced convection heat transfer in AlSi7Mg lattice structures fabricated by additive manufacturing

The thermal-hydraulic performance of lattice structures with different topologies and relative densities was investigated. AlSi7Mg sandwich panels cored with vertical fin, pyramidal, and tetrahedral lattices were fabricated using additive manufacturing. Four different relative densities (7.5 %, 10 %, 12.5 %, and 15 %) were considered for each lattice core. The experiment was conducted under constant heat flux and steady-state forced convection. Results showed that increasing relative density led to an increase in the average Nusselt number by 3.2–12.5 % in the vertical fin, 23.8–56.4 % in the pyramidal lattice, and 38.8–46.9 % in the tetrahedral lattice. To evaluate the efficiency of different topologies, the average Nusselt number was compared at a fixed pumping power. The pyramidal lattice exhibited the best performance among the test samples, followed by the tetrahedral lattice. The numerical analysis was performed to gain further insights into the heat transfer mechanisms involved. As the relative density increased, an increase in both the maximum fluid velocity and turbulent kinetic energy was observed in all test samples. The numerical results demonstrate that the observed improvement in thermal-hydraulic performance with increasing relative densities in experiments is attributable to the enhanced momentum of the fluid and turbulent mixing.

Experimental investigation of hybrid reinforced A356 aluminium alloy synthesised by stir casting technique

Abstract One of the most significant alloys to be employed in the automotive, aerospace, and military industries in recent years is A356 aluminium. Because of A356's excellent compatibility with other metals and nanoparticles, novel hybrid composites may be made using it. The characteristics of these hybrid composites are mostly the result of the additives' interaction with the A356 alloy's current elemental composition. Aluminium composites were synthesized through stir casting method by reinforcing 2%, and 4% SiC, 2% and 4 % Al2O3 and 0.5%, 1%, 1.5%, 2% and 2.5% SiC and Al2O3 both. The homogeneous distribution of SiC and Al2O3 microparticles in reinforced composite is revealed by scanning electron microscopy (SEM). The addition of SiC and Al2O3 reinforcements greatly improved the mechanical characteristics of the synthesised composites; for example, a composite with 4% SiC reinforcement reached its maximum hardness and maximum tensile strength of 165 HV and 257MPa respectively. Maximum elongation of 6.72 % was observed for 0.5% SiC and 0.5% Al2O3 reinforced composite. Minimum wear rate is observed for 4% SiC reinforced composite material. This study aims to identify gaps in the potential variations and compatibility of various additives with one another in order to create a brand-new hybrid reinforced alloy suitable for automotive braking system applications: brake rotors made of a disc or a brake pad, depending on the properties of the hybrid reinforced alloy that was made. Hence, the current work presented focuses on the preparation of hybrid reinforcement of A356 with silicon carbide and alumina powders.

Optimization of the thermoelectric performance of aluminum-doped zinc oxide-graphene heterojunctions under high temperature and high pressure

High-pressure effects can be used to effectively optimize the thermoelectric performance of wide-bandgap oxides. We build upon this finding to show that the synergistic effects of doping with aluminum and graphene composite give excellent thermoelectric performance under high pressure. By employing the parabolic band model, the Pisarenko curves are derived at different pressures, coupled with the band structure of Al-doped ZnO. An analysis indicates that pressure-induced narrowing of the bandgap in Al-doped ZnO reduces the electron excitation energy, thereby optimizing the electrical properties of the samples. The Debye Callaway model is also used to fit the lattice thermal conductivity of the samples, thus enabling an in-depth analysis of the phonon scattering mechanisms. Our analysis suggests that graphene composites significantly enhance point defect scattering and Umklapp scattering, thus increasing the phonon relaxation time and effectively reducing the lattice thermal conductivity of the samples. The improvement in the figure of merit (zT) of ZnO is attributed to the simultaneous enhancement of its electrical properties under high pressure and the synergistic optimization of reducing the lattice thermal conductivity through doping and composites. In this work, we consider a fixed doping ratio of Al and a constant proportion of graphene composite, and analyze the microstructure and thermoelectric properties of 0.1C–ZnAl0.04O (C–ZnAlO) samples synthesized under pressures ranging from 1 to 5 GPa, with the aim of elucidating the influence of pressure and graphene composite on the electro-acoustic transport properties of ZnO. We find that the zT value for a sample synthesized at 5 GPa is increased to 0.27 at 973 K.

Numerical Analysis of a Linear Quasi-Static and Vibrational Response of Gypsum Sandwich Panels Reinforced with Fiberglass Fabrics

Numerical Analysis of a Linear Quasi-Static and Vibrational Response of Gypsum Sandwich Panels Reinforced with Fiberglass Fabrics

Axial Impact Performances of Composite Aluminum Foam Tubes

An improved melt foaming method is employed to fabricate composite aluminum foam tubes (CAFTs) with varying diameter ratios, achieving metallurgical bonding between the aluminum foam and aluminum tubes. Based on the structural characteristics of aluminum foam‐filled tubes and traditional numerical formula for calculating the energy absorption properties of metal foams, a new calculation formula is proposed to accurately evaluate energy absorption performance of CAFTs under axial load, enabling more precise numerical calculation of total energy absorption. Furthermore, drop weight impact tests and finite element simulations are conducted to investigate the axial impact performance and deformation mechanism of CAFTs. The influence of diameter ratio on crashworthiness and energy absorption performance is also analyzed. As the diameter ratios decrease, both the impact resistance and total energy absorption of CAFTs increase, while the degree of tube damage gradually decreases. Moreover, finite element simulation results demonstrate that metallurgical combination between aluminum foam and aluminum tubes effectively transfers stress to thin‐walled tubes with better load‐bearing performance, preventing concentrated collapse of aluminum foam core. Additionally, the presence of aluminum foam provides robust restraint against deformation or rupture in thin‐walled tubes.

A finite element model for analyzing curved surface sandwich panel forming

The article establishes a finite element (FE) model of sandwich panel (referred to as CSC FE model) using shell structure core and solid structure face sheet and provides a detailed derivation of the data transfer process between the shell structure and the solid structure in the FE model. In order to explore the application of CSC FE model in the curved surface sandwich panel forming, this paper studies the single curvature and double curvature sandwich panel forming in detail. Based on the maturity of the three-point bending theory, in order to facilitate theoretical verification, the article chooses the three-point bending process to study the single curvature sandwich panels forming. It is proved that the CSC FE model can be effectively applied to single curvature sandwich panel forming through three-point bending theory, numerical simulations and experiments of brazed aluminum honeycomb panel (BAHP). Low cost and efficient multi-point forming (MPF) process is used to analyze the double curvature sandwich panel forming. By MPF experiments and numerical simulations of saddle-shaped and spherical BAHPs, and with the help of 3D laser scanning technology, it is proved that the CSC FE model can accurately predict the curved surface shape of double curvature sandwich panel forming.

Compressive behavior of Body-Centered-Cubic (BCC)-like ultra-lightweight Carbon Fiber Reinforced Polymer (CFRP) lattice-based sandwich structures

3D lattice structures comprise a connected network of segments that allow positioning of the base material where needed while maintaining an open-cell characteristic. These structures represent an ideal lightweight core material for high-performance sandwich panels. This work presents, for the first time, the performance of lattice-based cores fabricated via indirect additive manufacturing using pultruded Carbon Fiber Reinforced Polymer (CFRP) rods. The CFRP sandwich panels were tested under out-of-plane compression, and their compressive properties and failure modes were predicted via analytical and FE analyses, later contrasted with mechanical testing. Finally, the study compares favorably with similar core materials found in the literature.