Honeycomb Sandwich Structures Research Articles

Mechanical characteristics of auxetic composite honeycomb sandwich structure under bending

Auxetic honeycomb sandwich structures (AHS) composed of a single material generally exhibit comparatively lower energy absorption (EA) and platform stress, as compared to traditional non-auxetic sandwich structures (TNS). To address this limitation, the present study examines the use of aluminum foam (AF) as a filling material in the re-entrant honeycomb sandwich structure (RS). Filling the AHS with AF greatly enhances both the EA and platform stress in comparison to filling the TNS with AF, while the auxetic composite honeycomb sandwich structure effectively addresses interface delamination observed in traditional non-auxetic composite sandwich structures. Subsequently, the positive–negative Poisson’s ratio coupling designs are proposed to strengthen the mechanical features of a single honeycomb sandwich structure. The analysis results show that the coupling structure optimizes the mechanical properties by leveraging the high bearing capacity of the hexagonal honeycomb and the great interaction between the re-entrant honeycomb and the filling material. In contrast with traditional non-auxetic sandwich structures, the proposed auxetic composite honeycomb sandwich structures demonstrate superior EA and platform stress performance, suggesting their immense potential for utilization in protective engineering.

Dynamic response of GFRP/Nomex honeycomb sandwich panels subjected to multiple hail impacts – An experimental study

AbstractNowadays, more and more aircraft components are made of composite sandwich structures, and ice impacts are prone to cause internal damage to composite sandwich structures, so it is crucial to study the impact of hail on composite sandwich structures. Since hail impacts may occur several times at a single point, an experimental approach was used to investigate the dynamic response of GFRP/Nomex honeycomb sandwich panels under multiple hail impacts. The dynamic response of the structure was investigated in terms of response rate and deflection‐profile curves using 3D digital image correlation methods, and the effects of impact energy, hail size, and number of impacts on the impact resistance of the honeycomb sandwich structure were explored. The results show that the dynamic response process of sandwich panels can be categorized into the ball‐and‐crown phase, the rebound phase, and the vibration phase. Under the same impact energy, the impact of small‐sized hailstones is more threatening to honeycomb sandwich panels. As the number of impacts increases, the maximum deflection value of the back panel first increases uniformly, and when the layered damage area reaches the threshold value, fiber stripping occurs, and the increment of the maximum deflection value increases significantly.Highlights Since hail impacts may occur several times in real situations, this study conducted multiple impact experiments for one impact site. The dynamic response and damage pattern of the GFRP/Nomex honeycomb sandwich panels under multiple hail impacts were also investigated. The dynamic response process of GFRP/Nomex honeycomb sandwich panels was categorized into three phases: ball‐crown stage, rebound stage, and vibration stage. With the increase of the number of impacts, fiber stripping and fiber break damage began to occur when the layered damage area of the panel reached the threshold value. The honeycomb core has three main failure modes: cell wall folds, cell wall fracture, and cell wall debonding at the TGPW interface. Small‐diameter hails pose a more significant threat of damage to honeycomb sandwich panels at the same impact energy.

Assessment of mechanical performance of Al2O3 ceramic honeycomb sandwich structures produced with SLA 3D-printing regarding unpolymerized slurry removal strategy

AbstractAl2O3 ceramic honeycomb sandwich bars with a hexagonal core were manufactured through SLA 3D-printing to analyze the impact of hole placement, designed for the removal of uncured slurry, on the bending strength of the samples. Several holes were placed specifically on the samples in the design in two different ways. In the initial design, the holes were placed on the honeycomb sandwich structure’s upper and lower face-sheets. In the second design, the holes were positioned in the direction of the sample thickness, in the lateral walls. The moment of inertia values for the honeycomb structures were calculated with the help of experimental elastic modulus results, and true bending strength was determined according to these results. Nominal strength values were found using the common three-point bending formula. The true bending strength value of Al2O3 with lateral holes was 73% higher than Al2O3 with holes on face-sheets, while the nominal bending strength was 79% higher. Al2O3 samples with holes on face-sheets exhibited a significantly higher failure index compared with both the bulk samples and the Al2O3 samples with lateral holes. The holes on the face-sheets reduced the cross-sectional area of the tensile surface and contributed to an increase in stresses due to the stress concentration effect. The Al2O3 samples with lateral holes provided a great advantage of specific strength, reaching an average value of 65% above the specific strength of the bulk samples.

Study on the Deformation Mode and Energy Absorption Characteristics of Protective Honeycomb Sandwich Structures Based on the Combined Design of Lotus Root Nodes and Leaf Stem Veins

Sandwich structures are often used as protective structures on ships. To further improve the energy-absorbing characteristics of traditional honeycomb sandwich structures, an energy-absorbing mechanism is proposed based on the gradient folding deformation of lotus root nodes and a leafy stem vein homogenizing load mechanism. A honeycomb sandwich structure is then designed that combines lotus root nodes and leafy stem veins. Four types of peak-nest structures, traditional cellular structure (TCS), lotus root honeycomb structure (LRHS), leaf vein honeycomb structure (LVHS), and lotus root vein combined honeycomb structure (LRVHS), were prepared using 3D printing technology. The deformation modes and energy absorption characteristics of the four honeycomb structures under quasistatic action were investigated using a combination of experimental and simulation methods. It was found that the coupling design improved the energy absorption in the structural platform region of the LRHS by 51.4% compared to that of the TCS due to its mechanical mechanism of helical twisting and deformation. The leaf vein design was found to enhance the peak stress of the structure, resulting in a 4.84% increase in the peak stress of the LVHS compared to that of the TCS. The effects of the number, thickness, and position of the leaf vein plates on the honeycomb structure were further explored. The greatest structural SEA effect of 1.28 J/g was observed when the number of leaf vein plates was four. The highest SEA of 1.36 J/g was achieved with a leaf vein plate thickness of 0.6 mm, representing a 7.3% improvement compared to that of the 0.2 mm thickness. These findings may provide valuable insights into the design of lightweight honeycomb sandwich structures with high specific energy absorption.

Finite Element Analysis of Eddy Current Testing of Aluminum Honeycomb Sandwich Structure with CFRP Panels Based on the Domain Decomposition Method

Finite Element Analysis of Eddy Current Testing of Aluminum Honeycomb Sandwich Structure with CFRP Panels Based on the Domain Decomposition Method

Bioinspired honeycomb sandwich structures for enhanced hail impact resistance

The study explores the mechanical behavior of bioinspired honeycomb sandwich structures against hail impact using Ls-Dyna. The hail model, based on experimental values, is created with smoothed particle hydrodynamics. The force-time graph aligns with the peak value from the impact test on a rigid bar, showing good agreement with literature. The sandwich model, impacted by a hemispherical-nosed impactor, exhibits post-impact damage images and collapse in the z-axis consistent with experimental results. Diversified honeycomb cell profiles include wavy, spider web, bamboo, and combinations. When subjected to hail impact, the wavy model excels in sEA, spider web-bamboo in specific deformation, and bamboo in sPCF.

Study on the Energy Absorption Characteristics of Different Composite Honeycomb Sandwich Structures under Impact Energy

A honeycomb structure is a sandwich structure widely used in fuselage, among which the hexagonal honeycomb core is the most widely used. The energy absorption characteristics and impedance ability of the structure are the main reasons that directly affect the energy absorption characteristics of the honeycomb sandwich structure. Therefore, it is necessary to study the out-of-plane mechanical properties of the composite honeycomb sandwich structure. Based on the numerical simulation results, the energy absorption characteristics of several composite honeycomb sandwich structures are verified by drop hammer impact experiments. The research shows that the transient energy absorption characteristics of the composite honeycomb sandwich structure are mainly related to the cell size of the honeycomb structure. The smaller the size of the front cell, the stronger the overall impact resistance; the strength of the composite honeycomb sandwich structure exceeds that of 7075 aluminum alloy-NOMEX and carbon fiber-NOMEX honeycomb sandwich structures. In this paper, the energy absorption characteristics of composite honeycomb sandwich structures under different impact energy are compared and studied. The displacement, force and energy curves of energy absorption characteristics related to time variables are analyzed. The difference in protective performance between the composite honeycomb sandwich structure and existing airframe structure is compared and studied. The optimal structural design parameters of composite honeycomb sandwich under low-speed impact of drop hammer are obtained. The maximum energy absorption per unit volume of the designed honeycomb sandwich structure is 171.7% and 229.8% higher than that of the NOMEX-AL and NOMEX-C structures. The 6.4 mm and 3 mm cell sizes show good characteristics in high-speed buffering and crashworthiness. The composite honeycomb sandwich airframe structure can improve the anti-damage performance of the UAV airframe structure, ensure the same thickness and lightweight conditions as the existing honeycomb sandwich airframe structure, and improve the single-core bearing mode of the existing airframe structure.

Load-bearing capacity of composite honeycomb sandwich high-speed train floor

ABSTRACT The honeycomb sandwich structure of composite materials has broad prospects for application in the lightweight design of vehicle bodies. This study investigated the influence of relative density and height on an aluminium honeycomb’s out-of-plane quasi-static compression performance through experiments and simulations. The accuracy of the carbon fibre/aluminium honeycomb sandwich panel’s three-point bending model is verified based on the Hashin failure criterion and experimental validation. Furthermore, the load-bearing capacity of the carbon fibre/aluminium honeycomb sandwich floor is analysed, and the factors influencing the load-bearing capacity of the floor are further explored. The results show that the relative density significantly impacts the out-of-plane quasi-static compression performance of aluminium honeycomb, while the height has a minor influence. Compared with the original CRH5-type floor structure, the carbon fibre/aluminium honeycomb sandwich floor has a weight reduction of 45.23%, and it meets the strength requirements under uniformly distributed and concentrated load conditions. Changing the honeycomb wall thickness and panel thickness distribution can improve the load-bearing capacity of the floor.

Efficient design of composite honeycomb sandwich panels under blast loading

Hybrid composite honeycomb sandwich structures (HCHSS) were employed due to high specific strength and stiffness and higher impact resistance property required for the aerospace and defence fields. The numerical modelling of the efficient HCHSS was developed for the core, front and back face plate using the C3D8R elements to determine the realistic failure behaviour for the honeycomb sandwich structure. The ConWep blast simulation loading was applied for the HCHSS. Advanced composite materials were used for the blast analysis of the HCHSS (carbon/epoxy, graphite/epoxy, woven basalt fibres/polypropylene and woven Kevlar fibres/polypropylene). The damage initiation and damage propagation based progressive damage modelling was developed and implemented in the VUMAT code for composite materials to determine the actual failure behaviour of the HCHSS. The face sheets used in this model were of a stainless-steel alloy AL-6XN. The sandwich structure was subjected to blast loads of 1, 2 and 3 kg of TNT and their performance was compared w.r.t both front and back-face deflection. The effectiveness of sandwich panels was further examined by altering the thickness of the core. Fibre-metal laminates (FML) were used in place of the steel face sheets in the panel in order to minimise its mass, and a thorough analysis of the panel’s mass in relation to its peak deflection was carried out. Upon analysing the results, it was noted that the panel with the basalt fibre reinforced polymer (BFRP) core gave the best results compared to other composite materials. For a blast load of 3 kg TNT, the peak back face deflection (PBFD) of HCHSS with a BFRP core decreased by 10.64%, 7.61% and 4.75%, respectively, compared to panels with CFRP, GFRP, and KFRP cores. The peak deflection of the panel decreased as the BFRP core thickness increased. The energy absorption capacity of the panel also increased with increasing thickness. Additionally, it was found that panels with BFRP cores and KFRP-steel laminate face sheets provided the optimum balance of strong blast resistant performance and light weight. Compared to the metallic (steel) sandwich panel, the mass of the sandwich panel with KFRP-steel laminate face sheets and BFRP core was reduced by 33%, but at the same time, its PBFD increased by almost 50%.

Low‐velocity impact responses of polymethacrylimide foam–reinforced all‐composite Kagome honeycomb sandwich structures

AbstractThis article reports a carbon fiber–reinforced plastic Kagome composite honeycomb sandwich structure reinforced with polymethacrylimide (PMI) foam (PKCSS). Low‐velocity impact performances on the node, rib, and two cell centers of the PKCSS were experimentally compared with those on a composite Kagome honeycomb sandwich (CKHS), and the failure mechanism of the PKCSS was investigated. The impact process was analyzed through an explicit numerical analysis using ABAQUS. A three‐dimensional Hashin failure criterion was introduced using the VUMAT subroutine. Results confirmed that the PKCSS exhibits higher impact and specific loads than the CKHS, with the maximum improvements of 69.7% and 39.5%, respectively, under 50‐J impact energy. As an uncrushable material, the PMI foam provides strong impact resistance during its plateau stage. This technology of cell filling can be used to fabricate lightweight all‐composite honeycomb sandwiches for potential use in ultrahigh engineering applications.Highlights Cell filling is applied in an all‐composite Kagome honeycomb sandwich. The LVI performances of the PKCSS and CKHS are experimentally compared. C‐scanning is used to analyze the failure of the considered structures. The PKCSS's numerical model is established to investigate the impact process. The enhancement mechanism of the PMI foam is analyzed.

Quasi-static indentation responses of FMLs/2.5D woven carbon-fiber honeycomb sandwich structures under different structural parameters

Here, a new type of sandwich structure made of fiber metal laminates (FMLs) as facesheet and 2.5D woven carbon-fiber (CFRP) honeycomb as core was developed. The FMLs/CFRP honeycomb sandwich structures were subjected to quasi-static indentation tests to investigate the mechanical response with the variation of panel structure, honeycomb cell element size, honeycomb core wall thickness, and honeycomb core height. In addition to experiments, a finite element method (FEM) model was also created in ABAQUS/Explicit to analyze the damage mechanisms and failure modes of honeycomb sandwich structures under quasi-static indentation. Both the experimental and FEM simulation results revealed that the honeycomb sandwich structure underwent two different failure modes under quasi-static loading: localized damage dominated by indentation and global damage due to overall bending deformation. The combination of panel strength and honeycomb core strength determined the failure mode of the sandwich structure. Damage analysis of the honeycomb core showed that it mainly underwent fiber compression damage and matrix compression damage under quasi-static indentation. This study provides guidance to optimize the design of honeycomb sandwich structures.

Variational mode decomposition framework for modal shape visualization of honeycomb sandwich structures for full-field vibration measurements in non-uniform temperature fields

Thermal effects in hypersonic vehicles, such as severe aerodynamic heating, can greatly influence their thermodynamic behavior. These effects can cause uneven temperature distributions and drastic vibrations, which in turn impact the vibration characteristics of the vehicle structure. To address this issue, a comprehensive approach was developed to study the behavior of honeycomb sandwich structures in high-temperature environments. Firstly, a full-field thermal vibration testing system was established, which allowed for free-boundary multi-temperature region heating at 900 °C while applying unconnected excitation. Through this setup, we were able to obtain modal frequencies and modal shapes of the honeycomb sandwich structures under high-temperature conditions. To accurately simulate the heat transfer distribution of the honeycomb sandwich structure, the Q-learning algorithm was employed, which proved effective in achieving accurate and detailed predictions of the full-field heat transfer distribution. Furthermore, for the purpose of further enhancing the accuracy of the finite element model, a multi-state non-uniform temperature field model updating method was utilized. This updated model accounted for the influence of the multi-temperature region heating, resulting in a more reliable representation of the structure's behavior. Additionally, a variational mode decomposition (VMD) framework was applied to visualize and analyze the modal shapes of the honeycomb sandwich structures. By decomposing the time-domain signals with VMD, it is possible to efficiently obtain the modal shapes of the output-only response signals. Experimental results demonstrated that the identification method used in this study produced modal frequencies and modal shapes that closely matched those obtained using the PolyMAX method at room temperature. Therefore, the proposed approach offers an effective means of identifying the modal characteristics of structures subjected to non-uniform temperature fields, particularly in output-only scenarios.

Bending behaviors and toughening mechanism of carbon fiber-aluminum honeycomb sandwich structures with stitched fiber belts

Bending behaviors of carbon fiber-aluminum honeycomb sandwich structures, that are toughened by stitched fiber belts, are experimentally and numerically studied. It is found that the stitched fiber belts show potential to enhance the peak load of sandwich specimens by up to 44.3%, and to arrest interfacial crack growth. Firstly, FE models are proposed for the sandwich structures with stitched carbon fiber belts, and the FE models are verified by three-point bending tests. Secondly, the effects of stitched carbon fiber belts on bending behaviors of sandwich beam are studied. Combining the experimental and numerical results, the main toughening mechanism of stitched fiber belts is observed. The stitched fiber belts increase bonding area between face-sheets and honeycomb core, on one hand, and therefore enhance the interfacial strength. On the other hand, the angled fiber belts inside the core are found to enhance load bearing capacity and transverse shear stiffness.

Full-scale evaluation of creep coefficients and viscoelastic moduli in honeycomb sandwich pultruded GFRP composite cross-arms: Experimental and numerical study

The utilization of pultruded glass fibre-reinforced polymer composites (PGFRPC) to replace traditional wooden cross-arms in high transmission towers is a relatively recent development. While there have been numerous investigations into enhancing cross-arm structures, there remains a notable absence of research focused on the elastic characteristics of a full-scale PGFRPC cross-arm, particularly one enhanced with a honeycomb sandwich structure. To full-fill the gap, this paper presents an experimental and numerical study through cantilever beam flexural tests on assembled cross-arm condition to examine deflection behavior and the flexural creep response. For deflection behavior, the load was applied up to actual working load. For creep behavior, the hanging load was applied for 1000 h in open area condition followed ASTM D2990 standards. By using Findley's power law, confirming the ability of this empirical approach to simulate the viscoelastic response of the cross-arm. The results obtained prove that the addition of a honeycomb sandwich structure reduced deflection and improved resilience against bending forces, enhancing specific points' elastic modulus slightly. Long-term creep tests revealed Point Y3 had the highest strain, but the enhanced cross-arm displayed superior resistance and a shorter viscoelastic transition period, indicating increased stability. Besides that, the Findley's Power Law Model effectively represented creep behavior for both cross-arm types, with low errors. Over 50 years, both versions showed a significant reduction in average elastic modulus, with the enhanced variant 20 % stronger due to the honeycomb structure. In conclusion, this study validates the superior creep properties of the enhanced PGFRPC cross-arm and demonstrates the honeycomb sandwich structure's substantial role in increasing strength and extending the cross-arm's lifespan, making it a valuable enhancement for such applications.

Experimental Investigation on Influence of various Core Materials and their Cell Geometry on Strength to Stiffness of Honeycomb Sandwich Structure

Experimental Investigation on Influence of various Core Materials and their Cell Geometry on Strength to Stiffness of Honeycomb Sandwich Structure

Flexural response of additively manufactured honeycomb sandwich structures with continuous density-gradient variations

Sandwich structures with graded cellular cores exhibit promising flexural performances, but their reliance on gradient continuity and distribution warrants further exploration. In this study, seven honeycomb sandwich structures with diverse continuous density gradients, encompassing horizontal, uniform and vertical variations, were designed based on the Voronoi technique and fabricated via 3D printing. Quasi-static three-point bending tests and numerical simulations were conducted to comprehensively analyze the flexural response of density-graded honeycomb sandwich structures. The results reveal a significant influence of the honeycomb core's density distribution on flexural performance, with pronounced sensitivity to horizontal distribution (perpendicular to the loading direction) and less sensitivity to vertical distribution. A favorable flexural resistance is achieved by strategically assigning higher relative density cells to the mid-span of a honeycomb core layer, gradually diminishing towards the ends, which was further optimized into an arched density distribution along the horizontal direction. The influences of cover plate and honeycomb thicknesses on the deformation mechanisms and energy absorption were also investigated, and indicate that thin cover plates and honeycomb layer have a detrimental effect on the bending load-bearing and energy absorption of the sandwich structure.

Comparative study of the mechanical properties of glass and Kevlar fiber-reinforced honeycomb composite

Honeycomb sandwich structures have wide range of applications in the aircraft, automobile, and satellite sectors due to their superior properties such as high specific strength, stiffness, energy absorption, and high impact strength. In this study, mechanical characteristics such as compression, three-point bending, and in-plane impact properties of 3D woven honeycomb composites produced from Kevlar and glass fiber were investigated. The focus of this research is to compare the mechanical performance of woven honeycomb composites developed from these two fibers with similar cell structures. The results revealed that Kevlar fiber honeycomb composite shows higher peak load and energy absorption for flatwise and edgewise compression while in three-point bending and in-plane impact, glass fiber honeycomb composite shows higher peak load, and impact energy absorption. The deformations shown in all the mechanical properties give the ductile behavior for Kevlar fiber and brittle behavior for glass fiber composite. The findings of the study suggest that the failure modes are mostly determined by the nature of the material itself.

Design and low-velocity impact behavior of an origami-bellow foldcore honeycomb acoustic metastructure

The ancient art of origami has inspired the design and fabrication of numerous acoustic and energy-absorption mechanical metamaterials and metastructures. This study introduces an origami-inspired honeycomb acoustic metastructure designed for engineering applications that demand both high impact resistance and effective sound absorption. This acoustic metastructure is formed by bonding a panel containing periodically distributed perforated holes and a panel without perforations to a periodical array of trapezoidal origami-bellow units. Acoustic wave propagation and drop-weight impact simulations are conducted to investigate the acoustic performance and low-velocity impact behavior of the metastructure. The results show that the origami-bellow honeycomb structure exhibits superior sound absorption capacity over two frequency ranges, outperforming the conventional honeycomb-core sandwich structure. Furthermore, it is shown that, in comparison with both the conventional hexagonal honeycomb-core and the Miura-ori foldcore sandwich structures, the proposed acoustic metastructure demonstrates higher levels of impact resistance and energy absorption capacity. We also show that the mechanical performance of the introduced metastructure under low-velocity impact loads can be further enhanced by increasing the story height of the origami-bellow units. Besides, the matrix material of the origami foldcore can be tailored to suit various scenarios, providing noise control and collision robustness for a diverse range of engineering applications.

Eddy current testing of CFRP/Aluminium honeycomb sandwich structure

ABSTRACT Aluminium honeycomb sandwich structure with CFRP panels has broad applications in aerospace and other industries. This paper presents an experimental study on the eddy current (EC) testing of such structure. An EC probe consisting of two pancake coils, one up and one down, is used for the testing and the amplitude of the differential voltage of the coils at each position of probe scanning is measured. The result of linear scan shows that the local minimal EC responses correspond to the edges of the core walls. In the C-scan results, different types of defects in the honeycomb cores including wall fracture, node disconnection, and core wrinkle can be identified. Threshold processing is performed to improve the indication of the defects. Topological graph of honeycomb core is obtained by connecting the pixels of C-scan image at which the EC responses are the local minima. Detection of impact damages is carried out and the effects of impact energy on the C-scan image are analysed. When the impact energy is increased, the part of the image in the area of damage becomes more blurred, and the minimal signal decreases monotonically. The area of damage seen in C-scan image is not necessarily increased with the increase of impact energy.

Flexural creep response of honeycomb sandwich pultruded GFRP composite cross-arm: Obtaining full-scale viscoelastic moduli and creep coefficients

The application of pultruded glass fibre-reinforced polymer composites (PGFRPC) as a replacement material for conventional wooden cross-arm in high transmission towers is relatively new. Although there are several studies on enhancement of the cross-arm structure, there is still a lack of study on the elastic properties of a full-scale PGFRPC cross-arm enhanced with honeycomb sandwich structure. To full-fill the gap, this paper describes an experimental methodology used to obtain the elastic properties of the cross-arm using a three-point bending (3-PB) flexural test by following ASTM D790 standard for deflection behaviour and flexural creep response. The investigation involved several cross-arm members subjected to loading across different span lengths by propose two methods in order to measure the effective cross-arm member section flexural modulus (Ec) and shear modulus (Gc). The creep behaviour of the panels was successfully modeled using Findley's power law, confirming the ability of this empirical approach to simulate the viscoelastic response of the cross-arm. Next predictions were made for up to 50 years of service and the results shows the elastic modulus reduction for the enhanced cross-arm with the honeycomb sandwich structure was approximately reduce to 70 % compare with existing cross-arm which reduce almost 75 % at 50 years of application. The enhanced cross-arm exhibited lower deflection and better creep resistance and increased the bending strength of the cross-arm as well as extended its potential lifespan. Predictions indicated that the enhanced cross-arm maintained better mechanical properties over time compared to the existing one.