Sandwich Panels Research Articles

Study of Capacity Calsium Board – Styrofoam Sandwich Panels on Wall Systems under Cyclic Lateral Force

Study of Capacity Calsium Board – Styrofoam Sandwich Panels on Wall Systems under Cyclic Lateral Force

Numerical Evaluation of Aluminum-faced Sandwich Panels in Large Enclosure Fires

Numerical Evaluation of Aluminum-faced Sandwich Panels in Large Enclosure Fires

A semi-analytical model for predicting the shear buckling of laminated composite honeycomb cores in sandwich panels

Laminated composite honeycomb cellular core sandwich panels are widely utilized in various industries due to their exceptional stiffness-to-weight ratio and strength characteristics. Current analytical models often simplify honeycomb cores as homogenized continua, effectively predicting stiffness but falling short in capturing crucial failure modes, particularly shear buckling of honeycomb core walls. Existing theoretical studies on shear buckling are limited to isotropic materials and specific honeycomb geometries. While numerical models can simulate cell wall buckling, their computational demands render them impractical for large structures employing sandwich panels. This paper introduces a novel, simplified semi-analytical approach that accurately predicts the shear buckling load of laminated composite honeycomb cellular cores. The model accounts for bend-twist coupling effects and rotational restraints at laminate wall boundaries. To validate the proposed approach, predictions are compared with finite element analysis results for hexagonal honeycomb cores and cores of varying shapes, incorporating diverse fibre lay-up configurations. The findings demonstrate excellent agreement between the proposed approach and finite element analysis, indicating its reliability in predicting shear buckling. This research addresses the gap in existing methodologies by offering a practical and efficient tool for predicting shear buckling in laminated composite honeycomb cores, extending applicability beyond isotropic materials and specific honeycomb geometries. The proposed approach holds promise for optimizing the design and structural integrity of sandwich panels, impacting industries relying on these lightweight and high-performance structures.

Coupled thermal-electrical–mechanical characteristics of lightning damage in woven composite honeycomb sandwich structures

In this study, lightning strike damage of woven carbon fibre-reinforced polymer laminates (W-CFRPs) and woven composite honeycomb sandwich panels (W-CHSPs) are simulated using the proposed sequential thermal-electrical–mechanical finite element (FE) coupling model incorporating dielectric breakdown of materials. Surface current with an amplitude of 200 kA and corresponding lightning shockwave overpressure were applied on each composite. The FE model coupled with LaRC05 criterion was used to study the failure behaviours of intralaminar damage and interlaminar delamination of the W-CFRPs and W-CHSPs. A series of lightning strike tests were performed to validate the FE model. Detailed lightning damage assessments and mechanisms were characterized by a combination of visual inspection, image processing, ultrasonic scanning and micro computed tomography (Micro-CT) and showed good agreements with the FE-predicted results. It can be concluded that shockwave overpressure significantly impacts lightning-induced damages, thereby supporting the effectiveness of the newly proposed sequential thermal-electrical–mechanical coupling model, which demonstrates improved predictive accuracy.

Vibration damping of sandwich panels using the Acoustic Black Hole effect

Among the existing passive vibration control techniques, the use of the acoustic black hole (ABH) is a solution that has the advantage of not increasing the mass of the structure in which it is integrated. In this paper, the benefits of inserting an ABH into a three-layer sandwich panel (fibreglass skins and honeycomb core) are investigated. It is known that an ABH effect can be achieved in a panel by locally reducing its stiffness (using a reduction in plate thickness according to a power law profile) and increasing local damping (using a coating of viscoelastic material). A sandwich panel induces a shear effect that strongly affect the wave propagation and lead to specific properties to the ABH effect. The equations of motion of a thick, symmetrical sandwich panel with non-uniform characteristics are obtained within the framework of zig-zag theory by applying Hamilton's principle. These equations lead to a semi-analytical model of order 6, from which an effective bending stiffness, dependent on both frequency and space can be derived. Using this model, it is demonstrated that the sandwich effective bending stiffness favours the ABH effect. This interesting property is also validated by experimental tests on sandwich panels using laser vibrometry.

A novel engineered sandwich composite with ceramic-coated graphite fibre-reinforced face sheets and an auxetic core for enhanced broadband electromagnetic absorption: design using multiscale computational analysis

Abstract A novel sandwich composite is designed for enhanced broadband absorption using a multiscale computational analysis. The sandwich panel is configured with BaTiO3 coated graphite fiber reinforced polymer (C-GFRP) composite, while BaTiO3 based auxetic material is used as the core material. A computationally efficient in-house tool based on the variational asymptotic method is used to homogenise the electromagnetic properties and evaluate the reflection loss characteristics of the proposed sandwich structure using the scattering matrices. A detailed parametric study of 300 analyses is conducted to identify the optimal sandwich panel configurations for achieving broadband reflection loss under the normal incidence of transverse electric (TE) and transverse magnetic (TM) polarised waves. Two different configurations have been obtained, satisfying the requirements of broadband reflection loss in the X-band frequency range. Configuration (a) Vf = 15% without any ceramic coating, and configuration (b) Vf = 20% with ceramic coating volume fraction (Cf) of 70%. Configuration (a) and (b) maintained the desired reflection loss of greater than -10 dB up to an incidence angle of 40◦ and 60◦, respectively. With the demonstrated capability of covering the entire broadband frequency range, the proposed configurations can serve as baselines to explore novel ceramic-based engineered composite architectures for broadband absorption applications.

Thermoplastic composite sandwich panels with recycled PET foam core: A manufacturing process assessment

This study attempts to modify two distinct lamination processes of double-belt and compression molding to produce environmentally sustainable full thermoplastic sandwich panels. A precise assessment of fabrication parameters was conducted to ensure the quality of sandwich panels made of glass/Polypropylene composite skin and 100% recycled PET foam core sourced from consumer waste bottles. Evaluations of the skin-to-core adhesion properties revealed that the PET foam density in conjunction with the fabrication approach can affect the layers’ bonding. The formation of satisfactory interlayer connection under controlled process parameters was confirmed by Peel-off and flatwise tensile test results. Moreover, complementary three-point bending analyses highlighted deviations in panel performance. Panels manufactured by the compression molding method exhibited superior load-bearing capacity compared to those made via a double-belt machine. These observations are attributed to the inherent nature of the lamination procedures, taking single or multiple thermal treatment phases to fabricate the sandwich panels. Finally, the findings suggest that despite potential slight quality degradation, the production continuity capability of the double-belt method makes it a viable option for meeting industry requirements.

Design of lightweight aircraft trim panel with a high sound transmission loss

The trim panels of aircraft cabin are frequently made up of multilayer materials including a honeycomb, typically in the form of sandwich panels, which have the advantage of being lightweight and space-saving, but lack good acoustic insulation. It has been shown that, for 10% more mass, weights arranged in a fractal pattern in the honeycomb affect the vibratory pattern of a sandwich panel by creating multiple reflections of the bending waves on the inclusions. They thus generate a phenomenon of focusing vibratory waves providing localized modes while attenuating the structure's acoustic radiation. The objectives of this paper are to describe: first, the vibro-acoustic model of an overloaded homogenized bending panel (to mimic a trim panel with a fractal pattern); second, the physical phenomena associated to this concept; third, the impact on the modal behavior and the vibratory and acoustic responses.

Acoustic metamaterials of double-layer structure for sound insulation

Insulation against air-borne sound is one of the earliest research fields of acoustic metamaterials. The sound insulation of the conventional sound insulation structure is generally limited by the law of mass. When the density of the structural surface is doubled, the low-frequency sound insulation is only increased by 6dB.In our report, we introduce a double-layer resonator-type acoustic metamaterial, which consists of two honeycomb sandwich panels, two perforated panels, and a thin air layer. Firstly, for two singer -layer resonator-type acoustic metamaterial, different sound absorption frequency points were designed. Secondly, a calculation model of sound insulation metamaterial with double-layer resonator type is established. The results show that the sound insulation performance of the structure greatly breaks through the law of mass in the frequency range of 165Hz-3150Hz. Finally, for the application requirements of the manufacturer, the compartment wall components and composite sound insulation door core components are designed. The reasonable design of Double-layer resonator-based honeycomb metamaterial structural parameters can solve the problem of low-frequency noise of thin-layer lightweight structure.

The bending of 3D-printed bio-inspired sandwich panels with wavy cylinder cores

Beetle Elytron Plates (BEPs) represent a new class of biomimetic sandwich cores with excellent mechanical properties inspired by the microstructure of the beetle elytra. The cores have a hexagonal centre-symmetric configuration with through-thickness cylinders in the unit cell. In this work, we describe the behaviour of sandwich panels with novel BEP core configurations possessing wavy cylinders under four-point bending tests. Full-scale simulations are also carried out to validate the experimental data. The results show that all the sandwich panels produced with face skins adhesively bonded have material failure earlier than the adhesive bond failure. BEPs with wavy cylinders have larger peak loads compared to those with straight cylinders, and all BEPs show higher peak loads than those of sandwich panels with classical hexagonal honeycombs. Additionally, all the BEPs exhibit an enhanced ductility compared to honeycomb sandwich panels.

Hybrid lattice structure with micro graphite filler manufactured via additive manufacturing and growth foam polyurethane

The utilisation of lightweight structures is a common practice across a range of disciplines, including the construction of light steel frames, sandwich panels, and transportation infrastructure, among others. The advantages of lightweight structures include design flexibility, weight reduction, and the sustainability of materials that can be easily recycled. However, these advantages also present significant weaknesses. Compared to solid materials with compact weight, lightweight structures do not have the same characteristics. With the reduction in material weight, the strength of the lightweight structure decreases significantly compared to solid materials. In this study, the lightweight structure was made using additive manufacturing and reinforced with solid Composite Polyurethane Foam reinforced with graphite filler expanded into the lightweight structure. The results showed that in the compression test, the mixture with 2 % graphite filler had the highest value of 2.5 kN. The highest hardness test on the specimen with a 2 % graphite mixture was 19.8 HA. FT-IR testing showed that the carbon bonds from graphite in the 2 % specimen had the highest intensity. The test results showed that the addition of Polyurethane Foam into the structure could enhance material strength effectively without adding significant material weight.

Enhancing performance of sandwich panel with three-dimensional orthogonal accordion cores

This study introduces a novel three-dimensional orthogonal accordion structure (3D-OAS) as the cellular core of sandwich panels, achieving multi-directional zero Poisson’s ratio through the orthogonal combination of two-dimensional accordion structures. To analyze its static characteristics effectively, a two-dimensional equivalent Reissner–Mindlin model (2D-ERM) was established utilizing the variational asymptotic method (VAM). The accuracy of 2D-ERM was confirmed by conducting three-point bending tests on 3D-printed specimens and analyzing the in-plane and out-of-plane deformation results of the 3D finite element model (3D-FEM). The comparison of global displacement contours and path-displacement curves between 3D-FEM and 2D-ERM showed a high level of agreement in predicting static deformation. The equivalent stiffness of SP-3D-OAS steadily increased as the inclined angle deviates by 90-degree, irrespective of whether it pertains to the convex or concave angle. Evaluation of deformability in sandwich panels with different cellular core forms revealed superior comprehensive performance in 3D-OAS, followed by 3D-YRS and 3D-XYAS, with a reduction of 16.41% and 17.35% in specific stiffness, respectively. Compared to the 3D-FEM, 2D-ERM significantly reduces computation time without compromising engineering accuracy. The research results provide a useful reference for optimal design of sandwich panels with multi-directional ZPR cellular core.

Synthesis and Purification of Nano-sized Titanium Carbide Particles through Vacuum Carbothermal Reduction for enhanced Mechanical, Microstructural Morphology, and Tribological Properties in Friction Stir Processed A356-based Aluminum Composites

This study focused on the synthesis and purification of nano-sized titanium carbide (TiC) particles through vacuum carbothermal reduction under a hydrogen/argon atmosphere. The process involved the production of carbon-coated titanium precursors, followed by heating under vacuum conditions at 1500°C for 2.5 hours. The resulting products underwent additional treatment in either a hydrogen/argon (1:1) mixed gas or pure hydrogen gas. Experimental findings revealed that TiC powders exhibiting a single phase are obtained within a molar ratio of Ti to C ranging from 1:2 to 1:4. Adjusting the molar ratio of Ti/C in the precursors allowed for controlled variation in the particle size of the synthesized TiC powders, ranging from 50 to 80 nm. Treatment in hydrogen/argon mixed gas at 850°C for 3 hours resulted in TiC products with an impressive purity of 99.40%. The subsequent incorporation of 5% Nano-TiC-3 (Ti to C ranging from 1:3) as reinforcement into an aluminum alloy by Friction stir process technique demonstrated a remarkable 19.41% improvement in tensile strength, highlighting the efficacy of this specific reinforcement. The nano-TiC-3 reinforced composite exhibited uniform distribution without porosity. Additionally, a notable 50.81% improvement in hardness and the best wear resistance were observed for the 5% Nano-TiC-3 reinforced aluminum composite. This comprehensive study contributes valuable insights into the synthesis, purification, and application of nano-sized TiC particles, paving the way for the development of high-performance aluminum-based composites with enhanced mechanical and tribological properties.

Effect of Mg on the Microstructure, Mechanical Properties, and Surface Roughness of Functionally Graded A413 Composite: Machine Learning Approach at Wire‐Cut Electric Discharge Machining Zone

The present study assists the industrial sectors by implementing low‐weight high‐strength aluminium composite. The pristine magnesium as a reinforcement in three different weight percentages (3.5, 7, and 10.5) is utilized to fabricate the A 413 composite using centrifugal casting. The density analysis concludes a higher level of Mg inclusion prompts the material to save 3.9% of weight. Microstructural study of centrifugal casting specimens reveal a rich existence of hard phase Mg2Si in the outer zone, with its richness decreasing toward the inner zone. The tensile test result affirms the functionally graded nature of the material with the increasing trend of tensile strength from the inner to the outer. Fractured surface analysis concludes the existence of cracks and their propagation for the inner region specimen. The influence of magnesium on the surface finish of functionally graded composite at the wire cut electric discharge machining (WEDM) zone is predicted using a machine learning‐based random forest regressor (RFR) algorithm. The supervised learning algorithm declares that 10.5 wt% of Mg facilitates the minimal surface roughness of 0.229 µm with the optimal combination of parameters 6 A of current, 115 µs of pulse‐on time, 60 µs of pulse‐off time, and 8 N of wire tension.

Insights into Structural Changes During Scratch Deformation of Ductile Coating Systems: Plastic Flow, Microstructural Transformations, and Crack Development

This study investigates the structural changes occurring during the scratch deformation of ductile materials, focusing on a composite aluminum (Al) coating on a steel substrate fabricated using a solid-state aluminizing technique. By analyzing the results of the scratch test with transmission electron microscopy (TEM) and focused ion beam (FIB) techniques, the research provides a detailed examination of plastic flow, microstructural transformations, and crack development. Results demonstrate that strong adhesion at the interface and similar mechanical properties between steel and Al layers facilitate co-deformation, crucial for maintaining the integrity of the composite structure. The study features the formation of a rolling-like laminated structure and significant grain refinement in both the steel and Al components, driven by plastic deformation. Observed atomic-scale intermixing and the formation of an amorphous interlayer highlight extensive material interactions during deformation. The visualization of crack progression using FIB allows for an in-depth understanding of the fracture process. Subsurface cracks initiate within the thin Al interlayer and propagate toward the surface, evolving through the coalescence of nanopores into microvoids and larger cavities, ultimately leading to crack propagation. Secondary internal cracks may arise due to stress fields generated by the primary crack, contributing to a complex network of internal cracks.

Experimental study on non-load bearing multi-span sandwich wall panels for blast mitigation

Sandwich wall panels are known for their ability to provide resistance over a wide deformation range, rendering them suitable for blast resistance applications. These panels consist of layers of concrete with an insulating core, offering a structural solution with enhanced performance. Quasi-static testing was conducted on multi-span sandwich wall panels with intermediate connections to evaluate their behavior under controlled loading conditions. A total of twelve two-span details were examined and selected to match the standard designs employed in the Tilt-Up Construction (TCA) and Prestressed/Precast Concrete Industry (PCI). Among these details, three belonged to the TCA type with two duplicates, while the remaining two were representative of PCI designs with three duplicates. The results obtained from the quasi-static testing indicate that insulated sandwich wall panels possess sufficient deformation capability to meet the current blast response criteria. To assess the findings of the static experiments to the prevailing response limits, the outcomes were distilled into a multi-linear static resistance analysis. The findings support the use of insulated precast concrete (PC) sandwich wall panels, highlighting their suitability for blast-resistant designs within the constraints of current blast design limitations. Specimens with Halfen connectors showed 32 % higher energy absorption and a 58 % advantage over Stud connectors, making them superior for robust blast resistance applications.

Interfacial microstructure and synergistic enhancement mechanism of symmetric gradient SiCp-reinforced aluminum matrix sandwich structure

Inspired by the biological sandwich structure to achieve excellent mechanical properties with both high strength and high ductility, the symmetric gradient silicon carbide particles (SiCp) reinforced aluminum (Al) composites, consisting of 10% SiCp/Al-3% SiCp/Al-Al-3% SiCp/Al-10% SiCp/Al, was fabricated using spark plasma sintering technology. The flat interface was achieved through hot rolling, significantly improving the bonding of interlayers. The differences in SiCp content among layers led to distinct evolution patterns in microstructure. In the pure Al layer, a notable continuous recrystallization mechanism was observed, while in the 3% SiCp/Al and 10% SiCp/Al layers, the recrystallization mechanism was nucleation-growth. The transmission electron microscope results indicated that the hindrance of dislocation motion at the interlayer interface and SiCp-Al interface enhanced the dislocation density, thereby improving its plastic deformation capability. On the other hand, the deflection and passivation of cracks at the interlayer interface significantly improves toughness. The differences intragranular strain among layers were most pronounced at the interlayer interfaces, leading to them becoming the stress concentration zone. Uncoordinated plastic deformation leads to sequential failure of layers, vertical cracks first occurred in the 10% SiCp/Al layer, then propagated towards the interlayer interface and the 3% SiCp/Al layer, respectively.

A multi-bionic design strategy for modular energy absorption system based on interlocking suture integrated with Bouligand-like arranged perforations

Thin-walled tubes are widely used in the field of cushioning energy absorption as an ideal structural unit. However, the performance of the thin-walled tube system is greatly limited by the presence of redundant connection structures. To address these issues, a multi-bionic design strategy for high-performance modular system was developed in this work, which innovatively combines the robust joint structure of the interlocking suture with the efficient deformation mode of the Bouligand structures. In the design process, the suture-inspired system was studied separately, and its mechanical behaviors were investigated by FEM simulations and experiments. The results showed that the modular system has good structural scalability and tunable deformation mode, and can be adjusted on demand to accommodate different loads and geometric features. Furthermore, in order to reduce the weight and improve the deformation degree of the system, an optimization strategy inspired by the efficient deformation mode of the Bouligand structure was proposed by perforating a sequence of helix-arranged guide holes in the sidewalls of the tubes. The results showed that the double-helix perforated system can reduce the weight by 10% while increasing the specific energy absorption by 58% compared with the unperforated system. In addition, the specific energy absorption and energy absorption efficiency of the system are as high as 48.25 J/g and 56.17%, which is comparable to traditional honeycomb sandwich panels while retaining structural stability and adjustable performance. Therefore, this multi-bionic strategy can integrate the advantages of various natural structures and provide new insights for the design of high-performance protective systems.

Evaluation of mechanical properties and energy absorption of polyurethane foam core sandwich panels with kevlar/basalt-epoxy laminates as face sheets

Evaluation of mechanical properties and energy absorption of polyurethane foam core sandwich panels with kevlar/basalt-epoxy laminates as face sheets

Experimental analysis of quasi‐static indentation in composite sandwich multilayers with corrugated core

AbstractThis study examines the effects of multilayering in sandwich panel composite structures with different corrugated core configurations under quasi‐static indentation loading. The panels were fabricated using woven glass fibers and epoxy resin via the Vacuum Infusion Process. Experiments were conducted using two hemispherical cylindrical indenters with a diameter of 20 mm (ID = 20 mm) and 10 mm (ID = 10 mm) and the behavior of the composite structure in terms of contact force and fracture mechanisms for different core corrugations (square and butterfly) were investigated in two ways with foam and without foam. The experimental results demonstrate that, among corrugated core geometries without foam, butterfly cores outperform square cores in terms of structural strength, maximum force, moment force, energy absorption, specific energy absorption, and displacement until full indentation. Moreover, the butterfly core shows a higher peak load and different failure mechanisms compared to the square core. Under loading with a 10 mm indenter, the butterfly core without foam only experienced perforation in the loading area, without fracture completely. Also, adding foam did not change failure mechanisms and mechanical behavior in the butterfly geometry. However, in the square geometry, foam filled gaps between the core, preventing fracture completely and leading to only perforation in the loading area, unlike the specimen without foam. The visual analysis during the quasi‐static indentation process revealed several significant damage mechanisms, including matrix cracking, fiber breakage, delamination, buckling and crushing of cell walls, damage to top sheets, core separation, and complete indentation of the samples.Highlights Delamination and indentation failure mechanisms were seen on the butterfly core. Skin indentation and rib fracture failure mechanisms were seen on the square core. Butterfly corrugated cores revealed the best performance without/with foam. The core shape was more effective on the strength than the foam addition.