Mechanical response of metallic honeycomb sandwich panel structures to high-intensity dynamic loading

Explosive tests were performed in air to study the dynamic mechanical response of square honeycomb core sandwich panels made from a super-austenitic stainless steel alloy. Tests were conducted at three levels of impulse load on the sandwich panels and solid plates with the same areal density. Impulse was varied by changing the charge weight of the explosive at a constant standoff distance. At the lowest intensity load, significant front face bending and progressive cell wall buckling were observed at the center of the panel closest to the explosion source. Cell wall buckling and core densification increased as the impulse increased. An air blast simulation code was used to determine the blast loads at the front surfaces of the test panels, and these were used as inputs to finite element calculations of the dynamic response of the sandwich structure. Very good agreement was observed between the finite element model predictions of the sandwich panel front and back face displacements and the experimental observations. The model also captured many of the phenomenological details of the core deformation behavior. The honeycomb sandwich panels suffered significantly smaller back face deflections than solid plates of identical mass even though their design was far from optimal for such an application.     

Large inelastic response of unbonded metallic foam and honeycomb core sandwich panels to blast loading

Sandwich panels constructed from metallic face sheets with the core composed of an energy absorbing material, have shown potential as an effective blast resistant structure. In the present study, air-blast tests are conducted on sandwich panels composed steel face sheets with unbonded aluminium foam (Alporas, Cymat) or hexagonal honeycomb cores. Honeycomb cores with small and large aspect ratios are investigated. For all core materials, tests are conducted using two different face sheet thicknesses. The results show that face sheet thickness has a significant effect on the performance of the panels relative to an equivalent monolithic plate. The Alporas and honeycomb cores are found to give higher relative performance with a thicker face sheet. Under the majority of the loading conditions investigated, the thick core honeycomb panels show the greatest increase in blast resistance of the core materials. The Cymat core panels do not show any significant increase in performance over monolithic plates.     

Experiments on curved sandwich panels under blast loading

In this paper curved sandwich panels with two aluminium face sheets and an aluminium foam core under air blast loadings were investigated experimentally. Specimens with two values of radius of curvature and different core/face sheet configurations were tested for three blast intensities. All the four edges of the panels were fully clamped. The experiments were carried out by a four-cable ballistic pendulum with corresponding sensors. Impulse acting on the front face of the assembly, deflection history at the centre of back face sheet, and strain history at some characteristic points on the back face were obtained. Then the deformation/failure modes of specimens were classified and analysed systematically. The experimental data show that the initial curvature of a curved sandwich panel may change the deformation/collapse mode with an extended range for bending dominated deformation, which suggests that the performance of the sandwich shell structures may exceed that of both their equivalent solid counterpart and a flat sandwich plate.     

Prediction of the dynamic response of composite sandwich beams under shock loading

Finite element calculations are reported for the dynamic shock response of fully clamped monolithic and sandwich beams, with elastic face sheets and a compressible elastic–plastic core. Predictions of the peak mid-span deflections and deflected shapes of the beams are compared with the previously reported measured response of end-clamped sandwich beams, made from face sheets of glass fibre reinforced vinyl ester and a core of PVC foam or balsa wood [1]. Good agreement is observed, and the maximum sustainable impulse is also predicted adequately upon assuming a tensile failure criterion for the face sheets. The finite element calculations can also be used to bound the response by considering the extremes of a fully intact core and a fully damaged core. It is concluded that the shock resistance of a composite sandwich beam is maximised by selecting a composite with fibres of high failure strain.     

The influence of core height and face plate thickness on the response of honeycomb sandwich panels subjected to blast loading

This paper reports on an investigation into the behaviour of circular sandwich panels with aluminium honeycomb cores subjected to air blast loading. Explosive tests were performed on sandwich panels consisting of mild steel face plates and aluminium honeycomb cores. The loading was generated by detonating plastic explosives at a pre-determined stand-off distance. Core height and face plate thickness were varied and the results are compared with previous experiments. It was observed that the panels exhibited permanent face plate deflection and tearing, and the honeycomb core exhibited crushing and densification. It was found that increasing the core thickness delayed the onset of core densification and decreased back plate deflection. Increasing the plate thickness was also found to decrease back plate deflection, although the panels then had a substantially higher overall mass.     

Wet-sand impulse loading of metallic plates and corrugated core sandwich panels

We have utilized a combination of experimental and modeling methods to investigate the mechanical response of edge-clamped sandwich panels subject to the impact of explosively driven wet sand. A porthole extrusion process followed by friction stir welding was utilized to fabricate 6061-T6 aluminum sandwich panels with corrugated cores. The panels were edge clamped and subjected to localized high intensity dynamic loading by the detonation of spherical explosive charges encased by a concentric shell of wet sand placed at different standoff distances. Monolithic plates of the same alloy and mass per unit area were also tested in an identical manner and found to suffer 15-20% larger permanent deflections. A decoupled wet sand loading model was developed and incorporated into a parallel finite-element simulation capability. The loading model was calibrated to one of the experiments. The model predictions for the remaining tests were found to be in close agreement with experimental observations for both sandwich panels and monolithic plates. The simulation tool was then utilized to explore sandwich panel designs with improved performance. It was found that the performance of the sandwich panel to wet sand blast loading can be varied by redistributing the mass among the core webs and the face sheets. Sandwich panel designs that suffer 30% smaller deflections than equivalent solid plates have been identified.     

Performance of functionally graded sandwich composite beams under shock wave loading

The dynamic behavior of sandwich composites made of E-Glass Vinyl-Ester (EVE) facesheets and graded Corecell™ A-series foam was studied using a shock tube apparatus. The foam core was monotonically graded based on increasing acoustic wave impedance, with the foam core layer of lowest wave impedance facing the blast. The specimen dimensions were held constant for all core configurations, while the number of core layers varied, resulting in specimens with one layer, two layer, three layer, and four layers of foam core gradation. Prior to shock tube testing, the quasi-static and dynamic constitutive behavior (compressive) of each type of foam was evaluated. During the shock tube testing, high-speed photography coupled with the optical technique of Digital Image Correlation (DIC) was utilized to capture the real-time deformation process as well as mechanisms of failure. Post-mortem analysis was also carried out to evaluate the overall blast performance of these configurations. The results indicated that increasing the number of monotonically graded foam core layers, thus reducing the acoustic wave impedance mismatch between successive layers, helped maintain structural integrity and increased the blast performance of the sandwich composite.     

The effect of facesheet/core delamination in sandwich structures under transverse loading

The present work is concerned with the problem of a delamination crack along the facesheet/core interface of a sandwich structure which is submitted to transverse loading. In contrast to a loading by compressive inplane forces or a bending loading the presumed transverse loading does not lead to buckling of the delaminated facesheet but it may provoke further delamination crack growth. As a kind of crack driving force the energy release rate is studied for a virtual crack growth by means of Irwin's crack closure integral within a finite element modelling. The resultant energy release rate is dependent on various geometrical and material parameters which is investigated in some detail.     

Deformation and failure of blast-loaded metallic sandwich panels—Experimental investigations

Metallic sandwich panels with a cellular core such as honeycomb have the capability of dissipating considerable energy by large plastic deformation under impact/blast loading. To investigate the structural response of sandwich panels loaded by blasts, a large number of experiments have been conducted, and the experimental results are reported and discussed in this paper. Quantitative results were obtained based on the measurement in the tests by a ballistic pendulum with corresponding sensors, and then the deformation/failure modes of specimen were classified and analysed systematically. The experimental programme was designed to investigate the effects on the structural response of face-sheet and core configurations, i.e. face-sheet thickness, cell size and foil thickness of the honeycomb, and mass of charge. The experimental data were then compared with the predicted data from finite element simulations, and the results show a good agreement between the experimental and computational studies.     

Experimental investigation of energy-absorption characteristics of components of sandwich structures

Two series of experiments are performed to investigate the dynamic response of various essential components of a class of sandwich structures, under high-rate inertial loads. One consists of dynamic inertia tests and the other involves dynamic impact tests. A split Hopkinson bar apparatus is modified and used for these experiments.     

The structural response of clamped sandwich beams subjected to impact loading

The structural response of dynamically loaded monolithic and sandwich beams made of aluminum skins with different cores is determined by loading the end-clamped beams at mid-span with metal foam projectiles. The sandwich beams comprise aluminum honeycomb cores and closed-cell aluminum foam cores. Laser displacement transducer was used to measure the permanent transverse deflection of the back face mid-point of the beams. The resistance to shock loading is evaluated by the permanent deflection at the mid-span of the beams for a fixed magnitude of applied impulse and mass of beam. It is found that sandwich beams with two kind cores under impact loading can fail in different modes. Experimental results show the sandwich beams with aluminum honeycomb cores present mainly large global deformation, while the foam core sandwich beams tend to local deformation and failure, but all the sandwich beams had a higher shock resistance, then the monolithic beam. For each type of beams, the dependence of transverse deflection upon the magnitude of the applied impulse is measured. Moreover, the effects of face thickness and core thickness on the failure and deformation modes were discussed. Results indicated that the structural response of sandwich beams is sensitive to applied impulse and structural configuration. The experimental results are of worth to optimum design of cellular metallic sandwich structures.     

The elastic response of sandwich structures to local loading

The paper addresses the elastic response of sandwich panels to local static and dynamic loading. The bottom face is assumed to be clamped, so that the overall bending is eliminated. The governing equations are derived using the static Lamé equations for the core and the thin plate Kirchoff–Love dynamic theory for the faces. The plane and axisymmetric formulations are considered. The closed-form solutions are obtained using Fourier–Laplace (Hankel–Laplace) integral transformations for the cases of forced excitation and impact by a rigid body. The solutions allow to predict the stress–strain state of the structure. The analytical solutions demonstrate a good agreement with experimental data and finite element analysis.     

Fracture characterization of sandwich structures interfaces under mode I loading

The accurate prediction of failure of sandwich structures using cohesive mixed-mode damage models depends on the accurate characterization of the cohesive laws under pure mode loading. In this work, a numerical and experimental study on the asymmetric double cantilever beam (DCB) sandwich specimen is presented with the objective to characterize the debonding fracture between the face sheet and the core under pure mode I. A data reduction method based on beam theory was formulated in such a way to incorporate the complex damaging phenomena of the debonding due to the material and geometric asymmetry of the specimen, via the consideration of an equivalent crack length (a_e). Experimental DCB tests were performed and the proposed methodology was followed to obtain the debonding fracture energy (G_Ic). The experimental tests were numerically simulated and a cohesive damage model was employed to reproduce crack propagation. An inverse method was followed to obtain the local cohesive strength (σ_u,I) based on the fitting of the numerical and experimental load–displacement curves. With the value of fracture energy and cohesive strength defined, the cohesive law for interface mode I fracture is characterized. Good agreement between the numerical and the experimental R-curves validates the accuracy of the proposed data reduction procedure.     

Finite element modelling of core thickness effects in aluminium foam/composite sandwich structures under flexural loading

This paper models the flexural behaviour of a composite sandwich structure with an aluminium foam core using the finite element (FE) code LS-DYNA. Two core thicknesses, 5 and 20 mm, were investigated. The FE results were compared with results from previous experimental work that measured full-field strain directly from the sample during testing. The deformation and failure behaviour predicted by the FE model compared well with the behaviour observed experimentally. The strain predicted by the FE model also agreed reasonably well with the distribution and magnitude of strain obtained experimentally. However, the FE model predicted lower peak load, which is most likely due to a size effect exhibited by aluminium foam. A simple modification of the FE model input parameters for the foam core subsequently produced good agreement between the model and experimental results.     

Elastic structural response of anisotropic sandwich plates with a first-order compressible core impacted by a Friedlander-type shock loading

The foundation of the non-linear theory of asymmetric anisotropic sandwich plates with a first order compressible weak orthotropic core under a Friedlander-type explosive blast is presented. The equations of motion are developed by means of Hamilton’s Principle. Within the theory, the face sheets are asymmetric while adopting the Love-Kirchoff model. In addition, the core layer is assumed to be compressible (extensible) in the transverse direction thereby capturing any wrinkling or global instabilities. The theory is then simplified and applied for the case of sandwich plates with symmetric unidirectional fiber reinforced laminated composite facings with the axes of orthotropy not necessarily coincident with the geometrical axes. The governing solution is developed using the Extended-Galerkin method resulting in two coupled non-linear second order ordinary differential equations which are then solved using the 4th-order Runge–Kutta method for a system of differential equations.     

In-plane effective elastic properties of a novel cellular core for sandwich structures

Within this paper an analytical model is presented for the calculation of the in-plane effective elastic properties E_x and E_y of a novel cellular structure which is proposed to be used as a core in sandwich structures. The proposed cellular core may represent a less expensive and easily to produce alternative to the already known cellular structures used for the construction of sandwich structures. The developed analytical model is validated through experimental tests. The results obtained by analyzing the theoretical model show a good agreement with the tests. The structure topology is studied using a parameterized unit cell and it is shown the way in which the in-plane stiffness depends on the geometric parameters and relative density of the core.     

Modelling the response of reinforced concrete panels under blast loading

A finite element model is developed for the simulation of the structural response of steel-reinforced concrete panels to blast loading using LS-DYNA. The effect of element size on the dynamic material model of concrete is investigated and strain-rate effects on concrete in tension and compression are accounted for separately in the model. The model is validated by comparing the computed results with experimental data from the literature. In addition, a parametric study is carried out to investigate the effects of charge weight, standoff distance, panel thickness and reinforcement ratio on the blast resistance of reinforced concrete panels.