钢板夹泡沫铝组合板抗爆性能研究

鉴于泡沫铝材料优异的吸能特性和夹层结构在强度、刚度上的优势,提出了分层结构为钢板-泡沫铝芯层-钢板的抗爆组合板。对厚度为10 cm、7 cm和5 cm的组合板进行了5组不同装药量的爆炸试验,考察了各板在不同装药量爆炸条件下的变形及破坏情况,并对变形破坏过程进行了理论分析。研究表明:组合板承受爆炸冲击荷载时,通过局部压缩变形和整体弯曲变形吸收能量。钢板相同时,适当增大泡沫铝芯层厚度,增强面板与芯层间连接,可提高该组合板的抗爆性能,防止组合板发生剥离,减小其承受爆炸冲击荷载时产生的变形。     

A comparison of honeycomb-core and foam-core carbon-fibre/epoxy sandwich panels

Cellular core sandwich panels of carbon-fibre/epoxy fabric laminate skins, simulating the construction of an aircraft flap, were cured and bonded in a single-step autoclave operation. Nomex honeycomb and Rohacell WF foam of different densities were employed as the core material. The panels were examined to identify voids in the laminate skins and cell collapse and coalescence in the foam core. Test-pieces were subjected to low-energy impact and the induced damage was determined by ultrasonic C-scan. The maximum damage area in the face-skin was comparable to the projectile cross-sectional area. Residual compressive capacity showed an asymptotic decrease with increasing impact levels, most panels gave similar values but the modes of failure were different depending on the type of core. The resistance of the separate panel components to full impact puncture was assessed using instrumented impact load-deflection traces.     

Impact response of sandwich plates with a pyramidal lattice core

The ballistic performance edge clamped 304 stainless-steel sandwich panels has been measured by impacting the plates at mid-span with a spherical steel projectile whose impact velocity ranged from 250 to 1300 m s⁻¹. The sandwich plates comprised two identical face sheets and a pyramidal truss core: the diameter of the impacting spherical projectile was approximately half the 25 mm truss core cell size. The ballistic behavior has been compared with monolithic 304 stainless-steel plates of approximately equal areal mass and with high-strength aluminum alloy (6061-T6) sandwich panels of identical geometry. The ballistic performance is quantified in terms of the entry and exit projectile velocities while high-speed photography is used to investigate the dynamic deformation and failure mechanisms. The stainless-steel sandwich panels were found to have a much higher ballistic resistance than the 6061-T6 aluminum alloy panels on a per volume basis but the ballistic energy absorption of the aluminum structures was slightly higher on a per unit mass basis. The ballistic performance of the monolithic and sandwich panels is almost identical though the failure mechanics of these two types of structures are rather different. At high impact velocities, the monolithic plates fail by ductile hole enlargement. By contrast, only the proximal face sheet of the sandwich plate undergoes this type of failure. The distal face sheet fails by a petalling mode over the entire velocity range investigated here. Given the substantially higher blast resistance of sandwich plates compared to monolithic plates of equal mass, we conclude that sandwich plates display a potential to outperform monolithic plates in multi-functional applications that combine blast resistance and ballistic performance.     

Dynamic response of Kevlar®29/epoxy laminates under projectile impact-experimental investigation

This authors of this article investigated the dynamic response of woven Kevlar®29/epoxy laminates subjected to the impact loading. The cylindrical aluminum foam projectile and steel projectile were used to exert the impulse on the laminates. Deformation/failure modes, deflections, strain histories, and failure mechanisms were obtained and discussed. The results showed that with the high toughness of Kevlar fiber, the deformation modes of the laminates exhibited some characteristics similar to the metal panel, such as large global deformation. The failure mechanisms like matrix failure, fiber splitting, and fibrillation were observed. These micron failures led to the macroscopic delamination and fracture of the laminates.     

泡沫铝夹芯板抗冲击性能分析

试验设计了3块钢板夹泡沫铝夹芯板,厚度分别为50 mm、70 mm和100 mm。对每种厚度夹芯板进行七组不同落锤高度的冲击试验,测得了上、下面板变形值,记录了夹芯板的破坏情况。应用数值模拟软件ANSYS/LS-DYNA进一步还原夹芯板冲击过程,导出了面板与芯材的吸能占比。基于假设的夹芯板理论模型,给出了平均冲击荷载、局部变形和整体变形最大值的估算公式。结果表明:当夹芯板尺寸和材料强度一定时,局部变形值与落锤高度的平方根成正比,整体变形最大值、平均冲击力均与落锤高度的平方根成线性关系。夹芯板的抗冲击性能主要依靠增大泡沫铝芯层的变形进行耗能,芯层越厚,泡沫铝吸能占比越大,局部变形越小,夹芯板受到的冲击力越大。     

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.     

钢板夹泡沫铝组合板抗爆性能数值模拟

鉴于泡沫铝材料良好的吸能特性和三明治型组合构件在强度、刚度上的优势,通过有限元分析软件ANSYS/LS-DYNA对钢板-泡沫铝-钢板三明治型组合板进行了装药量为10.0kgTNT的非接触爆炸数值模拟,考察组合板在爆炸荷载作用下的动力响应。研究表明:钢板夹泡沫铝组合板承受爆炸冲击波荷载时,响应方式主要为组合板整体弯曲变形和泡沫铝芯层局部压缩变形,芯层压缩变形是组合板吸收耗散能量的主要途径;适当地增加泡沫铝芯层厚度和面板厚度能够提高组合板的抗爆性能,同时使组合板充分发挥耗能作用。     

Dynamic response of clamped sandwich beam with aluminium alloy foam core subjected to impact loading

The dynamic response of clamped sandwich beam with aluminium alloy open-cell foam core subjected to impact loading is investigated in the paper. The face sheet and the core of the sandwich beam have the different thickness. And the sandwich beam is impacted by a steel projectile in the mid-span. The impact force is recorded by using accelerometer. The results show that tensile crack and core shear are the dominant failure modes. And the impact velocity and the thickness of the face sheet and the foam core have a significant influence on the failure modes and the impact forces. Combining with the inertia effect and experimental results, the failure mechanisms of the sandwich beams are discussed. The thickness of the foam core plays an important role in the failure mechanism of the sandwich beam. In present paper, the failure of the sandwich beam with a thin core is dominated by the bending moment, while the sandwich beam with a thick core fails by bending deformation in the front face sheet and the bottom face sheet in opposite direction due to the plastic hinges in the front face sheet.     

钢板夹泡沫铝组合板抗弯性能研究

试验设计了6块钢板夹泡沫铝组合板,其中无侧板组合板与有侧板组合板各为3块,侧板材料与面板相同,泡沫铝芯层厚度分别为40 mm、60 mm和90 mm。对组合板进行抗弯试验,绘制了组合板跨中荷载-位移（P-δ）曲线,记录了组合板变形失效过程。基于Gibson模型最大承载力公式建立了无侧板组合板的失效模式图。推导了有侧板组合板最大承载力计算公式,建立了失效模式图。结果表明:泡沫铝芯层厚度越大,组合板承载力越高,加载刚度越大。建立的失效模式图可以较好预测组合板的失效模式。与无侧板组合板相比,仅增加侧板,可以显著提高组合板的承载能力和加载刚度,有效限制泡沫铝开裂后裂缝的进一步开展。通常无侧板组合板每种失效模式仅独立对应失效模式图中一块区域,而有侧板组合板失效模式图被划分为四块区域,且表皮屈服失效模式独立对应两块区域。     

Dynamic models for low-velocity impact damage of composite sandwich panels – Part B: Damage initiation

Equivalent single and multi degree-of-freedom systems are used to predict low-velocity impact damage of composite sandwich panels by rigid projectiles. The composite sandwich panels are symmetric and consist of orthotropic laminate facesheets and a core with constant crushing resistance. The transient deformation response of the sandwich panels subjected to impact were predicted in a previous paper, and analytical solutions for the impact force and velocity at damage initiation in sandwich panels are presented in this second paper. Several damage initiation modes are considered, including tensile and shear fracture of the top facesheet, core shear failure, and tensile failure of back facesheet. The impact failure modes are similar to static indentation failure modes, but inertial resistance and high strain rate material properties of the facesheets and core influence impact damage loads. Predicted damage initiation loads and impact velocities compare well with experimental results.     

复合泡沫填充管的高g值冲击防护特性

目的 为避免或减小高g值冲击对弹内轻质元器件的破坏,应加强对轻质元器件缓冲防护结构的研究。方法 基于新型复合泡沫和通孔泡沫铝的2种泡沫填充管,通过万能试验机和落锤冲击系统研究了2种泡沫填充管的静动态力学特性,并运用数值模拟方法研究高g值冲击下等质量的泡沫填充管与夹芯管的加速度缓冲效果和吸能机制。结果 数值模拟所得结构变形和落锤加速度与实验结果较为一致,验证了数值模拟方法的可靠性。复合泡沫平台应力具有显著的应变率效应,其填充管压溃载荷平稳且高于泡沫铝填充管,比泡沫铝填充管体现出更优异的高过载防护性能。等质量的泡沫夹芯管的抗冲击性能优于填充管,2种泡沫填充而成的夹芯管具有相似的高过载防护性能,泡沫材料压缩行为对夹芯管压溃载荷特征的影响低于填充管。结论 所得结果对轻质元器件的高g值缓冲防护有较强的指导意义。     

Three-point bending of sandwich beams with aluminum foam-filled corrugated cores

Sandwich panels having metallic corrugated cores had distinctly different attributes from those having metal foam cores, the former with high specific stiffness/strength and the latter with superior specific energy absorption capacity. To explore the attribute diversity, all-metallic hybrid-cored sandwich constructions with aluminum foam blocks inserted into the interstices of steel corrugated plates were fabricated and tested under three-point bending. Analytical predictions of the bending stiffness, initial failure load, peak load, and failure modes were obtained and compared with those measured. Good agreement between analysis and experiment was achieved. Failure maps were also constructed to reveal the mechanisms of initial failure. Foam insertions altered not only the failure mode of the corrugated sandwich but also increased dramatically its bending resistance. All-metallic sandwich constructions with foam-filled corrugated cores hold great potential as novel lightweight structural materials for a wide range of structural and crushing/impulsive loading applications.     

泡沫铝夹层结构复合材料低速冲击性能

以泡沫铝为夹芯材料,玄武岩纤维(BF)和超高分子量聚乙烯纤维(UHMWPE)复合材料为面板,制备夹层结构复合材料。研究纤维类型、铺层结构和芯材厚度对泡沫铝夹层结构复合材料冲击性能和损伤模式的影响规律,并与铝蜂窝夹层结构复合材料性能进行对比分析。结果表明:BF/泡沫铝夹层结构比UHMWPE/泡沫铝夹层结构具有更大的冲击破坏载荷,但冲击位移和吸收能量较小。BF和UHMWPE两种纤维的分层混杂设计比叠加混杂具有更高的冲击破坏载荷和吸收能量。随着泡沫铝厚度的增加,夹层结构复合材料的冲击破坏载荷降低,破坏吸收能量增大。泡沫铝夹层结构比铝蜂窝夹层结构具有更高的冲击破坏载荷,但冲击破坏吸收能量较小;泡沫铝芯材以冲击部位的碎裂为主要失效形式,铝蜂窝芯材整体压缩破坏明显。     

Modelling of aluminium foam core sandwich panels under impact perforation

Aluminium foam core sandwich panels are good energy absorbers for impact protection applications, such as light-weight structural panels, packing materials and energy absorbing devices. In this study, the high-velocity impact perforation of aluminium foam core sandwich structures was analysed. Sandwich panels with 1100 aluminium face-sheets and closed-cell A356 aluminium alloy foam core were modelled by three-dimensional finite element models. The models were validated with experimental tests by comparing numerical and experimental damage modes, output velocity, ballistic limit and absorbed energy. By this model the influence of foam core and face-sheet thicknesses on the behaviour of the sandwich panel under impact perforation was evaluated.     

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.     

Deformation and failure of clamped shallow sandwich arches with foam core subjected to projectile impact

The dynamic response of clamped shallow sandwich arches with core of aluminum foam has been experimentally studied by impacting the arches at mid-span with metal foam projectiles. The resistance to shock loading is measured by the permanent transverse deflection at mid-span of the arches. The deformation mechanisms of shallow sandwich arches were investigated. In addition, the deformation/failure modes of the shallow sandwich arch were classified and analyzed systematically. The effects of initial projectile momentum, face sheet thickness, core thickness and radius of curvature on the structural response were obtained. The results indicated that permanent deflection at mid-span can be efficiently controlled by increasing face sheet thickness, core thickness or appropriately increasing curvature. Meanwhile, shock resistance of the shallow sandwich arch can also be improved. The experimental results are useful in the optimum design of cellular metallic sandwich structures.     

Design of sandwich structures for concentrated loading

While sandwich construction offers well-known advantages for high stiffness with light weight, the problem of designing the sandwich structure to withstand localized loading, such as from accidental impact, remains an important problem. This problem is more difficult with lower stiffness cores, such as expanded foam. In the present study, experiments have been carried out on foam core sandwich beams with carbon/epoxy faces, under conditions of concentrated loading. The variables considered were the density of the foam and the relative thickness of the core. The common failure modes of sandwich structures were observed, including core failure in compression and shear, delamination, and fiber failure in the faces. These failure modes were systematically related to the test variables by means of a detailed stress analysis of the specimen, and a consideration of the failure properties of the constituent materials. The loading is characterized by localized high stress and strain concentrations that are not predicted in first-order shear deformation sandwich beam theory. The three-dimensional elasticity solution of Pagano was used to obtain the stress distributions. The strength prediction requires a detailed consideration of the localized nature of the loading, including the effects of strain gradients in the faces. The results show that failure modes and load levels can be predicted for sandwich structures under concentrated loading, but that accurate predictions require a consideration of the details of the concentrated loading. The results have a direct application in predicting the ability of sandwich structures to withstand localized loading such as from accidental impact.     

陶瓷棒填充点阵金属夹层结构的制备及抗侵彻实验

为提高轻量化复合装甲的抗侵彻能力,提出了内部填充陶瓷棒并由混杂短切玻璃纤维的环氧树脂封装的点阵金属夹层防护结构。首先,通过弹道冲击实验研究了陶瓷棒填充点阵金属夹层防护结构的抗弹丸侵彻能力;然后,结合失效模式和吸能效率,综合分析了该夹层防护结构的抗侵彻机制。结果表明:陶瓷棒填充点阵金属夹层防护结构的主要失效模式包括点阵金属结构和混杂填充材料的拉伸断裂、陶瓷棒的破裂、面板和背板的局部剪切破坏以及背板的总体弯曲变形。在球形弹丸侵彻过程中,由于点阵金属结构的塑性大变形和剪切扩孔、陶瓷棒和环氧树脂的断裂破坏以及面板的宏观弯曲变形,防护结构的抗侵彻能力得到大幅提高。研究结果可为新型轻质复合装甲的防护设计提供一定参考。      

弹载加速度记录仪抗冲击防护结构设计

针对弹体侵彻混凝土环境,提出一种中薄型防护外壳嵌套内壳体,两壳体间填充泡沫铝缓冲材料的记录仪抗冲击防护结构。针对应力波作用下防护外壳的屈曲和泡沫铝缓冲性能不足导致内部电路模块冲击断裂的典型失效模式,通过对记录仪抗冲击防护结构在应力波作用下的结构响应分析,提出一套以壳体厚度h、泡沫铝密度ρ、泡沫铝厚度h_b为主要设计指标的弹载加速度记录仪抗冲击防护结构设计方法。设计出防护外壳半径为29 mm,壁厚3 mm,泡沫铝密度1.1g/cm~3,泡沫铝厚度23 mm的抗冲击防护结构,经计算该结构理论抗冲击能力为63 300 g。在实弹侵彻混凝土试验中,测得冲击加速度峰值为56 300 g,在此冲击下记录仪壳体结构稳定,内部电路工作正常,验证了此抗冲击防护结构具有较高的可靠性。     

Failure initiation and propagation characteristics of honeycomb sandwich composites

The energy absorbed during the failure of a variety of structural shapes is influenced by material, geometry and the failure mode. Failure initiation and propagation of the honeycomb sandwich under loading involves not only non-linear behavior of the constituent materials, but also complex interactions between various failure mechanisms. Therefore, there is a need for an improved understanding of the material characteristics and energy absorption modes to facilitate the design of sandwich performance. In the present study, failure initiation and propagation characteristics of sandwich beams and panels subjected to quasi-static and impact loadings were investigated. Experimental studies involved a series of penetration and perforation tests on 2D beam and 3D panel configurations using a truncated cone impactor with impact velocities up to 10 m/s. Preliminary tests were also performed on the sandwich beams subjected to the three-point bending. Load-carrying, energy-absorbing characteristics and failure mechanisms under quasi-static and impact loading were determined. Dominant deformation modes involved upper skin compression failure in the vicinity of the indenter, core crushing and lower skin tensile failure.