Structure and Mechanical Properties of AFS Sandwiches Studied by in‐situ Compression Tests in X‐ray Microtomography

Al foam core / Al alloy skins sandwiches have potential for application in light weight structures. Recently, the foaming processes have improved and large, thick and 3D‐shape panels can be produced using the precursor technology. The microstructure of an AFS sandwich is analysed in this paper at a microscale and a mesoscale using X‐ray tomography and conventional SEM analysis. The main deformation mechanism of the core under compression is also studied thanks to in situ test. It is shown that the foam first present plastic buckling and then walls rupture. This is well correlated to the microstructure of the constitutive material of the core.     

Development of Through-Thickness Reinforcement in Advanced Composites Incorporating Rigid Cellular Foams

This paper presents a method of joining carbon-fibre plies and rigid cellular foam core with stitching for producing light-weight composite structures. After resin infusion and consolidation, the stitched sandwich panel exhibits superior damage tolerance as well as improved transverse properties due to the presence of through-thickness fibre reinforcement. First part of the paper deals with the conceptual development of a multi-needle stitching machine for rigid foams. A needle penetration model for computing the penetration forces has been reported—there is a good agreement between the experimental and theoretical penetration force-displacement curves. A number of sandwich panels with orthogonal and bias stitch orientations have been developed and examined for stitch quality with the aid of X-ray tomography. The paper also presents results from quasi-static indentation, three-point bending and transverse compression tests, on both the stitched and unstitched sandwich panels.     

Analysis of SMA composite laminates using a multiscale modelling technique

The present work deals with the analysis of smart laminates, obtained as stacking sequence of fibre‐reinforced composite laminae and composite shape memory alloy (SMA) layers. The behaviour of composite SMA (CSMA) laminate is studied developing a full micro–macro approach. In fact, a non‐linear 4‐node mixed interpolation of tensorial components (MITC4) laminate finite element, based on the first‐order shear deformation theory, is developed. The SMA layer constitutive relationship is determined solving a non‐linear homogenization problem at each non‐linear iteration of each time step for each integration Gauss point. Some numerical applications are developed in order to investigate the influence of the CSMA on the buckling behaviour of plates and on the transversal displacement control of plates subjected to different loading conditions. Copyright © 2006 John Wiley & Sons, Ltd.     

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。     

Experimental, numerical, and analytical results for buckling and post-buckling of orthotropic rectangular sandwich panels

Rectangular orthotropic sandwich fiber reinforced plastic (FRP) panels were tested for buckling in uniaxial compression. The panels, with either balsa or linear PVC foam cores, were tested in two sizes: 183 cm×92 cm (72 in.×36 in.) and 122 cm×92 cm (48 in.×36 in.) for aspect ratios of 2.0 and 1.3, respectively. The sandwich panels were fabricated using the vacuum-assisted resin transfer molding (VARTM) technique. The two short edges of the sandwich panels were clamped, while the two long edges were simply supported. The experimental elastic buckling loads of panels with an aspect ratio of 1.3 were 400 kN (90 klb) for balsa core panels and 267 kN (60 klb) for foam core panels. For balsa and foam core panels with an aspect ratio 2.0, the experimental buckling loads were 334 kN (75 klb) and 240 kN (54 klb), respectively. Experimental buckling results for balsa core panels of both sizes differed by 5–8% from numerical and analytical results. Differences in experimental and predicted buckling loads for foam core panels ranged between 15% and 23%. Post-buckling collapse of balsa and foam core panels with an aspect ratio of 1.3 were 694 kN (156 klb) and 347 kN (78 klb), respectively. For balsa and foam core panels with an aspect ratio of 2.0, post-buckling collapse occurred at 592 kN (133 klb) and 334 kN (75 klb), respectively. A numerical post-buckling analysis qualitatively followed that of the experimental results.     

Dynamic response of aluminum honeycomb sandwich panels under foam projectile impact

The dynamic response of honeycomb sandwich panels under aluminum foam projectile impact was investigated. The different configurations of panels were tested, and deformation/failure modes were obtained. Corresponding numerical simulations were also presented to investigate the energy absorption and deformation mechanism of sandwich panels. Results showed that the deformation/failure modes of sandwich panels were sensitive to the impact velocity and density of aluminum foam. When the panel was impacted by the aluminum foam projectile with the back mass of nylon, the “accelerating impact” stage can be produced and may lead to further compression and damage of the sandwich structures.     

Compressive and shear buckling analysis of metal matrix composite sandwich panels under different thermal environments

Combined inplane compressive and shear buckling analysis was conducted on flat rectangular sandwich panels using the Rayleigh-Ritz minium energy method with a consideration of transverse shear effect of the sandwich core. The sandwich panels were fabricated with titanium honeycomb core and laminated metal matrix composite face sheets. The results show that slightly slender (along the unidirectional compressive loading axis) rectangular sandwich panels have the most desirable stiffness-to-weight ratios for aerospace structural applications; the degradation of buckling strength sandwich panels with rising temperature is faster in shear than in compression; and the fiber orientation of the face sheets for optimum combined-load buckling strength of sandwich panels is a strong function of both loading condition and panel aspect ratio. Under the same specific weight and panel aspect ratio, a sandwich panel with metal matrix composite face sheets has a much higher buckling strength than one having monolithic face sheets.     

Failure mechanisms on composite specimens subjected to compression after impact

Composite panels are widely used in aeronautic and aerospace structures due to their high strength/weight ratio. The stiffness and the strength in the thickness direction of laminated composite panels is poor since no fibres are present in that direction and out-of-plane impact loading is considered potentially dangerous, mainly because the damage may be left undetected. Impact loading in composite panels leads to damage with matrix cracking, inter-laminar failure and eventually fibre breakage for higher impact energies. Even when no visible impact damage is observed at the surface on the point of impact, matrix cracking and inter-laminar failure can occur, and the carrying load of the composite laminates is considerably reduced. The greatest reduction in loading is observed in compression due to laminae buckling in the delaminated areas. The objective of this study is to determine the mechanisms of the damage growth of impacted composite laminates when subjected to compression after impact loading. For this purpose a series of impact and compression after impact tests were carried out on composite laminates made of carbon fibre reinforced epoxy resin matrix. An instrumented drop-weight-testing machine and modified compression after impact testing equipment were used together with a C-scan ultrasonic device for the damage identification. Four stacking sequences of two different epoxy resins in carbon fibres representative of four different elastic behaviours and with a different number of interfaces were used. Results showed that the delaminated area due to impact loading depends on the number of interfaces between plies. Two buckling failure mechanisms were identified during compression after impact, which are influenced more by the delamination area than by the stacking sequence.     

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。     

Buckling,collapse and failure analysis of FRP sandwich panels

Rectangular orthotropic fiber-reinforced plastic (FRP) sandwich panels were tested for buckling in uni-axial compression. The panels, with 0.32 cm (0.125 in.) face sheets and a 1.27 cm (0.5 in.) core of either balsa or linear poly(vinyl chloride) (PVC) foam, were tested in two sizes: 154×77 cm² (72×36 in.²) and 102×77 cm² (48×36 in.²). The sandwich panels were fabricated using the vacuum-assisted resin transfer molding process. The two short edges of the sandwich panels were clamped, while the two long edges were simply supported for testing. The clamped panel ends were potted into a steel frame. The experimental elastic buckling loads were then measured using strain gauges fixed to both sides of the panels. A total of 12 panels were tested under uni-axial compression. Bifurcation in the load versus engineering strain curve was noted in all cases. For all six sandwich panels tested using balsa core, the type of failure was easily identified as face sheet delamination followed by core shear failure. For all six PVC foam core sandwich panels tested, the type of failure consisted of core shear failure with little or no face sheet delamination. In the failed balsa core panels there was little or no evidence of balsa remaining on the FRP face sheet, however, in the PVC foam core panels there were ample amounts of foam left on the FRP face sheet. It was concluded that although the buckling loads for the foam core panels were not as high as those for the balsa core panels, PVC foam core bonding to the FRP face sheets was superior to balsa core bonding.     

Compression, flexure and shear properties of a sandwich composite containing defects

The mechanical properties of a sandwich composite containing interfacial cracks or impact damage are compared when loaded in edgewise compression, flexure or shear. The composite is made from glass fibre reinforced polymer (GFRP) laminate skins over a core of foamed poly vinyl chloride (PVC), and this sandwich material is used in some naval minehunting ships. The properties are reduced with increasing interfacial crack or impact damage length, but only when the defects cause a change in the failure mode, which is dependent on the load state. The principal failure modes under the different load states are compared. The properties are also dependent on the severity of impact damage, with low energy damage to the skin having a smaller effect on stiffness and strength than high energy impacts which damage both the skin and foam core. The implications of these findings on the structural integrity of a minehunting ship made from GFRP/PVC foam sandwich composite is discussed.     

Performance evaluation of sandwich panels subjected to bending compression and thermal bowing

The engineering performance of sandwich panels with expanded polystyrene foam core and steel or aluminium faces is evaluated in this paper. Such panels are usually used in semi-structural building applications with an insulating function. Bending, compression and thermal bowing experiments are conducted on these panels in the laboratory and their results are shown to conform in general to design values determined by current building codes and commercial practices. In edge-wise compression tests failure by column buckling has never occurred and localised face wrinkling is the usual failure mode. The adhesion between the polystyrene core and the metal skin as well as the location of the polystyrene joint in the panel are shown to have significant effects on the integral performance of the sandwich panels.     

Highly Stretchable,Shape Memory Organohydrogels Using Phase‐Transition Microinclusions

Shape memory effect in polymer materials has attracted considerable attention due to its promising applications in a variety of fields. However, shape memory polymers prepared by conventional strategy suffer from a common problem, in which high strain capacity and excellent shape memory behavior cannot be simultaneously achieved. This study reports a general and synergistic strategy to fabricate high‐strain and tough shape memory organohydrogels that feature binary cooperative phase. The phase‐ transition micro‐organogels and elastic hydrogel framework act synergistically to provide excellent thermomechanical performance and shape memory effect. During shape memory process, the organohydrogels exhibit high strain capacity, featuring fully recoverable stretching deformation by up to 2600% and compression by up to 85% beneath a load ≈20 times the organohydrogel's weight. Furthermore, owing to the micro‐organogel and hydrogel heterostructures, the interfacial tension derived from heterophases dominates the shape recovery of the organohydrogel material. Simple processing and smart surface patterning of the shape memory behavior and multiple shape memory effects can also be realized. Meanwhile, these organohydrogels are also nonswellable in water and oil, which is important for multimedia applications.     

Compressive strength after impact of CFRP-foam core sandwich panels in marine applications

A plastic micro buckling approach is investigated in order to see whether it can be used to analytically predict the residual strength of carbon fiber sandwich structures.

A parametric study on impact damage resistance and residual strength of sandwich panels with carbon fiber-vinylester faces and PVC foam core is conducted. Two sandwich configurations are studied. The first configuration consists of thin faces and an intermediate density core, representative of a panel from a superstructure. The second configuration consists of thick faces and a high density core, representative of a panel from a hull. Two different impactor geometries are used. One spherical impactor and one pyramid shaped impactor are used in a drop weight rig to inflict low velocity impact damage of different energy levels in the face of the sandwich.

The damages achieved ranges from barely visible damages to penetration of one face. Residual strength is tested using in-plane compression of the sandwich plates either instrumented with strain gauges or monitored with digital speckle photography.     

全厚度缝合复合材料泡沫芯夹层结构力学性能研究与损伤容限评定

探索了全厚度缝合复合材料闭孔泡沫芯夹层结构低成本制造的工艺可行性及其潜在的结构效益。选用3 种夹层结构形式, 即相同材料和工艺制造的未缝合泡沫芯夹层和缝合泡沫芯夹层结构及密度相近的Nomex 蜂窝夹层结构, 完成了密度测定、三点弯曲、平面拉伸和压缩、夹层剪切、结构侧压和损伤阻抗/ 损伤容限等7 项实验研究。结果表明, 泡沫芯夹层结构缝合后, 显著提高了弯曲强度/ 质量比、弯曲刚度/ 质量比、面外拉伸和压缩强度、剪切强度和模量、侧压强度和模量、冲击后压缩(CAI) 强度和破坏应变。这种新型结构形式承载能力强、结构效率高、制造维护成本低, 可以在飞机轻质机体结构设计中采用。      

Design and manufacture of all-PP sandwich panels based on co-extruded polypropylene tapes

This paper describes the creation of polypropylene sandwich panels, based on all-polypropylene (all-PP) composite laminates combined with a polypropylene based honeycomb or foam core. These all-PP composite laminates are based on high modulus polypropylene tape reinforcing a polypropylene matrix. Sandwich panels containing these all-PP composite laminate faces are compared with sandwich panels containing conventional glass fibre reinforced polypropylene laminate faces, and the mechanical properties, failure modes, and design requirements of these different materials are discussed.     

Local buckling loads of sandwich panels made with laminated faces

The paper is devoted to assessing the optimal arrangements of hybrid laminated faces of sandwich panels in order to maximize local buckling loads corresponding to the wrinkling of compressed faces. The analysis is carried out by modelling compressed faces as thin unsymmetric laminates resting on elastic two-parameter foundations. The First-order Shear Deformation Theory, in conjunction with the Rayleigh-Ritz method, has been used to evaluate buckling loads of simply supported flat laminates subjected to in-plane biaxial compression and shear forces. A numerical investigation is intended to support evidence for the influence of laminate parameters (fibre orientation, geometrical dimensions) and foundation parameters (modulus of subgrade reaction and shear modulus); obtained results are reported and discussed in the paper.     

明胶鸟弹撞击复合材料蜂窝夹芯板试验

开展明胶鸟弹撞击复合材料蜂窝夹芯板试验,研究夹芯结构在软体高速冲击下的损伤形式,分析相关因素对结构动态响应结果的影响。通过CT扫描对复合材料蜂窝夹芯板内部进行检测可知,面板出现分层、基体开裂、纤维断裂、凹陷、向胞内屈曲等损伤形式,蜂窝芯出现芯材压溃、与面板脱粘的损伤形式;分析复合材料蜂窝夹芯板后面板的动态变形过程及撞击中心处位移-时间数据可知,复合材料蜂窝夹芯板在撞击过程中出现由全局弯曲变形主导和局部变形主导的两种变形模式;通过对比不同工况下的复合材料蜂窝夹芯板损伤程度可知,复合材料蜂窝夹芯板损伤程度随鸟弹撞击速度的增加而增大;蜂窝芯高度为10 mm的复合材料蜂窝夹芯板较蜂窝芯高度为5 mm的复合材料蜂窝夹芯板的损伤程度大;初始动能较大的球形鸟弹较圆柱形鸟弹对复合材料蜂窝夹芯板造成的冲击损伤程度更大。      

Cutout reinforcements for shear loaded laminate and sandwich composite panels

This paper presents the numerical and experimental studies of shear loaded laminated and sandwich carbon/epoxy composite panels with cutouts and reinforcements aiming at reducing the cutout stress concentration and increasing the buckling stability of the panels. The effect of different cutout sizes and the design and materials of cutout reinforcements on the stress and buckling behaviour of the panels are evaluated. For the sandwich panels with a range of cutout size and a constant weight, an optimal ratio of the core to the face thickness has been studied for the maximum buckling stability. The finite element method and an analytical method are employed to perform parametric studies. In both constant stress and constant displacement shear loading conditions, the results are in very good agreement with those obtained from experiment for selected cutout reinforcement cases. Conclusions are drawn on the cutout reinforcement design and improvement of stress concentration and buckling behaviour of shear loaded laminated and sandwich composite panels with cutouts.     

Mechanical behaviour of cellular core for structural sandwich panels

This paper deals with the analysis of the mechanical properties of the core materials for sandwich panels. In this work, the core is firstly a honeycomb and secondly tubular structure. This kind of core materials are extensively used, notably in automotive construction (structural components, load floors...). For this study, three approaches are developed: a finite element analysis, an analytical study and experimental tests. Structural members made up of two stiffs, strong skins separated by a lightweight core (foam, honeycomb, tube...) are known as sandwich panels. The separation of the skins by the core increases the inertia of the sandwich panel, the flexure and shear stiffness. This increase is obtained with a little increase in weight, producing an efficient structure to resist bending and buckling loads. A new analytical method to analyse sandwich panels core will be presented. These approaches (theoretical and experimental) are used to determine elastic properties and ultimate stress. A parameter study is carried out to determine elastic properties as a function of geometrical and mechanical characteristics of basic material. Both theoretical and experimental results are discussed and a good correlation between them is obtained.