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Mechanics of Thin-Walled Structures and Other Lightweight Constructions

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Construction and Building Materials".

Deadline for manuscript submissions: closed (20 August 2025) | Viewed by 9908

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Prof. Dr. Haim Abramovich

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Department of Aerospace Engineering, Technion, Israel Institute of Technology, Haifa 32000, Israel
Interests: stability of thin-walled structures; static and dynamic behavior of thin-walled structures; smart structures; piezoelectric materials; shape memory materials
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Special Issue Information

Dear Colleagues,

The topic for this Special Issue is “Mechanics of Thin-Walled Structures and Other Lightweight Constructions.” Thin-walled and lightweight structures must provide operational demands and safety within a minimal weight. Typical structures would be made of thin load skins’ frames, stiffeners, and spars, all made of high strength and stiffness materials to comply with the desired minimal weight criteria. Although the topic was extensively presented in the literature, new and innovative studies on non-linear behavior as compared to their linear behavior started to be more and more present.

The present Special Issue aims to provide a new platform for recent studies on the structural behavior of thin-walled and lightweight structures in their linear and non-linear regimes.

These studies can present those structures' static and dynamic behavior, highlighting new numerical methods, finite element solutions, and experimental results.

Prof. Dr. Haim Abramovich
Guest Editor

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Keywords

thin-wall structures
lightweight construction
sandwich panels
fiber-reinforced polymer composite
beams
plates
panels
numerical analysis
experiments
displacements
stresses
boundary conditions
linear behavior
non-linear behavior

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Related Special Issue

Mechanics of Thin-Walled Structures and Other Lightweight Constructions (Second Edition) in Materials

Published Papers (9 papers)

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Research

18 pages, 5808 KB

Open AccessArticle

Shear and Compression Wrinkling Experimental Analysis with a Sandwich Beam Submitted to Three-Point Bending

by Befekadu Gashe, Abdulmaliq Alawode, Samuel Rivallant and Bruno Castanié

Materials 2025, 18(18), 4286; https://doi.org/10.3390/ma18184286 (registering DOI) - 12 Sep 2025

Viewed by 501

Abstract

Wrinkling is a localized buckling phenomenon that significantly compromises the structural integrity of lightweight sandwich structures. The objective of this study was to validate the experimental design of a sandwich beam to observe the initiation of wrinkling under compression and, more specifically, under shear stresses. The specimen under consideration consists of glass fibre–epoxy skins with polymethacrylimide (PMI) ROHACELL^® foam cores. The experimental tests were monitored using Digital Image Correlation (DIC) techniques, in conjunction with displacement and force sensors. A linear buckling simulation was performed using Finite Element Analysis (FEA) in ABAQUS and was compared with both the experimental test results and analytical predictions. The simulations demonstrated a good correlation with both the experimental data and analytical models for compression wrinkling. In the case of shear wrinkling, the numerical analysis significantly overestimated the wrinkling load in comparison to the experimental results. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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22 pages, 5409 KB

Open AccessArticle

Behavior of Defective Aluminum Panels Under Shear Forces Patched with Composite Plates—A New Engineering Approach

by Yuri Simanovskii and Haim Abramovich

Materials 2025, 18(17), 4138; https://doi.org/10.3390/ma18174138 (registering DOI) - 3 Sep 2025

Viewed by 1016

Abstract

Old airplanes produced in the 1970s are still flying, while being exposed to various new types of detriments, leading to a need to repair them to enable the safe use of the airborne body. The present state of the art advocates the use of laminated composite to repair aluminum parts due to their effective durability. The studies presented in the literature mainly focused on bodies under tensile loads. It seems that shear-type loading appearing in the fuselage of airplanes when being under torsion has been ignored in literature. Therefore, to fill this gap, the present study investigates the behavior of defective aluminum panels under pure shear. The present investigation uses a novel finite element (FE) method of modelling the loaded body by 2D and 3D elements. Then, the model is used to calculate the influence of various parameters, like the size of the repair patch, overlaps, sequences of the laminated composite plate, and other structural properties on the stability and strength of the examined part. To validate the numerical predictions, tests were performed on typical elements. Based on the experimental results, the fidelity of the FE model was assessed and the method approach of repairing using composite patches was validated. The main conclusion from the present study is the use of solid (3D) elements, over shell (2D) elements, due to their high-fidelity results. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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20 pages, 20993 KB

Open AccessArticle

Experimental Structural Template on Tensegrity and Textile Architecture Integrating Physical and Digital Approaches

by Zhiyuan Zhang, Salvatore Viscuso, Alessandra Zanelli and Jinghan Chen

Materials 2025, 18(8), 1721; https://doi.org/10.3390/ma18081721 - 9 Apr 2025

Cited by 1 | Viewed by 704

Abstract

The construction industry is a major contributor to global carbon emissions, driving the need for sustainable solutions. Ultra-lightweight structures have emerged as an effective approach to reducing material usage and energy consumption. This study explores the potential of ultra-lightweight architectural systems through a learning-by-doing methodology, integrating innovative composite materials, PolRe, and knitting techniques to enhance tensegrity structures for sustainable, deployable, and efficient structural designs. Combining physical modeling, inspired by Frei Otto and Heinz Isler, with digital simulations using Kangaroo 2 and Python, this research employs form-finding and finite element analysis to validate structural performance. A 1:5 scale prototype was constructed using a manual knitting machine adapted from traditional knitting techniques. The integration of elastic meshes and rigid joints produced modular tensegrity systems that balance tension and compression, creating reversible, deployable, and material-efficient solutions. This study bridges conceptual aesthetics with structural efficiency, providing a template for sustainable, ultra-lightweight, textile-based structures. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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14 pages, 4036 KB

Open AccessArticle

Comparative Analysis and Dynamic Size Optimization of Aluminum and Carbon Fiber Thin-Walled Structures of a Railway Vehicle Car Body

by Alessio Cascino, Enrico Meli and Andrea Rindi

Materials 2025, 18(7), 1501; https://doi.org/10.3390/ma18071501 - 27 Mar 2025

Cited by 5 | Viewed by 736

Abstract

In the context of modern railway engineering, the demand for lighter and more reliable vehicles has become a key objective for rolling stock manufacturers. Reducing energy consumption and minimizing environmental impact are driving the adoption of advanced materials and innovative design methodologies. This research activity focuses on a comparative analysis between aluminum and carbon fiber thin-walled structures used in railway vehicle car bodies. A high-fidelity finite element model (FEM) of a complete railway vehicle was developed to evaluate structural performance in compliance with European standards. Gaining deeper insights, one of the car body structures was isolated for a detailed dynamic analysis, enabling a comparative evaluation of the two materials. A structural dynamic size optimization process was applied to specific key components, aiming to maximize mass savings while maintaining mechanical integrity. The results exhibited an increase of approximately 10% in the first 10 car body eigenvalues, despite a mass reduction per unit of volume exceeding 30%, while largely preserving the nature of the eigenvectors. From a static perspective, both materials demonstrated good performance, with percentage differences below 20%. The optimization process highlighted significant potential for weight reduction in the analyzed structures. The findings highlight the critical role of optimization processes in streamlining design choices for lightweight structures. Moreover, they underscore the significant potential of high-performance carbon fiber materials in enhancing the efficiency and sustainability of railway vehicles. This study provides valuable insights for future research and practical applications in the field of lightweight railway vehicle design. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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20 pages, 4590 KB

Open AccessArticle

Computationally Efficient p-Version Finite Element Analysis of Composite-Reinforced Thin-Walled Cylindrical Shells with Circumferential Cracks

by Jae S. Ahn

Materials 2025, 18(7), 1404; https://doi.org/10.3390/ma18071404 - 21 Mar 2025

Cited by 1 | Viewed by 455

Abstract

Cylindrical shells are extensively employed in fluid transport, pressure vessels, and aerospace structures, where they endure mechanical and environmental stresses. However, under high pressure or external loading, circumferential cracks may develop, threatening structural integrity. Composite patch reinforcement is an effective method to mitigate crack propagation and restore structural performance. This study presents a finite element model using p-refinement techniques to analyze cylindrical shells with circumferential cracks reinforced by composite patches. The approach integrates equivalent single-layer (ESL) and layer-wise (LW) theories within a unified single-element mesh, significantly reducing the degrees of freedom compared to conventional LW models. Fracture analysis is conducted using the virtual crack closure technique (VCCT) to evaluate stress intensity factors. The model’s accuracy and efficiency are verified through benchmark and patch reinforcement simulations. Additionally, a parametric study examines how patch material, thickness, and adhesive properties affect reinforcement efficiency across varying crack angles. This study provides an effective methodology for analyzing composite-reinforced thin-walled cylindrical shells, offering valuable insights for aerospace, marine, and pipeline engineering. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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39 pages, 13329 KB

Open AccessArticle

Large Deflection Analysis of Bimodular Functionally Graded Truncated Thin Conical Shells Under Mechanical and Thermal Loads

by Xiao-Ting He, Ming-Wei Luo, He-Hao Feng and Jun-Yi Sun

Materials 2025, 18(2), 362; https://doi.org/10.3390/ma18020362 - 14 Jan 2025

Viewed by 1128

Abstract

The purpose of this study is to analyze the large deflection problem of bimodular functionally graded truncated thin conical shells under the transverse mechanical load and non-uniform thermal load, in which two different boundary constraints of the truncated shell with two ends simply supported and fully fixed are considered. It is assumed that the temperature distribution along the thickness direction satisfies the Fourier law of heat transfer, and the material properties change exponentially along the thickness direction while different properties in tension and compression are considered. The geometric equation of the conical shell is established based on the equivalent method of curvature correction of von-Kármán deformation theory, and the analytical solution of the problem is obtained by Ritz method. Numerical simulation of bimodular functionally graded conical shells under the thermal and mechanical loads is carried out by Abaqus, and the numerical solution agrees with the theoretical solution. The results show that the introduction of bimodular functionally graded material will affect the maximum displacement and this effect has different rules under the mechanical load and thermal load. In addition, factors such as the cone apex angle and the truncated distance have a great influence on the maximum displacement and its location of the conical shell. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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18 pages, 28496 KB

Open AccessArticle

Verification of Numerical Models of High Thin-Walled Cold-Formed Steel Purlins

by Přemysl Pařenica, Martin Krejsa, Jiří Brožovský and Petr Lehner

Materials 2024, 17(17), 4392; https://doi.org/10.3390/ma17174392 - 5 Sep 2024

Viewed by 1404

Abstract

High thin-walled cold-formed steel purlins of the Z cross section are important elements of large-span steel structures in the construction industry. The present numerical study uses the finite element method to analyse the 300 mm and 350 mm high Z cross sections in-depth. The prepared numerical models are verified and validated at several levels with experiments that have been previously published. Significant agreement between the numerical models and the experimental results regarding Mises stress, proportional strain, failure mode, and force-deformation diagram have been obtained. With the verification, the presented procedure and partial findings can be applied to other similar problems. The results can be used to help research and corporate groups optimise the structural design of cold-formed thin-walled steel structures. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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26 pages, 5898 KB

Open AccessArticle

Evaluation of the Influence of Bolt Fastener Spacing on the Elastic Critical Load from the Lateral-Torsional Buckling Condition of Built-Up Bending Members

by Rafał Piotrowski and Andrzej Szychowski

Materials 2024, 17(14), 3392; https://doi.org/10.3390/ma17143392 - 9 Jul 2024

Viewed by 1037

Abstract

In an experimental study of two-branched beams bent transversely about the major stiffness axis, the elastic critical load from the lateral-torsional buckling condition was determined. The tests were conducted on simply supported two-branch beam models with a built-up section consisting of two cold-formed channel members (2C) bolted back-to-back. The bolts were located at the mid-height of the built-up cross-section. Five groups of members differing in longitudinal bolt spacing were examined. The models were gravitationally loaded (using ballast) at the centre of the beam span. This approach eliminated the undesirable effect of the lateral support of the beam, e.g., by the actuator head. The critical load, measured by the concentrated transverse force (P_z_,cr), was determined using the modified Southwell method. It has been experimentally shown that, in built-up beams, there is an influence of bolt spacing on the elastic critical load from the lateral-torsional buckling condition. The lowest critical load capacity and the most non-linear behaviour of the built-up member were observed in beams bolted with only three bolts (at the supports and in the middle of the span). However, the experimental results obtained in this study show that increasing the number of bolts above a certain level (in the case of the tested models, it was seven bolts) does not result in a further increase in the critical load, which is a surprising result. The obtained values were 15 to 23% lower than the critical load determined numerically by the finite element method (LTBeamN) for an analogous element with a uniform I-section. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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15 pages, 7496 KB

Open AccessArticle

The Behavior of Long Thin Rectangular Plates under Normal Pressure—A Thorough Investigation

by Gilad Hakim and Haim Abramovich

Materials 2024, 17(12), 2902; https://doi.org/10.3390/ma17122902 - 13 Jun 2024

Cited by 2 | Viewed by 1259

Abstract

Thin rectangular plates are considered basic structures in various sectors like aerospace, civil, and mechanical engineering. Moreover, isotropic and laminated composite plates subjected to transverse normal loading and undergoing small and large deflections have been extensively studied and published in the literature. Yet, it seems that the particular case of long thin plates having a high aspect ratio appears to be almost ignored by various scholars despite its engineering importance. The present study tries to fill this gap, yielding novel findings regarding the structural behavior of long thin plates in the small- and large-deflection regimes. In contrast to what is normally assumed in the literature, namely that a long plate with a high aspect ratio can be considered an infinitely long plate, the present results clearly show that the structural effects of the ends continue to exist near the remote ends of the long plate. An innovative finding is that long plates would (only on movable boundary conditions for the large-deflection regime) exhibit a larger mid-width displacement in comparison with deflections of infinitely long plates. This innovative higher deflection appears for both small and large-deflection regimes for both all-around simply supported and all-around clamped boundary conditions. This new finding was shown to be valid for both isotropic and orthotropic materials and presents a novel engineering approach for the old assumption well quoted in the literature that a relatively long plate on any boundary condition can be considered an infinite plate. Based on the present research, it is recommended that this assumption should be used carefully as the largest plate mid-deflection might occur at finite aspect ratios. Full article

(This article belongs to the Special Issue Mechanics of Thin-Walled Structures and Other Lightweight Constructions)

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