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Lightweight and High-Strength Sandwich Panel

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: 20 December 2024 | Viewed by 22446

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Prof. Dr. Yifeng Zhong

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Guest Editor

School of Civil Engineering, Chongqing University, Chongqing 400044, China
Interests: metamaterials; auxetic; cellular structures; sandwich panel; truss lattice structures; mechanics
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Liming Chen

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Guest Editor

College of Aerospace Engineering, Chongqing University, Chongqing 400030, China
Interests: mechanics of composite materials and structures; impact damage and failure of structures; mechanics of metamaterials and metastructures; functional integrated design of aerospace materials and structures
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Special Issue Information

Dear Colleagues,

Lightweight and high-strength sandwich panel has the advantages of high specific strength and specific stiffness properties, and so has good application prospects in aerospace, shipbuilding, and construction industries. With the development of sandwich structure design and optimization, different core shapes appear and are applied in various engineering fields, such as honeycomb sandwich panels, lattice sandwich panels, foam sandwich panels, and so on. At the same time, the development of industry also requires the development of sandwich panel materials and processes, such as the emergence and production of fiber sandwich panels. This Special Issue is dedicated to the mechanical performances of lightweight sandwich panels. Topics of interest include (but are not limited to): experiments on lightweight and high-strength sandwich panels; mechanical analysis of lightweight and high-strength sandwich panels; numerical simulations of lightweight and high-strength sandwich panels; damage and failure of lightweight and high-strength sandwich panels; design and application of lightweight and high-strength sandwich panels; multiscale modeling of lightweight and high-strength sandwich panels; and the optimization of lightweight and high-strength sandwich panels.

Prof. Dr. Yifeng Zhong
Prof. Dr. Liming Chen
Guest Editors

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Keywords

multiscale modeling
damage and failure
design and application
experiments

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Published Papers (10 papers)

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Research

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25 pages, 5656 KiB

Open AccessArticle

Dynamic Characteristics of Composite Sandwich Panel with Triangular Chiral (Tri-Chi) Honeycomb under Random Vibration

by Hui Yuan, Yifeng Zhong, Yuxin Tang and Rong Liu

Materials 2024, 17(16), 3973; https://doi.org/10.3390/ma17163973 - 9 Aug 2024

Viewed by 284

Abstract

A full triangular chiral (Tri-Chi) honeycomb, combining a honeycomb structure with triangular chiral configuration, notably impacts the Poisson’s ratio (PR) and stiffness. To assess the random vibration properties of a composite sandwich panel with a Tri-Chi honeycomb core (CSP-TCH), a two-dimensional equivalent Reissner–Mindlin model (2D-ERM) was created using the variational asymptotic method. The precision of the 2D-ERM in free and random vibration analysis was confirmed through numerical simulations employing 3D finite element analysis, encompassing PSD curves and RMS responses. Furthermore, the effects of selecting the model class were quantified through dynamic numerical examples. Modal analysis revealed that the relative error of the first eight natural frequencies predicted by the 2D-ERM consistently remained below 7%, with the modal cloud demonstrating high reliability. The PSD curves and their RMS values closely aligned with 3D finite element results under various boundary conditions, with a maximum error below 5%. Key factors influencing the vibration characteristics included the ligament–rib angle of the core layer and layup modes of the composite facesheets, while the rib-to-ligament thickness ratio and the aspect ratio exert minimal influence. The impact of the ligament–rib angle on the vibration properties primarily stems from the significant shift in the core layer’s Poisson’s ratio, transitioning from negative to positive. These findings offer a rapid and precise approach for optimizing the vibration design of CSP-TCH. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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16 pages, 7104 KiB

Open AccessArticle

Mechanical Behavior of Bio-Inspired Honeycomb–Core Composite Sandwich Structures to Low-Velocity Dynamic Loading

by Tao Tao, Lizheng Li, Qiang He, Yonghui Wang and Junlan Guo

Materials 2024, 17(5), 1191; https://doi.org/10.3390/ma17051191 - 4 Mar 2024

Cited by 2 | Viewed by 1171

Abstract

In order to improve the impact resistance of sandwich panels under low-velocity impact, the lotus leaf vein is selected as a biological prototype to design a bio-inspired honeycomb (BIH) sandwich panel. ABAQUS is used to establish and effectively verify the finite element (FE) model of the BIH sandwich panel. To systematically compare and study the mechanical properties of BIH and conventional hexagonal honeycomb sandwich panels under low-velocity impact, the maximum displacement of face-sheets, the deformation mode, the plastic energy consumption and the dynamic response curve of the impact end are presented. At the same time, the performance differences between them are revealed from the perspective of an energy absorption mechanism. Furthermore, the influence of the circumscribed circle diameter ratio of the BIH trunk to branch (γ), the thickness ratio of the trunk to branch (K) and the impact angle (θ) on impact resistance is studied. Finally, the BIH sandwich panel is further optimized by using the response surface method. It can be concluded that, compared to conventional hexagonal honeycomb sandwich panels, the addition of walls in the BIH sandwich panel reduces the maximum deformation of the rear face-sheet by 10.29% and increases plastic energy consumption by 8.02%. Properly adjusting the structural parameters can effectively enhance the impact resistance of the BIH sandwich panel. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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14 pages, 4448 KiB

Open AccessArticle

The Effect of Microballoon Volume Fraction on the Elastic and Viscoelastic Properties of Hollow Microballoon-Filled Epoxy Composites

by Rojer Chitrakar, Md Sakhawat Hossain and Sabrina Nilufar

Materials 2023, 16(24), 7554; https://doi.org/10.3390/ma16247554 - 7 Dec 2023

Viewed by 1773

Abstract

This paper reports the study of hollow microballoon-filled epoxy composites also known as syntactic foams with various volume fractions of microballoons. Different mechanical and thermomechanical investigations were carried out to study the elastic and viscoelastic behavior of these foams. The density, void content, and microstructure of these materials were also studied for better characterization. In addition to the experimental testing, a representative 3D model of these syntactic foams was developed to further investigate their elastic behavior. The results indicate that changes in the volume percentage of the microballoons had a substantial impact on the elastic and viscoelastic behavior of these foams. These results will help in designing and optimizing custom-tailored syntactic foams for different engineering applications. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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14 pages, 2830 KiB

Open AccessArticle

Improved Interlaminar Properties of Glass Fiber/Epoxy Laminates by the Synergic Modification of Soft and Rigid Particles

by Jingwei Liu, Shenghui Tian, Jiaqi Ren, Jin Huang, Lin Luo, Bing Du and Tianyong Zhang

Materials 2023, 16(19), 6611; https://doi.org/10.3390/ma16196611 - 9 Oct 2023

Cited by 3 | Viewed by 1147

Abstract

Poor interlaminar fracture toughness has been a major issue in glass fiber-reinforced epoxy resin (GF/EP) laminate composites. In this paper, soft carboxy-terminated nitrile (CTBN) rubber particles and rigid nano-SiO₂ are used to toughen the epoxy resin (EP) matrix to improve the interlayer properties of GF/EP laminate composites. The effects of adding two toughening agents on the mechanical and interlayer properties of GF/EP laminates were studied. The results showed that adding the two kinds of particles improved the mechanical properties of the epoxy matrix. When the additional amount of flexible CTBN rubber particles was 8 wt%, and the rigid nano-SiO₂ was 0.5 wt%, the fracture toughness of the matrix resin was increased by 215.8%, and the tensile strength was only decreased by 2.3% compared with the pure epoxy resin. On this basis, the effects of two kinds of particles on the interlayer properties of GF/EP composites were studied. Compared with the unmodified GF/EP laminates, the interlayer shear strength and mode I interlayer fracture toughness is significantly improved by a toughening agent, and the energy release rate G_IC of interlayer shear strength and interlayer fracture toughness is increased by 109.2%, and 86.8%, respectively. The flexible CTBN rubber particles and rigid nano-SiO₂ improve the interfacial adhesion between GF and EP. The cavitation of the two particles and the plastic deformation of the matrix is the toughening mechanism of the interlayer properties of the composite. Such excellent interlaminar mechanical properties make it possible for GF/EP laminates to be widely used as engineering materials in various industries (e.g., aerospace, hydrogen energy, marine). Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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25 pages, 8948 KiB

Open AccessEditor’s ChoiceArticle

Dynamic Characteristics and Effective Stiffness Properties of Sandwich Panels with Hierarchical Hexagonal Honeycomb

by Zixuan Bai, Cheng Chen, Xinlong Yang, Yifeng Zhong and Rong Liu

Materials 2023, 16(17), 5741; https://doi.org/10.3390/ma16175741 - 22 Aug 2023

Cited by 2 | Viewed by 1149

Abstract

The dynamic characteristics of sandwich panels with a hierarchical hexagonal honeycomb (SP-HHHs) show significant improvements due to their distinct hierarchy configurations. However, this also increases the complexity of structural analysis. To address this issue, the variational asymptotic method was utilized to homogenize the unit cell of the SP-HHH and obtain the equivalent stiffness, establishing a two-dimensional equivalent plate model (2D-EPM). The accuracy and effectiveness of the 2D-EPM were then verified through comparisons with the results from a detailed 3D FE model in terms of the free vibration and frequency- and time-domain forced vibration, as well as through local field recovery analysis at peak and trough times. Furthermore, the tailorability of the typical unit cell was utilized to perform a parametric analysis of the effects of the length and thickness ratios of the first-order hierarchy on the dynamic characteristics of the SP-HHH under periodic loading. The results reveal that the vertices serve as weak points in the SP-HHH, while the vertex cell pattern significantly influences the specific stiffness and stiffness characteristics of the panel. The SP-HHH with hexagonal vertex cells has superior specific stiffness compared to panels with circular and rectangular vertex cells, resulting in a more lightweight design and enhanced stiffness. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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19 pages, 9653 KiB

Open AccessArticle

Out-of-Plane Flexural Behavior of Insulated Wall Panels Constructed with Large Insulation Thicknesses

by Jacob Luebke, Fray F. Pozo-Lora, Salam Al-Rubaye and Marc Maguire

Materials 2023, 16(11), 4160; https://doi.org/10.3390/ma16114160 - 2 Jun 2023

Cited by 2 | Viewed by 1305

Abstract

Insulated concrete sandwich wall panels (ICSWPs) are gaining popularity as energy regulations become stricter worldwide. ICSWPs are now being constructed with thinner wythes and thicker insulation to keep up with the changing market, which is reducing material costs and increasing thermal and structural efficiency. However, there is a need for adequate experimental testing to validate the current design methods for these new panels. This research aims to provide that validation by comparing the predictions of four different methods with experimental data obtained from six large-scale panels. The study found that while current design methods adequately predict the behavior of thin wythe and thick insulation ICSWPs within the elastic region, they do not accurately predict their ultimate capacity. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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11 pages, 2358 KiB

Open AccessArticle

Analysis of Surface Texture and Roughness in Composites Stiffening Ribs Formed by SPIF Process

by Raheem Al-Sabur, Andrzej Kubit, Hassanein I. Khalaf, Wojciech Jurczak, Andrzej Dzierwa and Marcin Korzeniowski

Materials 2023, 16(7), 2901; https://doi.org/10.3390/ma16072901 - 6 Apr 2023

Cited by 7 | Viewed by 1846

Abstract

Studying roughness parameters and the topography of stiffening ribs in composite sandwich structures is important for understanding these materials’ surface quality and mechanical properties. The roughness parameters describe the micro-geometry of the surface, including the average height deviation, roughness depth, and waviness. The topography of the surface refers to the spatial arrangement and distribution of features such as bumps, ridges, and valleys. The study investigated the roughness parameters under three scenarios based on two SPIF process parameters: tool rotational speed(N) and feed rate (f). The vertical step was held constant at 0.4 mm across all scenarios. In scenario A, the process parameters were set at f = 300 mm/min and n = 300 rpm; in scenario B, f = 1500 mm/min and n = 3000 rpm; and in scenario C, f = 1500 mm/min and n = 300 rpm. The experimental research topography analyses revealed that the surface roughness of the stiffened ribs was highly dependent on the SPIF process parameters. The highest feed rate and tool rotational speed produced the smoothest surface texture with the lowest maximum height (Sz) value. In contrast, the lowest feed rate and tool rotational speed resulted in a rougher surface texture with a higher maximum height (Sz) value. Furthermore, the contour plots generated from the topography analyses provided a good visual representation of the surface texture and roughness, allowing for a more comprehensive analysis of the SPIF process parameters. This study emphasizes optimizing the SPIF process parameters to achieve the desired surface quality and texture of stiffened ribs formed in Litecor^® panel sheets. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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14 pages, 4597 KiB

Open AccessArticle

Optimization of Pin Position and Angle for Z-Pin-Reinforced Foam Core Sandwich Structures

by Eduardo Fischer Kerche, Agnė Kairytė, Sylwia Członka, Amanda Albertin Xavier da Silva, Maikson Luiz Passaia Tonatto, Francisco Luiz Bresolin, Rafael de Avila Delucis and Sandro Campos Amico

Materials 2023, 16(1), 352; https://doi.org/10.3390/ma16010352 - 30 Dec 2022

Cited by 1 | Viewed by 1842

Abstract

Sandwich panels (SP) are very promising components for structures as they ally high levels of specific stiffness and strength. Civil, marine and automotive industries are some examples of the sectors that use SPs frequently. This work demonstrates the potential of manufacturing Z-pin-reinforced foam core SPs, using a design strategy that indicated optimal values for both pin position and angle, keeping the same pin diameter as determined in a previous study. A simple search algorithm was applied to optimize each design, ensuring maximum flexural stiffness. Designs using optimal pin position, optimal pin angle and optimal values for both parameters are herein investigated using numerical and experimental approaches. The optimal pin position yielded an increase in flexural stiffness of around 8.0% when compared to the non-optimized design. In this same comparison, the optimal pin angle by itself increased the flexural stiffness by about 63.0%. Besides, the highest increase in the maximum load was found for those composites, molded with optimized levels of pin position and pin angle, which synergistically contributed to this result. All results were demonstrated with numerical and experimental results and there was a good agreement between them. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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15 pages, 2564 KiB

Open AccessArticle

Buckling Behavior of Sandwich Cylindrical Shells Covered by Functionally Graded Coatings with Clamped Boundary Conditions under Hydrostatic Pressure

by Abdullah H. Sofiyev, Nicholas Fantuzzi, Cengiz Ipek and Gülçin Tekin

Materials 2022, 15(23), 8680; https://doi.org/10.3390/ma15238680 - 5 Dec 2022

Cited by 5 | Viewed by 1925

Abstract

The buckling behavior of sandwich shells with functionally graded (FG) coatings operating under different external pressures was generally investigated under simply supported boundary conditions. Since it is very difficult to determine the approximation functions satisfying clamped boundary conditions and to solve the basic equations analytically within the framework of first order shear deformation theory (FOST), the number of publications on this subject is very limited. An analytical solution to the buckling problem of FG-coated cylindrical shells under clamped boundary conditions subjected to uniform hydrostatic pressure within the FOST framework is presented for the first time. By mathematical modeling of the FG coatings, the constitutive relations and basic equations of sandwich cylindrical shells within the FOST framework are obtained. Analytical solutions of the basic equations in the framework of the Donnell shell theory, obtained using the Galerkin method, is carried out using new approximation functions that satisfy clamped boundary conditions. Finally, the influences of FG models and volume fractions on the hydrostatic buckling pressure within the FOST and classical shell theory (CT) frameworks are investigated in detail. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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Review

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25 pages, 6926 KiB

Open AccessReview

Application of Lightweight Structure in Automobile Bumper Beam: A Review

by Bing Du, Qichang Li, Changqi Zheng, Suozhu Wang, Cong Gao and Liliang Chen

Materials 2023, 16(3), 967; https://doi.org/10.3390/ma16030967 - 20 Jan 2023

Cited by 26 | Viewed by 8785

Abstract

The bumper beam is an important device to ensure the safety of the car, which can effectively alleviate the force and absorb energy when the car collides. Traditional bumper beams are mostly made of high-strength steel, which has high strength and a low production cost but a heavy weight. With the requirement of being lightweight, high-strength steel is not able to meet the needs of lightweight cars, and composite materials have become the answer to the problem of a light weight in cars due to their excellent performance of being lightweight and high strength. This article introduces the case study on materials of bumper beams and presents the application of traditional materials and composite materials in bumper beams. Then, the fabrications and processes of bumper beams, a performance assessment, experimental tests, and a finite element analysis of the bumper beam are carried out. This paper also represents the study of optimization in automobile bumper beams. Full article

(This article belongs to the Special Issue Lightweight and High-Strength Sandwich Panel)

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