Design of composite lattice materials combined with fabrication approaches

2018 ◽  
Vol 53 (3) ◽  
pp. 393-404 ◽  
Author(s):  
Jun Xu ◽  
Yaobo Wu ◽  
Xiang Gao ◽  
Huaping Wu ◽  
Steven Nutt ◽  
...  
Keyword(s):  
Shear Strength ◽  
Mechanical Performance ◽  
Analytical Models ◽  
Core Material ◽  
Foam Core ◽  
Hierarchical Lattice ◽  
Bottom Up ◽  
Lattice Materials ◽  
Assembly Technique ◽  
Composite Lattice

Lattice materials can be designed through their microstructure while concurrently considering fabrication feasibility. Here, we propose two types of composite lattice materials with enhanced resistance to buckling: (a) hollow lattice materials fabricated by a newly developed bottom-up assembly technique and the previously developed thermal expansion molding technique and (b) hierarchical lattice materials with foam core sandwich trusses fabricated by interlocking assembly process. The mechanical performance of sandwich structures featuring the two types of lattice cores was tested and analyzed theoretically. For hollow lattice core material, samples from two different fabrication processes were compared and both failed by nodal rupture or debonding. In contrast, hierarchical lattice structures failed by shear buckling without interfacial failure in the sandwich struts. Calculations using established analytical models indicated that the shear strength of hollow lattice cores could be optimized by judicious selection of the thickness of patterned plates. Likewise, the shear strength of hierarchical foam core truss cores could be maximized (with minimal weight) through design of truss geometry. The bottom-up assembly technique could provide a feasible way for mass production of lattice cores, but the design about how to assembly is critical. Hierarchical lattice cores with foam sandwich trusses should be a suitable choice for future lightweight material application.

Impact Response of Sacrificial Cladding Structure with an Alporas Aluminum Foam Core Under Blast Loading

2020 ◽  
Vol 12 (08) ◽  
pp. 2050094
Author(s):  
Ibrahim Elnasri ◽  
Han Zhao
Keyword(s):  
Strain Rate ◽  
Aluminum Foam ◽  
Blast Loading ◽  
Front Propagation ◽  
Analytical Models ◽  
Core Material ◽  
Foam Core ◽  
Arbitrary Lagrangian Eulerian ◽  
Inertia Effects ◽  
Ale Methods

This paper presents numerical and analytical studies of the response of a sacrificial cladding structure with an Alporas aluminum foam core and a thick mild steel cover and rear plates under blast loading. A suitable numerical model in LS-DYNA based on the coupled Load Blast Enhanced/Multi-Material Arbitrary Lagrangian–Eulerian (LBE/MM-ALE) methods is selected and validated using the experimental data available in the literature. The shock front propagation and micro-inertia effects are responsible for the strength enhancement predicted in the virtual blast test. Two models with different decaying blast loading functions are examined to study the fluid–structure interaction (FSI) effect. The simulation results show that the FSI effect is negligible if the foam core is strain-rate insensitive. Further investigations should be conducted with analytical models if the core material of the sacrificial cladding structures exhibits a strong strain-rate effect (for example, Alporas foam).

Effect of salt water exposure on foam-cored polyurethane sandwich composites

2018 ◽  
Vol 22 (4) ◽  
pp. 1256-1273 ◽  
Author(s):  
Z Huo ◽  
M Mohamed ◽  
JR Nicholas ◽  
S Anandan ◽  
K Chandrashekhara
Keyword(s):  
Moisture Absorption ◽  
Mechanical Performance ◽  
Salt Water ◽  
Flexural Modulus ◽  
Interfacial Fracture ◽  
Core Material ◽  
Foam Core ◽  
Sandwich Composites ◽  
Water Exposure ◽  
Polyurethane Composite

This study investigated the effect of moisture absorption on the mechanical performance of polyurethane sandwich composites. The core material was a closed cell polyurethane foam. Face sheets were made of E-glass/polyurethane composite laminates. Vacuum-assisted resin transfer molding process was used to manufacture specimens for testing. The foam core, laminates, and sandwich composites were submerged in salt water for prolonged periods of time. Mechanical property degradation due to moisture absorption for each constituent was evaluated. Compression test was performed on the foam core samples. Laminates were evaluated by three-point bending tests. The interfacial bond strength in the sandwich structure was evaluated by double cantilever beam mode-I interfacial fracture test. The testing results revealed that the effect of salt water exposure on the compressive properties of the foam core is insignificant. The flexural modulus of polyurethane laminates degraded 8.9% and flexural strength degraded 13.0% after 166 days in 50% salinity salt water at 34°C conditioning. The interfacial fracture toughness of polyurethane sandwich composites degraded 22.4% after 166 days in 50% salinity salt water at 34°C conditioning.

Investigation on Shear Strength of Steel-Polymer Interface in Plastic Pipe Reinforced by Cross Helically Wound Steel Wires

2013 ◽  
Author(s):  
Jun Shi ◽  
Jianfeng Shi ◽  
Jinyang Zheng
Keyword(s):  
Shear Strength ◽  
Load Transfer ◽  
Mechanical Performance ◽  
Analytical Models ◽  
Polymer Interface ◽  
Pull Out ◽  
Steel Wires ◽  
Reinforced Plastic ◽  
The Matrix ◽  
Fibre Matrix

Shear strength of fibre-matrix adhesive interface is crucial important to the mechanical performance of fibre-reinforced plastic pipes and fittings, due to its function for load transfer between the fibre and the matrix. In this study, pull-out tests of steel-polymer specimens were carried out with different embedded lengths. Ultrasonic scanning was adopted to monitor the failure procedure of the interface. From the analysis of UT scanning graphs, it could be determined that the studied steel-polymer interface failed rapidly on the whole embedded length under the maximal pull-out force, but not in the manner that crack initiated from a stress concentration point under a relatively small pull-out force and then propagated gradually. Different kinds of pull-out analytical models were discussed. Finally the analytical model of yielding interface was applied to characterize the steel-polymer interfacial adhesive property. Combing with experimental results of pull-out tests of different embedded lengths, the nominal bond shear strength was calculated out.

Mechanical performance of honeycomb sandwich structures built by FDM printing technique

2021 ◽  
pp. 089270572199789
Author(s):  
S Gohar ◽  
G Hussain ◽  
A Ali ◽  
H Ahmad
Keyword(s):  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Sandwich Structures ◽  
Weight Ratio ◽  
High Strength ◽  
Core Material ◽  
Interfacial Bond Strength ◽  
Fused Deposition ◽  
Competitive Prices ◽  
Composite Face

Honey Comb Sandwich Structures (HCSS) have numerous applications in aerospace, automobile, and satellite industry because of their properties like high strength to weight ratio, stiffness and impact strength. Fused Deposition Modeling (FDM) is a process which, through its flexibility, simple processing, short manufacturing time, competitive prices and freedom of design, has an ability to enhance the functionality of HCSS. This paper investigates the mechanical behavior (i.e. flexural, edgewise compression and Interfacial bond strength) of FDM-built HCSS. The influence of face/core material was examined by manufacturing four types of specimens namely ABS core with Composite (PLA + 15% carbon fibers) face sheets, ABS core with PLA face sheets, TPU core with composite face sheets and TPU core with PLA face sheets. To measure the effect of face sheets geometry, raster layup was varied at 0°/90° and 45°/−45°. The mechanical characterization revealed that an optimum combination of materials is ABS core with composite face sheets having raster layup of 0°/90°. This study indicates that HCSS with complex lamination schemes and adequate mechanical properties could be manufactured using FDM which may widen the applications of FDM on an industrial scale.

scholarly journals Experimental Analysis of Perimeter Shear Strength of Composite Sandwich Structures

Materials ◽  
2020 ◽  
Vol 14 (1) ◽  
pp. 12
Author(s):  
Łukasz Święch ◽  
Radosław Kołodziejczyk ◽  
Natalia Stącel
Keyword(s):  
Experimental Analysis ◽  
Sandwich Structures ◽  
Maximum Load ◽  
Core Material ◽  
Foam Core ◽  
Honeycomb Core ◽  
Loading Test ◽  
Composite Sandwich ◽  
Destruction Mechanism ◽  
Static Loading Test

The work concerns the experimental analysis of the process of destruction of sandwich structures as a result of circumferential shearing. The aim of the research was to determine the differences that occur in the destruction mechanism of such structures depending on the thickness and material of the core used. Specimens with a Rohacell foam core and a honeycomb core were made for the purposes of the research. The specimen destruction process was carried out in a static loading test with the use of a system introducing circumferential shear stress. The analysis of the tests results was made based on the load-displacement curves, the maximum load, and the energy absorbed by individual specimens. The tests indicated significant differences in the destruction mechanism of specimens with varied core material. The specimen with the honeycomb core was characterized by greater stiffness, which caused the damage to occur locally in the area subjected to the pressure of the punch. In specimens with the foam core, due to the lower stiffness of that core, the skins of the structure were bent, which additionally transfers compressive and tensile loads. This led to a higher maximum force that the specimens obtained at the time of destruction and greater energy absorption.

Advances in joining technologies for the innovation of 21st century lightweight aluminium-CFRP hybrid structures

2022 ◽  
pp. 095440892110730
Author(s):  
Renangi Sandeep ◽  
Arivazhagan Natarajan
Keyword(s):  
Shear Strength ◽  
Laser Welding ◽  
Heat Input ◽  
Mechanical Performance ◽  
Current Knowledge ◽  
Ultrasonic Welding ◽  
Hybrid Structures ◽  
Joint Shear Strength ◽  
Hybrid Joints ◽  
Welding Processes

In the twenty-first century, the application of carbon fiber reinforced polymer (CFRP) materials in the vehicle industry are growing rapidly due to lightweight, high specific strength, and elasticity. In the automobile and aerospace industries, CFRP needs to be joined with metals to build complete structures. The demand for hybrid structures has prompted research into the combination of CFRP and metals in manufacturing. Aluminium and CFRP structures combine the mechanical properties of aluminium with the superior physical and chemical properties of CFRP. However, joining dissimilar materials is often challenging to achieve. Various joining technologies are developed to produce hybrid joints of CFRP, and aluminium alloys include conventional adhesives, mechanical and thermal joining technologies. In this review article, an extensive review was carried out on the thermal joining technologies include laser welding, friction-based welding technologies, ultrasonic welding, and induction welding processes. The article primarily focused on the current knowledge and process development of these technologies in fabricating dissimilar aluminium and CFRP structures. Besides, according to Industry 4.0 requirements, additive manufacturing-based techniques to fabricate hybrid structures are presented. Finally, this article also addressed the various improvements for the future development of these joining technologies. Ultrasonic welding yields the maximum shear strength among the various hybrid joining technologies due to lower heat input. On the other hand, laser welding produces higher heat input, which deteriorates the mechanical performance of the hybrid joints. Surface pretreatments on material surfaces prior to joining showed a significant effect on joint shear strength. Surface modification using anodizing is considered an optimal method to improve wettability, increasing mechanical interlocking phenomena.

Influence of titanium oxide-based colourants on the morphological and tribomechanical properties of injection-moulded polyoxymethylene spur gears

2019 ◽  
Vol 39 (8) ◽  
pp. 774-783
Author(s):  
Dominik Schubert ◽  
Sebastian Hertle ◽  
Dietmar Drummer
Keyword(s):  
Titanium Oxide ◽  
Mechanical Performance ◽  
Core Material ◽  
Spur Gears ◽  
Delivery Methods ◽  
White Pigment ◽  
Crystalline Core ◽  
Coarse Microstructure ◽  
Tribomechanical Properties ◽  
Carrier Systems

Abstract Regardless of colouration for functional or aesthetic purposes, technical polymer parts, like gears, require consistent properties. However, there is a lack of research into the effect of colourants on the tribomechanical properties of gears. Therefore, the effects of two pigments, titanium dioxide (white) and chrome antimony titanium oxide (yellow), and three delivery methods, masterbatch, liquid colour and direct compounding, on part morphology, dimensions, tribological and mechanical performance of injection-moulded polyoxymethylene (POM) spur gears are investigated in this paper. The white pigment accelerates the crystallisation of POM, causing fine and highly-crystalline morphological structures and smaller dimensions. However, the yellow pigment decelerates crystallisation, resulting in a coarser morphology with highly crystalline core material and bigger parts. Furthermore, the delivery method affects only the tribomechanical properties. Using a masterbatch decreases loads at break and increases deflection at break, since the carrier material acts as an impact modifier and a weak spot. The liquid colour decreases wear due to lubricating properties, whereas the pure pigments increases abrasion, especially in combination with a coarse microstructure. However, the effects of carrier systems and changes in morphology are always superimposed. Considering the performance and tolerance of technical components, colourants have to be carefully selected to ensure beneficial properties.

New Higher-Order Models for Sandwich Plates with a Flexible Core and their Accuracy Assessment

2019 ◽  
Vol 19 (03) ◽  
pp. 1950024 ◽  
Author(s):  
Ali Tian ◽  
Renchuan Ye ◽  
Peng Ren ◽  
Pengming Jiang ◽  
Zengtao Chen ◽  
...  
Keyword(s):  
Dynamic Models ◽  
Accuracy Assessment ◽  
Order Theory ◽  
Higher Order ◽  
Analytical Models ◽  
Core Material ◽  
Sandwich Plates ◽  
Higher Order Theory ◽  
Flexible Core

Two higher-order analytical models based on a new higher-order theory for sandwich plates with flexible cores are developed considering the effect of the core material density and skin-to-core-stiffness-ratio (SCSR). The main difference between the two models is the role of the flexible core in the dynamic response of sandwich plates with cores of different stiffnesses. Firstly, the governing equations of a simply supported sandwich plate with a flexible core are derived based on the two models, and the analytical solutions are determined by using Navier’s approach. Then, the free vibration, static, dynamic bending and stress field characteristics of the sandwich plates with different SCSRs are investigated. The results obtained by the proposed method are compared with other published results. In particular, an accuracy assessment of the present dynamic models is conducted for different SCSRs. Finally, conclusions on the applicability of the proposed method and other theories on sandwich plates with different SCSRs are drawn.

scholarly journals Moisture Absorption Effects on the Mechanical Properties of Sandwich Biocomposites with Cork Core and Flax/PLA Face Sheets

Molecules ◽  
2021 ◽  
Vol 26 (23) ◽  
pp. 7295
Author(s):  
Hom Nath Dhakal ◽  
Chulin Jiang ◽  
Moumita Sit ◽  
Zhongyi Zhang ◽  
Moussa Khalfallah ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Failure Modes ◽  
Moisture Absorption ◽  
Mechanical Performance ◽  
Core Sample ◽  
Environmental Benefits ◽  
Matrix Cracking ◽  
Core Material ◽  
Poly Lactic Acid ◽  
The Core

The aim of this study was to evaluate the moisture absorption behaviour and its influence on the mechanical properties of newly developed sandwich biocomposites with flax fibre-reinforced poly-lactic acid (PLA) face sheets and soft cork as the core material. Three different types of sandwich biocomposite laminates comprised of different layup configurations, namely, non-woven flax/PLA (Sample A), non-woven flax/PLA and cork as core (Sample B) and non-woven flax/paper backing/PLA, cork as core (Sample C), were fabricated. In order to evaluate the influence of moisture ingress on the mechanical properties, the biocomposites were immersed in seawater for a period of 1200 h. The biocomposites (both dry and water immersed) were then subjected to tensile, flexural and low-velocity falling weight impact tests. It was observed from the experimental results that the moisture uptake significantly influenced the mechanical properties of the biocomposites. The presence of the cork and paper in sample C made it more susceptible to water absorption, reaching a value of 34.33%. The presence of cork in the core also has a considerable effect on the mechanical, as well as energy dissipation, behaviours. The results of sample A exhibited improved mechanical performance in both dry and wet conditions compared to samples B and C. Sample A exhibits 32.6% more tensile strength and 81.4% more flexural strength in dry conditions than that in sample C. The scanning electron microscopy (SEM) and X-ray micro-CT images revealed that the failure modes observed are a combination of matrix cracking, core crushing and face core debonding. The results from this study suggest that flax/PLA sandwich biocomposites can be used in various lightweight applications with improved environmental benefits.

Experimental investigations on the sandwich composite beams and panels with elastomeric foam core

2017 ◽  
Vol 21 (3) ◽  
pp. 865-894 ◽  
Author(s):  
AR Nazari ◽  
H Hosseini-Toudeshky ◽  
MZ Kabir
Keyword(s):  
Carrying Capacity ◽  
Sandwich Structures ◽  
Failure Mechanisms ◽  
Composite Beams ◽  
Core Material ◽  
Foam Core ◽  
Sandwich Beams ◽  
Load Carrying Capacity ◽  
The Core ◽  
Load Carrying

In this paper, the load-carrying capacity and failure mechanisms of sandwich beams and panels with elastomeric foam core and composite laminate face sheets are investigated. For this purpose, the flexural behavior of laminated composite beams and panels (applied as face sheets) is firstly investigated under three-point bending and central concentrated loads, respectively. Then, the same examination is conducted for the sandwich beams and panels, in which the proposed elastomeric foam is utilized as the core material. It is shown that the failure mechanisms which are associated to the core in the sandwich structures with crushable foams are not considered in the examined sandwich structures. The collapse of the sandwich specimens, examined here, is observed due to the failure of the skins in some steps. By multi-step collapse of these specimens via separately failure of the top and bottom skins, a considerable amount of energy is absorbed between these steps. Due to non-brittle behavior of the core material under loading, a large compression resistance is observed after failure of the top skin which led to the recovery of the load-carrying capacity in the sandwich beams. A similar behavior for the sandwich panels led to the increase of the ultimate strength after appearance of the failure lines on the top skin. The general outcomes of this investigation promise a good influence for the application of elastomeric foam as core material for sandwich structures.

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