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This study investigates free vibration analysis of a microplate featuring a honeycomb (HC) core and incorporates two nanocomposite piezoelectric (NP) layers. Carbon nanotubes (CNTs) are hired to enhance the electro-mechanical performance of the piezoelectric patches, which are subjected to an externally applied electric voltage. All layers are tightly bonded together and are supported by an elastic substrate according to the Pasternak model, capable of withstanding both normal and shear loads. To establish the kinematic relations, a trigonometric plate theory is employed. The governing equations of motion are deduced through the application of Hamilton's principle and variational technique. The modified strain gradient theory, which includes three material length-scale parameters (MLSPs), is used to account for the scale effect. An analytical approach based on Fourier series functions is employed to solve the differential equations of motion. Subsequently, the impact of various factors, such as the geometrical characteristics of the HC core, distribution patterns of CNTs, and other significant parameters, on the normalized frequencies of the model is assessed after validating the accuracy of the results. The outcomes of this research have the potential to facilitate the advancement and production of lightweight and intelligent structures and devices, ultimately enhancing their efficiency. [ABSTRACT FROM AUTHOR]

Compared with traditional honeycomb and stiffened sandwich structures, lattice-based structures are considered an ideal substitute for traditional core structures due to their high stiffness and other potential multifunctional application characteristics. Based on that, the sound radiation characteristics of the sandwich plate with different truss cores under structure borne excitation were investigated in the current paper, wherein three truss cores, including pyramidal, tetrahedral and 3D-kagome cores types, are considered. The governing equations for the vibration and sound radiation analysis of the sandwich plate structure are carried out using the static equilibrium method, and then solved via the Navier approach and Rayleigh integral. By comparing the experimental results, the validity of the proposed theoretical model is verified. The theoretical model is subsequently used to investigate the influences of truss core geometric parameters and types, face sheet-core face sheet thickness ratio and aspect ratio on sandwich plate sound radiation characteristics. The results indicate that, in the range [ 5 ∘ ≤ θ ≤ 52 ∘ ] and [ 52 ∘ < θ ≤ 85 ∘ ] , the tetrahedral and 3D-Kagome core types have the maximum natural frequency values, respectively, while the resonance peaks of sound pressure level curves move to lower frequency region with the increase in truss core radius and face sheet-core face sheet thickness ratio, and the sandwich plate with the 3D-kagome core shows better sound radiation characteristics in the wide frequency range. [ABSTRACT FROM AUTHOR]

This paper describes the in-plane impact behavior of 3D woven honeycomb sandwich composites comprising glass fiber reinforced epoxy composite. In this study, 3D woven honeycomb structures with similar cell shapes were developed with different cell geometry by varying the cell size, free wall length, bonded wall length, opening angle, and the number of honeycomb layers keeping the overall thickness of the composite constant. The variation of cell geometry was carried out by changing the number of picks in the honeycomb walls. Composite samples were made using VARIM (vacuum-assisted resin infusion method) process. The behavior of the force-displacement curve and the energy-time relationship under impact loading of 100 J were analyzed. The total energy absorption was determined for different cell geometry and the number of layers of the honeycomb composites. The results showed that structural changes in honeycomb composite significantly affect the specific energy absorption. The specific energy absorption increases with a large cell size, less opening angle, higher wall length, and a greater number of layers. [ABSTRACT FROM AUTHOR]

Highlights This paper investigates a honeycomb sandwich structure that draws inspiration from the craft of origami. A specific folding pattern was applied to the honeycomb to create the origami‐based re‐entrant honeycomb (ORH), aimed at improving the energy absorption properties of the sandwich structure. The study on the energy absorption properties of structures under low‐velocity impact (LVI) utilized both experimental and numerical approaches. The energy absorption properties of the sandwich structure were examined by conducting LVI tests with different impact energy and then compared to the mechanical properties of the traditional re‐entrant honeycomb sandwich structures (TRHSS). Additionally, a refined finite element model has been established and its accuracy verified. Numerical studies were conducted to explore the effects of structural parameters on the energy absorption properties of ORH sandwich structure (ORHSS). The results show that the ORHSS exhibited a significant reduction in peak force when subjected to LVI, in contrast to the TRHSS. Furthermore, the ORHSS exhibit significant efficiency in energy absorption. Enhancing the wall thickness t$$ t $$ or folding angle V/H$$ V/H $$ can significantly improve the energy absorption properties of the ORHSS, thereby boosting the honeycomb's contribution to this process. This optimization results in an improved absorptive effect of the structure. The findings offer new recommendations for developing lightweight absorbent materials with potential applications across various industries. A novel composite sandwich structure serves as an efficient device for absorbing energy. This sandwich structure exhibits excellent cushioning and energy absorption capabilities. Changing geometric parameters can enhance the impact performance of the structure. A larger folding angle V/H$$ V/H $$ makes the core more prone to deformation. The greater the forward length V$$ V $$ of the ORH, the lower specific energy absorption (SEA) of the ORHSS. [ABSTRACT FROM AUTHOR]

This paper proposed a composite sandwich structure containing multilayer honeycombs, and a multi-objective optimization model containing its load-bearing and wave-absorbing properties, which were correlated with the geometric parameters of the honeycomb, was developed. The critical elastic buckling load was performed as an indicator to characterize the load-bearing capacity, and the bandwidth of the sandwich was employed as an indicator to characterize the wave-absorbing characteristics. This multi-objective optimization model was optimized based on JAYA algorithm and the results showed that the optimized structure had a significant improvement in both load-bearing and wave-absorbing capacities compared to the original structure. [ABSTRACT FROM AUTHOR]

This study investigated the thermal and mechanical properties of polyurethane foam (PUF) sandwich panels reinforced with varying amounts of clay nanoparticles (0, 0.5, 1 and 2 wt%) fabricated using the compression molding process. However, these composites were fixed to cores with a honeycomb structure. The morphology of PUF sandwich panels reinforced with clay nanoparticles was examined by scanning electron microscopy (SEM). The presence of clay nanoparticles in the honeycomb structure let to a reduction in cell size and an increase in the number of cells per unit volume. The impact of clay nanoparticles on the thermal properties of PUF reinforced with clay nanoparticles was investigated using thermogravimetric and dynamic mechanical thermal analysis (DMTA). The results indicated that the incorporation of clay nanoparticles as reinforcement enhanced the thermal properties of the PUF sandwich panel samples. Mechanical characterization technique including compression, three-point bending and drop weight impact tests displayed that the PUF reinforced with 1 wt% clay nanoparticles exhibited the most significant improvement in mechanical properties. [ABSTRACT FROM AUTHOR]

Honeycombs are commonly used as core materials in sandwich panels, and the core geometry significantly impacts the bending behaviour of these structures. Understanding how core characteristics influence the mechanical properties of sandwich panels is essential. The comparison between different honeycomb sandwich panel configurations is quite complex. This study delves into the intricate comparison between various honeycomb sandwich panel configurations, serving as a benchmark for integral 3D printed panels featuring hexagonal cores in both L- and W-directions, and circular cores. Notably, wrinkling phenomena are observed in the L-direction of the hexagonal cores. Circular cell panels exhibit increased load capacity, flexural modulus, and toughness. Additionally, hexagonal L-core panels demonstrate a higher toughness modulus than their W-core counterparts, making them less rigid yet stronger. Furthermore, L-cell core panels possess a lower density than circular cores, whereas W-cell cores exhibit higher density, compromising their specific mechanical properties. [ABSTRACT FROM AUTHOR]

Sandwich panel structures are widely used for light-weight applications due to their high strength and stiffness to density ratios. They are composed of two main parts: the skins and the core. This paper investigates a Miura-ori structural sandwich core with open cells that can be used as an alternative to the existing honeycomb structures. A fully parametric design approach, starting from drawing to Finite Element Analysis (FEA), is presented to efficiently analyze the effect of different geometries on the resulting structure. The geometric model was built based on the kinematic model, which can represent the folding process of the foldcore using the Matlab script. The obtained coordinates of the vertices of the folding pattern were exported to ANSYS APDL where the surfaces were automatically created and meshed. The created mesh was imported to LS-Dyna where explicit compression analyses were performed to evaluate the compression stiffness and strength of the studied geometries. The developed parametric model aims to find the best configuration for a given application, based on three sets of geometric parameters that define the shape of the Miura Ori folding pattern. Therefore, in the range of the studied geometries, the best parameter combination for specific compression stiffness and specific compression strength was found. To evaluate the performance of the foldcore and to validate the FE model, experimental quasi-static compression tests were undertaken with two kinds of specimens ('strip' and "panel"), and the measured force-displacement curves were obtained. The result of the test agrees with that of the FE simulations, with an error of <6.6% in the elastic region. [ABSTRACT FROM AUTHOR]

To optimize the assembly methods of honeycomb structures and enhance their design flexibility, this study investigated the impact mechanical responses of tandem honeycomb-core sandwich structures with varying misalignment assembly lengths. Impact tests were conducted across different energy levels on single-layer and tandem honeycomb-core sandwiches to observe their impact processes and failure behaviors. Our findings indicate that tandem honeycomb cores significantly enhance the impact resistance compared with single-layer configurations, even though a misaligned assembly can deteriorate this property. A finite element model was developed and validated experimentally; the model showed good agreement with the experiments, thereby allowing the simulation and evaluation of the impact responses. Herein, we reveal that specific misalignment lengths can either increase or decrease the impact resistance, providing insights into improving the resilience of tandem honeycomb-core structures. Our results not only contribute to enhancing the impact resistance of honeycomb-core sandwich structures but also offer a valuable basis for their practical applications in engineering. [ABSTRACT FROM AUTHOR]

AbstractVortex-bladeless wind power generators are revolutionary concepts that use wind vortex-induced vibration to generate electricity through oscillation and vibration. This unique approach allows for a simpler design, environmental friendliness, on-site production, and lower initial costs than traditional wind turbines. This article presents a vibration analysis on the rod of a vortex bladeless wind power generator for a sandwich Timoshenko beam with various face sheets, including carbon nanotube (CNT), graphene platelets (GPL), and carbon nanorods (CNR), and cores, including positive and negative Poisson’s ratios in honeycomb structure, porous material, and metal foam. The governing equations of motion are derived using Hamilton’s principle and solved using trigonometric functions for different boundary conditions. The results of this research are compared with previous studies, and the maximum error is 3.05%. This study examined the effects of various parameters on the dimensionless natural frequencies. To obtain the highest peak amplitude for maximum energy harvesting, to choose the best rod for the bladeless wind power generator among the four types of cores and three types of factsheet layers, the honeycomb core with a positive Poisson’s ratio and the GPL-reinforced composite with the SNUPD distribution are selected because they have the most deflection. Some researchers have worked in the field of sandwich beams. Still, in this study, the main goal is to investigate the Timoshenko sandwich beam by examining all types of cores and reinforcements to increase efficiency and optimize bladeless wind generators to achieve maximum power. [ABSTRACT FROM AUTHOR]

Due to the high energy absorption capability and excellent bending strength of the sandwich panels, they are mostly preferred as protective structures against explosive blast attacks. The evaluation of their blast-mitigation characteristics through experiments is highly dangerous, costly, time-consuming, and polluting for the environment. Therefore, in this presented work, a series of numerical analyses were performed to evaluate the blast mitigation of the outstanding sandwich panels with honeycomb, corrugated, auxetic, and foam cores. The masses of sandwich panels were kept constant, and their areal densities were maintained constant throughout the study to effectively compare their performance under identical air blast loading conditions. To apply the air blast loads to the designed sandwiches, 1–3kg of spherical-shaped trinitrotoluene charges were used for a 100mm stand-off distance. The sandwiches are made of high-strength AL-6XN steel and crushable aluminum foam. The rate-dependent Johnson–Cook constitutive model of plasticity and the crushable foam model with volumetric hardening were used for the evaluation of sandwich panels’ plastic deformations. The findings of the work depicted that the honeycomb core is more efficient than the other core structures of the same masses because the sandwich panels with honeycomb core provide smaller back skin deflections, globalized core crushing, and higher core energy absorption than the other sandwich panels for extreme conditions of air blast loading. [ABSTRACT FROM AUTHOR]

This study aims to investigate the non-linear free vibration behavior of composite sandwich panels composed of Graphene-reinforced composite (GRC) skins and honeycomb auxetic core. Here, modified Halpin-Tsai micromechanics and bottom-up multi-scale-based schemes are employed to compute the spatial-dependent elastic properties of Graphene nanocomposite and auxetic honeycomb core, respectively. The non-linear kinematic field is based on Kant's higher-order shear-deformation theory and the Green strain. Using the Hamilton principle, the nonlinear governing equations are affirmed and solved further through Picard's iteration-based 2D-isoparametric finite element approximations via Lagrangian elements. The mesh convergence and validation tests are executed to confirm the consistency and correctness of the developed model. The established sandwich model is further employed for various parametric conditions by varying the core-to-face sheet thickness, auxetic honeycomb properties, graphene volume fraction, shell configurations, temperature, and support conditions. These numerous results exemplify the non-linear frequencies at small-to-large amplitudes for the sandwich shell structures and are discussed in detail. In addition, parametric optimization is conducted using the response surface method to investigate the optimal values of auxetic honeycomb parameters, resulting in maximum frequency response. Findings confirm that, within the selected ranges of the geometric parameters of auxetic honeycomb core, higher values of the thickness of the cell rib (∼1.9 cm) and the length of the vertical cell rib (∼0.15 cm) and lower value of the core thickness (∼5 cm) yield the maximum frequency. [ABSTRACT FROM AUTHOR]

With cores of the hexagonal honeycomb (HH), staggered corrugated lattice (SCL), bidirectional corrugated lattice (BCL), reinforced hexagonal honeycomb (RHH), and reinforced staggered corrugated lattice (RSCL) made by cutting, bonding, arranging and weaving the trapezoidal corrugation (TC) formed by mold hot pressing, six types of composite sandwich panels of the same macro size were proposed. The failure processes of the six sandwich panels in three-point bending experiments were compared and analyzed, and the effects of core configuration and reinforced stiffener on the bending response were evaluated. A general analytical model was established to predict the bending stiffness and failure mode of six sandwich panels, which was also visually presented by a three-dimensional numerical model. The numerical and experimental results validated the effectiveness of the analytical model. The effects of ply parameters and corrugated sizes on bending responses were studied by a combing application of experiment, analytical and numerical models. The three-dimensional failure mechanism maps were displayed to evaluate the failure mode and failure load. The longitudinal discontinuity of the bonding zone of the core could significantly weaken the bending performance and bonding strength of BCL, SCL, RSCL, and HH. The peak load of SCL and HH was enhanced by 45.97% and 60.29%, respectively, by setting stiffeners. Both RHH and TC could achieve bending stiffness of more than 3.5 kN·mm−1, while the failure load of the latter could be up to 25 kN. The design parameter space of bending stiffness, failure load with respect to ply orientation angle, core wall thickness, corrugated web angle, and horizontal segment length was provided intuitively. [ABSTRACT FROM AUTHOR]

Highlights The mechanical properties of the carbon fiber and glass fiber composite honeycomb sandwich structure were studied through compression experiments. The influence of different aluminum honeycomb edge lengths, upper and lower panel thickness, aluminum honeycomb thickness, and loading speed on the compression failure load of carbon fiber composite laminates sandwich structure is analyzed. The influence of different aluminum honeycomb edge lengths and thicknesses on the compression failure load of glass fiber composite laminates sandwich structure was studied. The results show that the thickness of the panel has a significant effect on the failure load of the carbon fiber composite laminate sandwich structure, and the loading speed has a significant effect on the failure load of the carbon fiber composite laminate sandwich structure. The greater the loading speed, the greater the value of the failure load. The edge length and thickness of the aluminum honeycomb have a certain effect on the damage load of the carbon fiber composite laminates sandwich structure, but the influence on the mechanical properties of the glass fiber composite laminates sandwich structure is much greater. The compression performance of composite sandwich structures was experimentally studied. The influence of composite panel thickness was studied. The influence of aluminum honeycomb edge length and thickness was studied. The influence of loading speed was studied. [ABSTRACT FROM AUTHOR]

The primary challenge during the secondary bonding process of full-height honeycomb sandwich structures is the aramid honeycomb core's height shrinkage. This paper systematically investigated the height evolution behavior of the honeycomb core by using a creep testing machine. The results showed that the out-of-plane compression deformation curve of aramid honeycomb cores is mainly divided into three stages: the dehumidification stage, the pressurization stage and the creep stage. Under conditions of high temperature and pressure, height shrinkage was attributed to the dehydration caused by moisture infiltration, and the compression creep resulted from the slippage of polymer molecular chains. Dehydration shrinkage is stable, whereas compression creep reflects typical viscoelastic polymer characteristics. By employing the viscoelastic Burgers mechanical model and applying the nonlinear surface fitting method, the total height shrinkage deformation behavior of the aramid honeycomb core during the curing process can be accurately predicted by summing the above three stages. This research contributes valuable insights for the manufacturing process of honeycomb sandwich structures. [ABSTRACT FROM AUTHOR]

AbstractDue to its superior performance, the foldcore structure has the potential to replace traditional honeycomb materials. Single-ridgeline V-shaped, double-ridgeline M-shaped, and curved S-shaped foldcore structures were designed based on the principle of origami by controlling areal density. Three foldcore sandwich structures were fabricated from GFRP by hot compression molding method, and PU foam-filled foldcore sandwich structures were also prepared by in-situ foaming. The strength analysis models of the three types of foldcore under out-of-plane compression load were established through differentiation and integration. Subsequently, the quasi-static compression performance and failure modes of the foldcore were investigated through experiments. The analysis model has a certain degree of accuracy in predicting the strength of the structure. It was found that the primary failure mode of V-shaped foldcore under out-of-plane compressive loading was wall buckling. In contrast, the M-shaped foldcore had higher buckling resistance and the failure mode changes from buckling to crushing. S-shaped foldcore had a higher compression strength, and its failure mode changed to wall shear fracture. In addition, lightweight foam filling improved the failure stress of the foldcore. [ABSTRACT FROM AUTHOR]

This study investigates lightweight and efficient candidates for sound absorption to address the growing demand for sustainable and eco-friendly materials in noise attenuation. Juncus effusus (JE) is a natural fiber known for its unique three-dimensional network, providing a viable and sustainable filler for enhanced sound absorption in honeycomb panels. Microperforated-panel (MPP) honeycomb absorbers incorporating JE fillers were fabricated and designed, focusing on optimizing the absorber designs by varying JE filler densities, geometrical arrangements, and MPP parameters. At optimal filling densities, the MPP-type honeycomb structures filled with JE fibers achieved high noise reduction coefficients (NRC) of 0.5 and 0.7 at 20 mm and 50 mm thicknesses, respectively. Using an analytical model and an artificial neural network (ANN) model, the sound absorption characteristics of these absorbers were successfully predicted. This study demonstrates the potential of JE fibers in improving noise mitigation strategies across different industries, offering more sustainable and efficient solutions for construction and transportation. [ABSTRACT FROM AUTHOR]

In this study, a novel theoretical approach based on high-order shear deformation theory is proposed to investigate the damping properties of honeycomb panels partially filled with foam. The assessment of damping properties in composite materials is accomplished through finite element theory, which elucidates the theoretical underpinnings for determining damping parameters specific to these materials. Subsequently, the damping parameters of the partially foam-filled honeycomb panel are determined based on the ratio of dissipated energy to strain energy. Ultimately, a comprehensive theoretical testing methodology is established, with tests conducted concurrently on composite materials to benchmark against data obtained via theoretical approaches. The findings underscore the capability of the proposed approach to assess the damping characteristics of diverse materials and extract their corresponding damping parameters. This method provides an effective theoretical model for investigating the damping characteristics in partially foam-filled fully composite honeycomb core sandwich structures. The model can also be applied to assess the damping properties of similar structures, offering practical guidance. [ABSTRACT FROM AUTHOR]

Highlights Novel Stitched Foam‐filled Honeycomb Sandwich (SFHS) panels have been fabricated using vacuum‐assisted resin transfer molding to address the weak interfaces between the face sheets and the core in the Foam‐filled Honeycomb Sandwich (FHS) panel. The SFHS panels have shown better load‐bearing capacity and performance characteristics compared to FHS panel after Low‐Velocity Impact (LVI) tests. After the LVI test, MATLAB image processing was used to analyze the impact damage areas and failure mechanisms. In addition, Machine Learning regression algorithms were employed to predict the optimal amount of energy absorbed during low‐velocity impact testing of fabricated panels with a maximum impactor drop height of 700 mm. The results indicated that nylon yarn stitching significantly improved energy absorption and interfacial behavior compared to unstitched honeycomb panels. This research also revealed that SFHS1 panels with adjacent honeycomb cell stitching are more impact resistant, provide increased load carrying capacity, and are cost‐effective. These panels can be utilized by modern engineers to increase economy, durability, and functionality in industrial, automotive, and construction applications. Stitched Foam Filled Honeycomb Sandwich (SFHS) panels, manufactured via resin transfer molding, and eliminates weak interfaces between the face sheets and core. SFHS panels outperformed unstitched panels in load‐bearing and energy absorption during low‐velocity impact, as confirmed by MATLAB image analysis showing reduced damage and failure. Machine learning algorithms particularly polynomial regression model predicted maximum absorption energy precisely with 99.9% accuracy, close to experimental results. SFHS panels can be used in automotive and industrial applications due to their through‐thickness stitching. [ABSTRACT FROM AUTHOR]

Two main goals are pursued in the present work. First, the global buckling of axially loaded sandwich beams with composite face sheets and aluminum honeycomb cores under humid environments is investigated. An analytical solution with high accuracy is developed based on piecewise low-order shear deformation theory (PLSDT) to estimate the critical buckling loads. A parametric study is carried out to examine the influence of geometric parameters on the buckling loads of simply supported and clamped sandwich beams under different wet conditions. The obtained results indicate that humidity plays a significant role in the buckling behavior of honeycomb sandwich beams. As the second purpose of the present work, the weight minimization of sandwich beams is studied. The optimization variables include the face sheet thickness, core thickness, honeycomb cell size and honeycomb cell wall thickness. Moreover, different failure modes, including global buckling, face sheet dimpling, face sheet wrinkling, core shear instability, and face sheet failure are considered as design constraints. Imperialist competitive algorithm (ICA), a powerful socio-politically motivated global search strategy, is applied to handle the constrained optimization problem. The optimization results show that the presence of humidity in the environment significantly changes the optimal design of sandwich beams and makes them heavier. Furthermore, it is observed that by increasing the length of the structure, the optimal design is more affected by humidity. Moreover, it is found that ICA is a very powerful optimization tool both in obtaining the best values of geometric parameters and in reducing the computational cost. [ABSTRACT FROM AUTHOR]

In recent days, the sandwich structure has created significant evolutionary changes in world technology, which are used in many sectors like automobile, aeronautical, defence, etc., The structural-based studies are evaluated and replaced with the sandwich structure, which contains three layers; a core layer, upper and lower face sheets. This article evaluates the transverse shear modulus of the sandwich core structure of 3D-printed materials. Henceforth the bioinspired structural design is adopted as core structure which is bio-mimicked from the microstructural layer design of the woodpecker's beak. Forming the wavy patterns is incorporated with the conventional honeycomb shape. The edges of the structure's waviness are modeled as champer edges with the required dimensions. The fused deposition modeling (FDM) process is carried out to bring out the expected sandwich core design. Here, the article speaks about the contest between the various types of materials like polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), high impact polystyrene (HIPS), carbon fiber-polylactic acid (CF-PLA), carbon fiber - acrylonitrile butadiene styrene (CF-ABS), carbon fiber-polyethylene terephthalate glycol (CF-PETG). Each material contains specific properties; Henceforth, each material property is validated by ASTM E1876 standard. The objective is to find the good effectiveness of transverse shear modulus by the Nondestructive process called alternative dynamic method among the 3D-printed Bioinspired materials. In this study, CF-PLA stands ahead to give efficient transverse shear modulus property values. These results can be carried forward to structural development, enhancing the structure's performance as the futuristic pathway. [ABSTRACT FROM AUTHOR]

Honeycomb sandwich panels are utilized in many industrial applications due to their high bending resistance relative to their weight. Defects between the core and the facesheet compromise their integrity and efficiency due to the inability to transfer loads. The material system studied in the present paper is a unidirectional carbon fiber composite facesheet with a honeycomb core with a variety of defects at the interface between the two material systems. Current nondestructive techniques focus on defect detectability, whereas the presented method uses high-frequency ultrasound testing (UT) to detect and quantify the defect geometry and defect type. Testing is performed using two approaches, a laboratory scale immersion tank and a novel portable UT system, both of which utilize only single-side access to the part. Coupons are presented with defects spanning from 5 to 40 mm in diameter, whereas defects in the range of 15–25 mm and smaller are considered below the detectability limits of existing inspection methods. Defect types studied include missing adhesive, unintentional foreign objects that occur during the manufacturing process, damaged core, and removed core sections. An algorithm is presented to quantify the defect perimeter. The provided results demonstrate successful defect detection, with an average defect diameter error of 0.6 mm across all coupons studied in the immersion system and 1.1 mm for the portable system. The best accuracy comes from the missing adhesive coupons, with an average error of 0.3 mm. Conversely, the worst results come from the missing or damaged honeycomb coupons, with an error average of 0.7 mm, well below the standard detectability levels of 15–25 mm. [ABSTRACT FROM AUTHOR]

Aluminum honeycomb sandwich structure with panels made of carbon fiber reinforced polymer (CFRP) are widely used in aerospace and other fields. Simulation of the eddy current (EC) testing of the sandwich structure using the finite element (FE) method is challenging as the traditional FE method has difficulties in mesh division and the solution of the algebraic equations. This paper proposes to use the domain decomposition FE method to solve such problems. The top CFRP panel, the aluminum honeycomb core, and the bottom CFRP panel of the sandwich structure and the ferrite core of the coil are placed in different subdomains and the subdomains are meshed independently. This method simplifies the mesh generation and does not require regenerating the meshes when simulating the scanning testing with the ferrite-core coil. In this way, the efficiency of simulation is greatly improved. The EC distributions in the sandwich structure are computed and the influence of defect on EC distribution is analyzed. The C scans of the sandwich structures are simulated. The images of the EC responses to the defects, such as wall fracture, node disconnection, and core wrinkle, are obtained. The simulation results are validated by experiments. [ABSTRACT FROM AUTHOR]

Sandwich panels are the fundamental structural element in a wide range of applications, including in satellite primary structures. While sandwich constructions are very efficient, their complex multi-material assembly leaves room for further optimisation of the core volume and improvement in the integration phase. One key technology that can enable the transition to multifunctional sandwich panel cores tailored to certain applications is the additive manufacturing (AM) of satellite primary structure sandwich panel cores. This paper investigates the feasibility of replacing the baseline Aluminium honeycomb core with a core printed out of AlSi10Mg through Powder Bed Fusion. Sandwich panels with carbon fiber-reinforced plastic (CFRP) facesheets and printed honeycomb cores as well as fully printed corrugated panels are produced and tested under three point bending (3PB) and compression as part of the EU funded ReDSHIFT project. The Instron 5560 (3PB) and 4204 (compression) are used to perform the experiments that follow the ASTM C393-11 and C365 standards. When compared against the baseline CFRP-AL panels, the 3D printed honeycomb cores carry up to twice as much load per unit mass in bending and four times as much in compression, while also being stiffer. The fully printed corrugates samples are weaker than the honeycombs, but in conjunction with the honeycomb geometry may present a promising avenue for developing multifunctional cores. While limitations with current metal printing technology prevent AM cores from matching the mass of baseline designs, the superior specific performance and geometrical freedom make printed cores a promising design alternative. [ABSTRACT FROM AUTHOR]

This paper investigates the method for water ingress detection in an aluminum honeycomb sandwich structure by laser ultrasonics. To clarify the propagation of Scholte waves generated at the solid-liquid interface, the theoretical dispersion curves in the water-aluminum layered structure are calculated by the global matrix method. Using a laser ultrasonic visualizing inspector, the guided wave propagation in the wavefields has been visualized, which shows the mode conversion behaviors occurring in the water ingress area. The clarification of mode conversion is then investigated by the finite element method. The Scholte modes at the solid-fluid interface and the Lamb modes in the face sheet are interconverted because of the change in the waveguide structure. Wavenumber filter reconstruction and the resulting energy maps are applied to illustrate the mode conversion in the wavefields and to detect the water ingress area. Results show that the appearance of the water layer contributes to the mode conversion behaviors during the guided wave propagation in the honeycomb sandwich structure, which offers the potential for water ingress detection based on the mode conversion behaviors. [ABSTRACT FROM AUTHOR]

Honeycomb Sandwich Composites (HSCs) have been widely used in aerospace and aircraft industries because of their high temperature and corrosion resistance, etc. As defects and damage to HSCs are unavoidable, non-destructive testing (NDT) is essential to ensure the reliability of HSCs. A series of artificial flat-bottomed holes (FBHs) defects of HSCs were prepared for pulse thermography (PT) and LFM-Chirp-Square pulse-compression thermography (PuCT). LFM-Chirp-Square PuCT has the advantage of frequency modulation over PT to detect different depth ranges of FBHs defects. In order to improve the efficiency of defect detection, pulse phase thermography (PPT) and total harmonic distortion (THD) techniques were applied to process the infrared image sequences. The results show that THD processing technique outperforms the PPT processing technique in improving the signal-to-noise ratio (SNR) from feature images. The combination of LFM-Chirp-Square PuCT and THD techniques can be applied to improve the defect detection identification results in HSCs. [ABSTRACT FROM AUTHOR]

In this study, a three-point bending test was carried out to determine the mechanical properties of hexagonal-shaped honeycomb core sandwich panels made of jute yarn with two distinct fiber orientations. A custom-made handloom was used to weave the unidirectional jute mat, and hand-layup with the cold press process was applied to fabricate the hexagonal honeycomb sandwich panel. To explore the effectiveness of different natural fibers for producing honeycomb core sandwich panels, a Finite Element Method (FEM) analysis was performed on different natural fibers with different fiber orientations. The resistance to environmental deterioration of bending properties was also investigated. Overall, this work offers perceptive information about the mechanical characteristics of sandwich panels made of jute honeycomb core and their behavior under various climatic circumstances, which may be relevant in a variety of engineering applications. Finally, it is noteworthy that the mechanical properties of jute fibers are anisotropic, which implies that their strength varies with the direction of loading. Sandwich panels with horizontal fiber orientation of hexagonal honeycomb core withstand a 36% higher bending strength than those with vertical fiber orientation. [ABSTRACT FROM AUTHOR]

This article reports a carbon fiber–reinforced plastic Kagome composite honeycomb sandwich structure reinforced with polymethacrylimide (PMI) foam (PKCSS). Low‐velocity impact performances on the node, rib, and two cell centers of the PKCSS were experimentally compared with those on a composite Kagome honeycomb sandwich (CKHS), and the failure mechanism of the PKCSS was investigated. The impact process was analyzed through an explicit numerical analysis using ABAQUS. A three‐dimensional Hashin failure criterion was introduced using the VUMAT subroutine. Results confirmed that the PKCSS exhibits higher impact and specific loads than the CKHS, with the maximum improvements of 69.7% and 39.5%, respectively, under 50‐J impact energy. As an uncrushable material, the PMI foam provides strong impact resistance during its plateau stage. This technology of cell filling can be used to fabricate lightweight all‐composite honeycomb sandwiches for potential use in ultrahigh engineering applications. Highlights: Cell filling is applied in an all‐composite Kagome honeycomb sandwich.The LVI performances of the PKCSS and CKHS are experimentally compared.C‐scanning is used to analyze the failure of the considered structures.The PKCSS's numerical model is established to investigate the impact process.The enhancement mechanism of the PMI foam is analyzed. [ABSTRACT FROM AUTHOR]

Based on the proposed multi-arc curved edge concave adjustable Poisson's ratio cell, five kinds of sandwich panels with negative Poisson's ratio (NPR) were constructed by changing the in-plane thickness of cells: homogeneous, positive gradient, negative gradient, symmetrical positive gradient, and symmetrical negative gradient. The failure mechanical properties of the sandwich panels under the action of local impact were numerically studied. The influences of impact speed and gradient arrangement modes on the failure mode of the sandwich panels, the punch contact force (PCF) and the energy absorption effect (EAE) were investigated. It is found that the failure behavior of sandwich panels is different under different impact speeds. At the same impact speed, the thickness distribution pattern of the sandwich panel core layer will significantly affect the shock resistance of the panel. The study shows that the EAE of sandwich panels can be effectively enhanced by introducing gradient design method, and the sandwich panels with negative gradient arrangement show the best energy absorption effect. [ABSTRACT FROM AUTHOR]

In the field of lightweight structures, foldcore sandwich structure is regarded as a promising replacement for conventional honeycomb sandwich structure. In this study, a new M-type glass fiber foldcore structure was fabricated by hot-pressing molding technology, and the effects of various factors on the low-velocity impact characteristics were investigated. In addition, a 3 D progressive damage numerical model matching the experimental results was established. The results showed that the impact energy exerted a certain influence on the response characteristics of the sandwich structure, but did not change the development trend of the load curve. The sandwich panel was able to achieve the overall load-carrying potential for the impactor whose size was longer than the foldcore span (25 mm). In addition, as the sharpness of the impactor increased, the damage range of the sandwich panel became concentrated and the load-bearing capacity gradually decreased. As revealed by the findings, the maximum load and specific energy absorption of laminated sandwich panels were improved by 150 and 40% respectively compared to single sandwich panel at base position. Therefore, it is beneficial to appropriately reduce the core span and increase the number of laminations to improve impact resistance of foldcore sandwich in practical applications. [ABSTRACT FROM AUTHOR]

The honeycomb sandwich panel presents a highly promising solution for enhancing ballistic behavior owing to its excellent strength-to-weight ratio and impact resistance. This study focuses on investigating the shock mitigation properties of honeycomb sandwich panels through experimentation and numerical simulation of high-velocity impact tests. Single-scale and double-scale hierarchical honeycomb cores are manufactured using selective laser melting with AlSi10Mg powder, combined with a pair of stainless steel (SS 316) sheets. High-velocity impact experiments were conducted within a velocity ranging from 100 to 270 m/s to examine the effects of different cores and projectile nose shapes on the dynamic response of the panels. Numerical simulations using ABAQUS/Explicit software were performed and validated against the experimental results. The sandwich panel with a double-scale hierarchical honeycomb core exhibited 7.8% and 6.1% more energy absorption compared to the single-scale hierarchical honeycomb core against conical and hemispherical nose projectiles, respectively. Additionally, the ballistic limit for the hemispherical projectile was found to be 8.9% higher than the conical-nose projectile under the same impact velocity and panel thickness. Moreover, an increase in panel thickness from 12 mm to 25 mm prompted a significant improvement of approximately 39% in specific energy absorption and a 44% increase in ballistic limit velocity. These findings highlight the considerable potential of single-scale and double-scale hierarchical honeycomb sandwich panels for the development of threat-resistant structures in critical dynamic loading applications. [ABSTRACT FROM AUTHOR]

The flatwise compression and mechanical response of gradient-tandem Nomex honeycomb sandwich panels were investigated by quasi-static compression tests. Finite element models of the gradient-tandem Nomex honeycomb sandwich panels were established to evaluate the effects of layer sequences, separator materials, and layer heights on the mechanical properties through parametric studies. The different assembly of honeycomb sequence and separator material affected the deformation sequence and peak stress of the sandwich panels. Under quasi-static compression, the response curves are smoother when the appropriate separator material and assembly sequence are chosen. Meanwhile, the peak stresses are effectively reduced. The research results can guide the individualized design of tandem Nomex honeycomb sandwich panels. [ABSTRACT FROM AUTHOR]

The failure behavior and load-carrying capacity of Nomex honeycomb sandwich panels under three-point bending are experimentally and numerically studied. The failure modes observed in experiments are core shear failure and face-sheet/core debonding. A detailed model considering Nomex paper and resin coating is built with Abaqus/explicit simulation. The Hill 1948 quadratic anisotropic yield criteria are adopted to describe the plastic behavior of Nomex paper and the principal stress criteria are used for predicting the failure of resin coating. The effectiveness of the proposed meso-scale model is validated by comparing the experimental and the numerical results. The effects of geometric parameters on the bending behaviors are discussed in detail. It is shown that the ultimate force and bending stiffness of Nomex honeycomb sandwich panels is significantly influenced by the core orientation, resin thickness and cell size. The cutting position has no effect on the ultimate force and bending stiffness. [ABSTRACT FROM AUTHOR]

Composite materials, particularly honeycomb composites, are widely utilized in various industries, including aerospace, due to their high energy absorption against the impact and exceptional strength-to-weight ratio. This study aims to leverage the plastic and elastic properties of these materials to develop a simplified numerical model that incorporates orthotropic properties for core modeling. By doing so, the need for detailed honeycomb structure modeling is eliminated, resulting in reduced computational costs and time. A comprehensive three-dimensional finite element model, accounting for structural intricacies, is presented based on experimental data from a reputable source (isotropic model) and its equivalent finite element model (orthotropic model). The model is validated by the experimental results, demonstrating good agreement. The study also investigates parameters such as energy absorption, the internal energy of the core and faces, maximum displacement, and maximum contact force under low-velocity impact scenarios with spherical and cylindrical projectiles. These findings highlight the effectiveness of the orthotropic model, particularly in showcasing greater energy absorption in the core of the sandwich panel when subjected to a cylindrical impactor. [ABSTRACT FROM AUTHOR]

The dynamic mechanical behavior and cushioning performance of honeycomb sandwich panels, which are extensively employed in product cushioning packaging due to their exceptional energy absorption capabilities, were examined using a combination of experimental and numerical methods. Several factors, such as maximum acceleration–static stress, cushioning coefficient–static stress, and other curves, were analyzed under various impact conditions. The simulated stress–strain, deformation modes, cushioning coefficients, and other parameters demonstrate consistency with the experimental results. The acceleration, maximum compression, and cushioning coefficient obtained from the experiment and simulation calculation were 30.68 g, 15.44 mm, and 2.65, and 31.96 g, 14.91 mm, and 2.79, respectively. The results indicate that all error values were less than 5%, confirming the precision and reliability of the model. Furthermore, the model was utilized to simulate and predict the cushioning performance of honeycomb sandwich panels with different cell structures and paper thicknesses. These results provide a solid basis for enhancing the design of subsequent honeycomb element structures. [ABSTRACT FROM AUTHOR]

Due to their high load-bearing capacity and excellent energy dissipation properties, metal honeycomb lightweight sandwich panels are commonly utilized as highly efficient weight-saving components in the automotive, aerospace, and military industries. Especially the auxetic honeycomb sandwich panels have higher yield strength, more robust shear modulus, fracture toughness, less fatigue expansion, and higher vibration and energy absorption. In this paper, the ballistic resistance and energy absorption mechanisms of a novel re-entrant auxetic honeycomb (RSH) sandwich panel are investigated. The ballistic limits and energy absorption of the re-entrant star-shaped honeycomb (RSH), star-shaped honeycomb (SSH), and re-entrant star-shaped honeycomb (RH) sandwich panels are compared and analyzed, as well as the deformation mechanism during projectile penetration. The results show that the RSH sandwich panel has the best in-plane ballistic performance among the three types of honeycomb sandwich panels. For the same relative density, the ballistic limit of the RSH sandwich panel is 17.4% and 7.1% higher than that of the SSH and RH sandwich panels respectively. In addition, the effects of different design parameters on the ballistic resistance of RSH sandwich panels are investigated by changing the panel thickness, the relative density of the core layer, the cell angle and the cell size. It can be concluded that increasing the thickness of the face sheet is more effective in improving the ballistic limit (perforation energy) of the RSH with a thinner core layer. However, increasing the relative density of the core layer is more effective in enhancing the ballistic limit (perforation energy) for thicker core layers. Cell size has a significant effect on the ballistic resistance of RSH sandwich panels compared to cell angle, especially at impact velocities close to the ballistic limit. [ABSTRACT FROM AUTHOR]

Through the method of numerical simulation, the detection rules of different defect characteristics and the detection effect of detection process parameters on different defects were explored. The optimal detection process parameters for GFRP/NOMEX honeycomb sandwich structure specimens with delaminating, debonding, water accumulation, and glue plugging defects were obtained. Experimental research was carried out to verify its detection effect for actual tests. The result is that the technology under this parameter can get better defect detection effect. [ABSTRACT FROM AUTHOR]

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. [ABSTRACT FROM AUTHOR]

In this study, a three-rib intersecting composite diamond honeycomb structure is fabricated by interlocking technology. The mechanical properties of the composite interlocked diamond honeycomb (CIDH) and corresponding sandwich structure (CIDHSS) are experimentally tested. The stiffness, strength, and failure characteristics of CIDH and CIDHSS are analyzed. The results show that CIDH has better mechanical properties than the interlocked Kagome and square honeycombs. The edge effect limits the edge compressive strength and stiffness of CIDH. Debonding is the main failure mode that limits both bending and compressive strength of CIDHSS. The reinforced plate added to the edge effectively improves the anti-debonding ability. [ABSTRACT FROM AUTHOR]

Bamboo is an environmentally friendly building structural material. This work investigated the cavity structural characteristics and physical and mechanical properties of honeycomb sandwiches and natural bamboo in the longitudinal direction. The effective elastic parameters of periodically arranged hexagonal bamboo honeycomb cells under in-plane and out-of-plane loads were modeled using analytical and numerical approaches. Then, the effective elastic parameter model of bamboo honeycomb cells was validated by experiments and finite element analysis. The average errors between the calculated and experimental equivalent modulus of elasticity, Poisson's ratio, and shear modulus in the three principal axis directions were 7.43, 4.37, and 8.68%, respectively. The average relativities between the model values of the elastic parameters of the bamboo honeycomb cell and the simulation results in the three directions were 5.46, 5.40, and 6.12%, respectively. The experimental and finite element analysis showed that the constructed effective elastic parameter model of the bamboo honeycomb cell better reflected the state of the bamboo core when subjected to force. This study provides insights for further research on the mechanical properties of bamboo materials and their application in bamboo-based lightweight and high-strength sandwich structures. [ABSTRACT FROM AUTHOR]

The cell array type significantly affects the global stresses in curved honeycomb sandwich panels. In this study, the curved sandwich panels with the out-plane honeycomb core (COP) and the in-plane honeycomb core (CIP) are proposed. Their local impact resistance is numerically investigated using finite element simulation calibrated with air cannon test results. Various impact scenarios including different projectile diameters, different impacting velocities, angles, as well as locations are considered. The performances of the COP and CIP panels with similar overall mass and relative density are compared by evaluating their impact histories and energy absorption properties. It is demonstrated that the CIP panel shows improved impact mitigation and energy absorption property under local impact. However, its overall displacement is significantly larger than that of the COP panel. Based on the impact behavior of COP and CIP panels, the hybrid two-layer structures (HOI and HIO) are designed. It is found that the HIO panel shows an increase in energy absorption of approximately 3% over the COP and CIP panels and a reduction in the overall displacement of at least 28% over the CIP panel. Moreover, HIO configuration with the thinner cell wall thickness of the upper core demonstrates improved impact mitigation. [ABSTRACT FROM AUTHOR]

Due to its advantages in terms of enhancing the performance of structures in the desired applications, the bio-inspired design approach has recently attracted the interest of researchers in a number of engineering disciplines. A hybrid bio-inspired design is suggested for the sandwich structures to absorb the energy of the blast loads in the current study. The sandwich structure's core, which often has a regular grid pattern resembling a honeycomb structure, is crucial to how well the panel absorbs energy. In order to achieve the best results, we first chose the structure of the core grid by taking into account potential 2D grids (polygons and multi-pointed stars) through Genetic Algorithm optimization. Next, we combined a bio-inspired bi-tubular thin-walled structure with the core grid to take advantage of its high energy absorption capacity. Finally, the performance of the suggested design is compared with four frequently implemented ones. The results show that the hybrid design has better energy absorption characteristics compared with the bionic and conventional designs presented in the literature. [ABSTRACT FROM AUTHOR]

For the support structure of wind tunnel tests, a honeycomb sandwich structure is used to embed the wind tunnel tail brace to form a honeycole test process. Using Rayleigh beam theory and equivalent method, the lateral bending dynamic model of the support rod is solved and the natural frequency expression of the lateral bending vibration of the support rod is obtained. Taking the static strength of the support rod as the optimization design objective, the honeycomb sandwich structure was quantitatively described and the optimal design scheme was obtained through orthogonal experiments. The simulation and calculation results of the proposed support and hollow support are verified and compared with each other. The error between the first three natural frequencies of the honeycomb sandwich support given in this article and the simulation results is less than 9.52 %, which proves that the calculation results are relatively accurate. On the premise of meeting the constraints and load requirements, the low order resonant deformation of the transient dynamics simulation analysis is reduced by 30.27 %, significantly improving the vibration damping ability of the wind tunnel support system. [ABSTRACT FROM AUTHOR]

The response of sandwich structures under the synergistic effects of blast wave and fragments is a topic of interest for researchers and designers. Thus, the performance of a sandwich structure used for enhancing the protection of a target structure is numerically investigated because it may experience such complex loading conditions resulting from combined blast and fragment impact. A conventional sandwich structure modelled using aluminium alloy resists a bare blast load imposed on it. Analysis, however, reveals that fragments penetrate through the front facesheet of a conventional sandwich structure, indicating a lower resistance of the front facesheet to combined blast and fragment effects. Thus, the behaviour of conventional aluminium honeycomb sandwich structures is compared with enhanced sandwich configurations consisting of a front facesheet covered with multilayer lightweight composite Kevlar fabric material. The Kevlar fabric arrests the maximum number of fragments, and reduces their momentum, thereby reducing the damage level in the sandwich structure. The effect of the charge weight and shape of the fragments on the damage modes of the sandwich structure is also assessed. With the increase in charge weight, the momentum of the fragments is found to increase, and these penetrate the back facesheet of the sandwich structure. [ABSTRACT FROM AUTHOR]