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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]

Aluminium honeycomb core is a thin-walled cellular structure extensively used in crash resistance applications in automotive industry. To overcome current challenges in adhesive-bonded honeycomb, new fabrication route using micro friction stir lap welding has been proposed. With a specific energy absorption capacity as high as 28.2 kJ/kg in flatwise impact testing, fabricated honeycomb demonstrated its potential for industrial applications. The structure exhibited no weld cracks or cell wall delamination, unlike adhesive-bonded honeycombs. However, in friction stir welding of thin sheets (0.5 mm), achieving an optimized heat input is challenging due to limited scope for variation in process parameter and tool design. Therefore, control of heat outflow by proper selection of backing plate material is the alternative approach for achieving desirable joint performance. Experiments with backing plates having a range of thermal diffusivities demonstrated that joint produced with mild steel backplate exhibited maximum shear-tensile strength. Conversely, joint with aluminium backplate exhibited poor plastic flow of material. Effective sheet thickness and lap width were predominantly affected by heat accumulation in weld, resulting in different failure modes. [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]

A circular honeycomb lower limb protection device was proposed to reduce the damage to the occupant's lower limbs under a vehicle under-belly blast. First, a local equivalent model of the occupant-restraint system was established, and drop impact tests and theory were used to validate the model's accuracy. Then, under the same mass, the protection performance of eight lower limb protection devices using circular honeycomb, hexagonal honeycomb, reentrant honeycomb, etc., as sandwiches were compared. It was found that the lower limb protection device with a circular honeycomb sandwich provides the best defence for lower limbs. Subsequently, the effect of gradient structure settings and dimensional parameters on the protection performance of circular honeycomb lower limb protection devices was investigated. Finally, multi-objective optimization has been carried out to further improve its protection performance. The results indicated that the protection performance of the lower limb protection device could be effectively improved by reasonably selecting the cell arrangement, gradient type and gradient interval of the honeycomb sandwich. When the optimized lower limb protection device was employed, the occupant's left and right lower tibial peak forces were decreased to 3.67 kN and 3.55 kN, respectively. Compared with the initial design, the optimized lower limb protection device reduced the left and right lower tibial peak forces by 21.1% and 23.8%, respectively, and the total mass decreased by 51.5%. [ABSTRACT FROM AUTHOR]

The integration of inserts into sandwich panel constructions is a complex multi-step process with significant human intervention that also limits the geometrical freedom of the insert design. In a standard sandwich construction, the panel core is made up of multiple materials across its main components: insert, potting and core. This multi-material assembly is not only difficult to manufacture, but it also promotes stress jumps at the insert-core interface, leading to a sub-optimal load distribution from the bolt to the panel core. Additive manufacturing (AM) can lead to a single-part core and insert assembly with more optimised insert geometries that can better transmit the loads applied to the panel. Previous work by the authors has explored the manufacturing limits and the failure modes of AM inserts integrated in cores printed out of sintered AlSi10Mg. The conclusions were that the core walls and insert elements should have a minimum design thickness of 0.5 mm to survive the tapping process without facesheets attached and it was found that the main failure mode of the geometries tested in pull-out was buckling of the insert walls. Based on these results, the paper proposes a novel insert design philosophy that can delay the buckling of 3D printed inserts and move the failure point of the insert away from the bolt. A set of inserts that follow this design direction is manufactured and tested under normal pull-out loads and the optimised designs outperform standard printed insert geometries by a factor of three. The design philosophy can be further developed to offer a suitable alternative to the current insert standard. [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]

Honeycomb cores made of phenol resin impregnated paper are widely used in sandwich structures of aircraft. Owing to the rather weak core material, this kind of sandwich is prone to a range of damages as a result of impact loading which may accidentally occur during operation. When employed in aircraft these structures have to be damage tolerant. This means barely visible damages have to be considered in the structural design process. In the standard design process for damage tolerant aircraft structures especially the effect of impacts has to be considered but is mostly investigated on unloaded sandwich components. However, aircraft structures are not completely stress free, even when the aircraft is in parking position. At least the structural weight will cause a permanent static preload. In the literature there are only few investigations dealing with the impact behaviour of preloaded honeycomb sandwich structures. In general, studies on composite structures have shown that tension preloads lead to higher structural impact resistance, while prestressing in compression reduces mechanical properties such as impact strength and stiffness of the structure. For this reason, a compression preload is considered as the more critical load case. In order to evaluate the effect of static compression preloads an experimental study on five different honeycomb sandwich configurations was conducted. The experimental investigations showed that even low preloads cause a higher structural damage area, which results in a lower residual strength of the structure. The results indicated that it is recommendable to consider structural compression preloads in the aircraft structural design process. [ABSTRACT FROM AUTHOR]