Numerical Investigation into In-Plane Crushing of Tube-Reinforced Damaged 5052 Aerospace Grade Aluminum Alloy Honeycomb Panels

This paper aims to investigate the crashworthiness performance degradation of a damaged 5052 aluminum honeycomb panels under in-plane uniaxial quasi-static compression and the possibility of improving it using reinforcement tubes. The in-plane crushing behaviors and energy absorption capacities of the intact, damaged, and tube-reinforced damaged panels with different damage sizes in both X₁ and X₂ directions are numerically simulated by using the nonlinear FE method Abaqus/Explicit, and the crashworthiness performances are compared with each other. The validation of finite element model involves comparing the obtained simulation results with theoretical and experimental ones. Very good agreement between numerical, experimental, and theoretical results is achieved. The first maximum compressive load and the mean crushing load of the different honeycomb configurations are analyzed and compared through the load–strain curves. The energy absorption capacity of the damaged and the tube-reinforced damaged panels is calculated and then compared with their corresponding intact ones. The deformation modes are explained in detail. The obtained results show that the crashworthiness performance degradation is directly proportional to the damage size as well as the insertion of reinforcement tubes considerably improves in-plane crushing resistance of damaged honeycomb panels.     

Influence of Impregnation with Modified Starch of a Paper Core on Bending of Wood-Based Honeycomb Panels in Changing Climatic Conditions

The main objective of the study was to determine the effect of impregnation of the paper core with acetylated starch on the mechanical properties and absorbed energy in the three-point bending test of wood-based honeycomb panels under varying temperatures and relative air humidity conditions. Nearly six hundred beams in various combinations, three types of facings, three core cells geometries, and two paper thicknesses were tested. The experiment results and their statistical analysis prove a significant relationship between the impregnation of paper with modified starch and mechanical properties. The most effective in absorbing energy, the honeycomb panels, consisted of a core with a wall thickness of 0.25 mm and a particleboard facing.     

Deformation Behaviors and Energy Absorption of Composite Re-Entrant Honeycomb Cylindrical Shells under Axial Load

Composite materials and re-entrant honeycomb structures have superior mechanical performance in energy absorption capacity. Inspired by laminate composite layers, single-layer re-entrant honeycomb cylindrical shells (RHCSs) with different orientations were established, and composite RHCSs were proposed by combining the single-layer RHCSs with different orientations. The deformation behaviors of single layer RHCSs under quasi-static compression were studied by experimentation, and single-layer RHCSs with varying orientations did not show negative Poisson’s ratio effects. The energy absorption capacity of single-layer and composite RHCSs was researched using simulation. To analyze the energy absorption capacity, we determined the plateau stress, the mean force and specific energy absorption of single-layer and multi-layer composite RHCSs under different impact velocities; the following conclusions were obtained: compared with the single-layer RHCSs, the multi-layer composite RHCSs, which had the same size, the energy absorption capacity improved significantly under the same impact velocities. The energy absorption capacity of the multi-layer composite RHCSs improved with increasing number of layers under low velocity.     

Micro Fracture Behavior of Composite Honeycomb Sandwich Structure

To study the influence of structure size and composite forms on the mechanical properties of the composite double honeycomb sandwich structure, a composite double honeycomb sandwich structure was initially designed. The dynamic response of a composite double-layer honeycomb sandwich structure under high-speed impact was studied through theoretical analysis and numerical simulation. Ls-dyna software was used to simulate the initially designed composite structure. According to the numerical simulation results and the proposed method for calculating the fracture energy of the composite double honeycomb sandwich structure, the effects of different composite forms on the mechanical properties were analyzed. The results show that the proposed fracture energy calculation method can effectively describe the variation trend of the honeycomb structure and the micro-element fracture situation in the valid time. The fracture energy curve has a high sensitivity to cell density and material, and the strength of the top core has a great influence on the overall energy absorption. Compared with the traditional honeycomb protection structure, the energy absorption of the initially designed composite honeycomb sandwich structure was improved effectively.     

On Wrinkling in Sandwich Panels with an Orthotropic Core

This paper deals with the local loss of stability (wrinkling) problem of a thin facing of a sandwich panel. Classical solutions to the problem of a facing instability resting on a homogeneous and isotropic substructure (a core) are compared. The relations between strain energy components associated with different forms of core deformations are discussed. Next, a new solution for the orthotropic core is presented in detail, which is consistent with the classic solution for the isotropic core. Selected numerical examples confirm the correctness of the analytical formulas. In the last part, parametric analyses are carried out to illustrate the sensitivity of wrinkling stress to a change in the material parameters of the core. These analyses illustrate the possibility of using the equations derived in the article for the variability of Poisson’s ratio from −1 to 1 and for material parameters strongly deviating from isotropy.     

Research on Mechanical Properties of Origami Aluminum Honeycomb for Automobile Energy Absorbing Box

With the increasing number of automobiles on the road, passive safety has become a particularly important issue. In this paper, an energy-absorbing material, origami aluminum honeycomb, was manufactured by a welding process for use as an automobile energy absorbing box. The mechanical properties and deformation of welded origami aluminum honeycomb in three directions were studied through quasi-static and dynamic compression tests. The results show that the origami aluminum honeycomb had good mechanical energy absorption performance, and the optimal directions are identified. Combined with theoretical analysis, the errors between experiments and simulations are shown. The origami honeycomb structure was designed for use as an automobile energy absorbing box. Analysis shows that it could absorb at least 10% of the kinetic energy of a vehicle during a collision, and could play a role in protecting the interior of the vehicle.     

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

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

Failure Analysis of Hat-Stringer-Stiffened Aircraft Composite Panels under Four-Point Bending Loading

Hat-stringer-stiffened composite panels have been widely used in aircrafts. Accurate failure analysis of them is important for the safety and integrity of the fuselage. During the service period, these panels will bear not only the lateral force caused by the bending of fuselage, but also the radial pressure caused by the internal and external differential pressure during the take-off and landing of the aircraft. However, the latter case lacks investigation. Therefore, experimental and numerical studies for the static and fatigue failure of hat-stringer-stiffened composite panels under four-point bending loading have been performed in this work. To accurately predict the fatigue failure, a novel theoretical model has been proposed based on the fatigue damage theory. In addition, a user-defined subroutine USDFLD is developed for the implementation of the proposed theoretical model in Abaqus. Experimental results show that the main failure modes are the delamination of the skin and debonding between the girder flange and the skin. The experimental average value of the initial debonding load and displacement in static tests are 897.3 N and 10.8 mm, respectively. Predictions exhibit good agreement with experimental results with relative errors within 10%. Experimental average fatigue failure life of the specimens is 33,085 cycles, which is also close to the prediction with relative errors within 10%. This indicates the reliability and applicability of the established theoretical model and numerical method for predicting the failure of hat-shaped girder structures.     

Composite Behavior of Insulated Concrete Sandwich Wall Panels Subjected to Wind Pressure and Suction

A full-scale experimental test was conducted to analyze the composite behavior of insulated concrete sandwich wall panels (ICSWPs) subjected to wind pressure and suction. The experimental program was composed of three groups of ICSWP specimens, each with a different type of insulation and number of glass-fiber-reinforced polymer (GFRP) shear grids. The degree of composite action of each specimen was analyzed according to the load direction, type of the insulation, and number of GFRP shear grids by comparing the theoretical and experimental values. The failure modes of the ICSWPs were compared to investigate the effect of bonds according to the load direction and type of insulation. Bonds based on insulation absorptiveness were effective to result in the composite behavior of ICSWP under positive loading tests only, while bonds based on insulation surface roughness were effective under both positive and negative loading tests. Therefore, the composite behavior based on surface roughness can be applied to the calculation of the design strength of ICSWPs with continuous GFRP shear connectors.     

Residual Strength Prediction of Aluminum Panels with Multiple Site Damage Using Artificial Neural Networks

Multiple site damage (MSD) cracks are small fatigue cracks that may accumulate at the sides of highly loaded holes in aging aircraft structures. The presence of MSD cracks can drastically reduce the residual strength of fuselage panels. In this paper, artificial neural networks (ANN) modeling is used for predicting the residual strength of aluminum panels with MSD cracks. Experimental data that include 147 unique configurations of aluminum panels with MSD cracks are used. The experimental dataset includes three different aluminum alloys (2024-T3, 2524-T3, and 7075-T6), four different test panel configurations (unstiffened, stiffened, stiffened with a broken middle stiffener, and bolted lap-joints), many different panel widths and thicknesses, and the sizes of the lead and MSD cracks. The results presented in this paper demonstrate that a single ANN model can predict the residual strength for all materials and configurations with high accuracy. Specifically, the overall mean absolute error for the ANN model predictions is 3.82%. Furthermore, the ANN model residual strength predictions are compared to those obtained using the most accurate semi-analytical and computational approaches from the literature. The ANN model predictions are found to be at the same accuracy level of these approaches, and they even outperform the other approaches for many configurations.     

Composite Hat Structure Design for Vehicle Safety: Potential Application to B-Pillar and Door Intrusion Beam

Regarding crashworthiness, many published works have focused on designing thin-walled structures for frontal collisions compared to side-impact collisions. This paper presents an experimental investigation and finite element modelling of a carbon-reinforced thin-walled top-hat section subjected to quasi-static and dynamic transverse bending loads at different impact speeds. The top-hat sections and their closure assembly plates were made of MTM44 prepreg carbon. The specimens were manufactured by vacuum bagging. Dynamic work was performed to validate the results obtained from the finite element analysis (FEA). The predicted results are in good agreement with the experimental results. The study also showed that the peak load and energy absorption owing to dynamic loading were higher than those under static loading. In the four-point bend analysis, the stacking sequence affected the energy absorption capabilities by 15–30%. In addition, the distance between the indenters in the four-point analysis also affected the energy absorption by 10% for the same impact condition, where a larger distance promoted higher energy absorption. The study also demonstrated that a top-hat shaped thin-walled structure is suitable for deep intrusion beams in vehicle doors for side-impact crashworthiness applications.     

Experimental and Numerical Investigation of the Effect of Projectile Nose Shape on the Deformation and Energy Dissipation Mechanisms of the Ultra-High Molecular Weight Polyethylene (UHMWPE) Composite

The effect of projectile nose shape on the ballistic performance of the ultra-high molecular weight polyethylene (UHMWPE) composite was studied through experiments and simulations. Eight projectiles such as conical, flat, hemispherical, and ogival nose projectiles were used in this study. The deformation process, failure mechanisms, and the specific energy absorption (SEA) ability were systematically investigated for analyzing the ballistic responses on the projectile and the UHMWPE composite. The results showed that the projectile nose shape could invoke different penetration mechanisms on the composite. The sharper nose projectile tended to shear through the laminate, causing localized damage zone on the composite. For the blunt nose projectile penetration, the primary deformation features were the combination of shear plugging, tensile deformation, and large area delamination. The maximum value of specific energy absorption (SEA) was 290 J/(kg/m²) for the flat nose projectile penetration, about 3.8 times higher than that for the 30° conical nose projectile. Furthermore, a ballistic resistance analytical model was built based on the cavity expansion theory to predict the energy absorption ability of the UHMWPE composite. The model exhibited a good match between the ballistic resistance curves in simulations with the SEA ability of the UHMWPE composite in experiments.     

Flexural Response of Degraded Polyurethane Foam Core Sandwich Beam with Initial Crack between Facesheet and Core

Structural systems developed from novel materials that are more durable and less prone to maintenance during the service lifetime are in great demand. Due to many advantages such as being lightweight as well as having high strength, corrosion resistance, and durability, the sandwich composites structures, in particular, have attracted attention as favorable materials for speedy and durable structural constructions. In the present research, an experimental investigation is carried out to investigate the flexural response of sandwich beams with a pre-cracked core-upper facesheet interface located at one end of the beam. During the development of the sandwich beams, an initial pre-cracked debond was created between the core and facesheet by placing a Teflon sheet at the interface. Both three-point and four-point flexural tests were conducted to characterize the flexural behavior of the sandwich beams. The effects of the loading rate, core thickness, and placement of the initial interfacial crack under a compressive or tensile stress state on the response and failure mechanism of Carbon Fiber-Reinforced Polymer (CFRP)/Polyurethane (PU) foam sandwich beams were investigated. It was found that the crack tip of the initial debonding between the upper facesheet and the core served as a damage initiation trigger followed by the fracture failure of the core due to the growth of the initial crack into the core in an out-of-plane mode. Finally, this leads to facesheet damage and rupture under flexural loadings. An increase in the core thickness resulted in a higher peak load, but the failure of the sandwich beam was observed to occur at significantly lower displacement values. It was found that the behavior of sandwich beams with higher core thickness was loading rate-sensitive, resulting in stiffer response as the loading rate was increased from 0.05 to 1.5 mm/s. This change in stiffness (10–15%) could be related to the squeezing of all pore space, resulting in the collapse of cell walls and thereby making the cell behave as a solid material. As a result, the occurrence of the densification phase in thick core beams occurs at a faster rate, which in turn makes the thick cored sandwich beams exhibit loading rate-sensitive behavior.     

Investigation into Thermomechanical Response of Polymer Composite Materials Produced through Additive Manufacturing Technologies

This paper presents the static mechanical behavior and the dynamic thermomechanical properties of four market-available reinforced and non-reinforced thermoplastics and photopolymer materials used as precursors in different additive manufacturing technologies. This article proposes a characterization approach to further address development of aeronautic secondary structures via 3D-printed composite materials replacing conventional manufactured carbon fiber reinforced polymer (CFRP) composites. Different 3D printing materials, technologies, printing directions, and parameters were investigated. Experimental results showed that carbon-reinforced ONYX_R material exhibits a transition point at 114 °C, a 600 MPa tensile strength, and an average tensile strain of 2.5%, comparable with conventional CFRP composites manufactured via autoclave, making it a suitable candidate for replacing CFRP composites, in the aim of taking advantage of 3D printing technologies. ONYX material exhibits higher stiffness than Acrylonitrile-Butadiene-Styrene Copolymer (ABS), or conventional Nylon 6/6 polyamide, the flexural modulus being 2.5 GPa; nevertheless, the 27 °C determined transition temperature limits its stability at higher temperature. Daylight High Tensile (further called HTS) resin exhibits a tensile strength and strain increase when shifting the printing direction from transversal to longitudinal, while no effect was observed in HighTemp DL400 resin (further called HTP).     

On the Effects of Core Microstructure on Energy Absorbing Capabilities of Sandwich Panels Intended for Additive Manufacturing

Increasing transportation safety can be observed as one of the biggest engineering challenges. This challenge often needs to be combined with the need to deliver engineering solutions that are able to lower the environmental impact of transportation, by reducing fuel consumption. Consequentially, these topics have attracted considerable research efforts. The present work aims to address the previously cited challenges by maximizing the energy absorption capabilities of hybrid aluminum/composite shock absorbers with minimal thickness and mass. This engineering solution makes it possible to lighten vehicles and reduce fuel consumption, without compromising safety, in terms of crashworthiness capabilities. A numerical sensitivity study is presented, where the absorbed energy/mass (AE/m) and the absorbed energy/total panel thickness (AE/H_tot) ratios, as a consequence of low-velocity impact simulations performed on six different shock absorbers, are compared. These hybrid shock absorbers have been numerically designed by modifying the core thickness of two basic absorbers’ configurations, characterized, respectively, by a metallic lattice core, intended to be produced through additive manufacturing, and a standard metallic honeycomb core. This work provides interesting information for the development of shock absorbers, which should be further developed with an experimental approach. Indeed, it demonstrates that, by integrating composite skins with a very light core producible, by means of additive manufacturing capabilities, it is possible to design shock absorbers with excellent performance, even for very thin configurations with 6 mm thickness, and to provide a significant increase in AE/m ratios when compared to the respective equal volume standard honeycomb core configurations. This difference between the AE/m ratios of configurations with different core designs increases with the growth in volume. In detail, for configurations with a total thickness of 6 mm, the AE/m increases in additive manufacturing configurations by approximately 93%; for those with a total thickness of 10 mm, the increase is 175%, and, finally, for those with a total thickness of 14 mm, the increase is 220%.     

Evaluation and Numerical Investigations of the Cyclic Behavior of Smart Composite Steel–Concrete Shear Wall: Comprehensive Study of Finite Element Model

The composite shear wall has various merits over the traditional reinforced concrete walls. Thus, several experimental studies have been reported in the literature in order to study the seismic behavior of composite shear walls. However, few numerical investigations were found in the previous literature because of difficulties in the interaction behavior of steel and concrete. This study aimed to present a numerical analysis of smart composite shear walls, which use an infilled steel plate and concrete. The study was carried out using the ANSYS software. The mechanical mechanisms between the web plate and concrete were investigated thoroughly. The results obtained from the finite element (FE) analysis show excellent agreement with the experimental test results in terms of the hysteresis curves, failure behavior, ultimate strength, initial stiffness, and ductility. The present numerical investigations were focused on the effects of the gap, thickness of infill steel plate, thickness of the concrete wall, and distance between shear studs on the composite steel plate shear wall (CSPSW) behavior. The results indicate that increasing the gap between steel plate and concrete wall from 0 mm to 40 mm improved the stiffness by 18% as compared to the reference model, which led to delay failures of this model. Expanding the infill steel plate thickness to 12 mm enhanced the stiffness and energy absorption with a ratio of 95% and 58%, respectively. This resulted in a gradual drop in the strength capacity of this model. Meanwhile, increasing concrete wall thickness to 150 mm enhanced the ductility and energy absorption with a ratio of 52% and 32%, respectively, which led to restricting the model and reduced lateral offset. Changing the distance between shear studs from 20% to 25% enhanced the ductility and energy absorption by about 66% and 32%, respectively.     

Quantitative Assessment of the Influence of Tensile Softening of Concrete in Beams under Bending by Numerical Simulations with XFEM and Cohesive Cracks

Results of the numerical simulations of the size effect phenomenon for concrete in comparison with experimental data are presented. In-plane geometrically similar notched and unnotched beams under three-point bending are analyzed. EXtended Finite Element Method (XFEM) with a cohesive softening law is used. Comprehensive parametric study with the respect to the tensile strength and the initial fracture energy is performed. Sensitivity of the results with respect to the material parameters and the specimen geometry is investigated. Three different softening laws are examined. First, a bilinear softening definition is utilized. Then, an exponential curve is taken. Finally, a rational Bezier curve is tested. An ambiguity in choosing material parameters and softening curve definitions is discussed. Numerical results are compared with experimental outcomes recently reported in the literature. Two error measures are defined and used to quantitatively assess calculated maximum forces (nominal strengths) in comparison with experimental values as a primary criterion. In addition, the force—displacement curves are also analyzed. It is shown that all softening curves produce results consistent with the experimental data. Moreover, with different softening laws assumed, different initial fracture energies should be taken to obtain proper results.     

Development of a Formability Prediction Model for Aluminium Sandwich Panels with Polymer Core

In the present work, the compatibility relationship on the failure criteria between aluminium and polymer was established, and a mechanics-based model for a three-layered sandwich panel was developed based on the M-K model to predict its Forming Limit Diagram (FLD). A case study for a sandwich panel consisting of face layers from AA5754 aluminium alloy and a core layer from polyvinylidene difluoride (PVDF) was subsequently conducted, suggesting that the loading path of aluminium was linear and independent of the punch radius, while the risk for failure of PVDF increased with a decreasing radius and an increasing strain ratio. Therefore, the developed formability model would be conducive to the safety evaluation on the plastic forming and critical failure of composite sandwich panels.     

Research on Preparation and Properties of Carbon Fiber Reinforced Zinc-Based Aluminum Rich Alloy Composite

Aiming at the problems of poor bonding between the carbon fiber and the metal matrix and the friction and wear performance of the composite material during the preparation of carbon fiber reinforced zinc-based aluminum rich alloy composites, the carbon fiber surface metallization process was studied. Taking ZA27 as the research object, a new type of zinc-based aluminum rich alloy composite material was prepared by using surface metallized chopped carbon fibers with different contents as reinforcement materials. The microscopic morphology, element distribution and phase composition of the surface metallized carbon fiber and composite materials were characterized, and the hardness and friction and wear properties of the composite materials were tested. The results show that: the surface metallization of carbon fiber effectively reduces the diffusion of carbon elements into the matrix material during the sintering process, and improves the interface bonding between the carbon fiber and the matrix material; Compared with ZA27 alloy, the hardness of 6vt% carbon fiber is increased by 29.6%, and the average friction coefficient and wear rate are reduced by about 18.4% and 96%, respectively, indicating that the carbon fiber reinforced zinc-based aluminum rich alloy composite material optimizes the friction and wear performance of traditional materials.