Search Results (78)

A novel honeycomb with gradient-thickness cell walls (HGTCWs) is fabricated through chemical etching to achieve progressive thickness reduction in the cell walls. This engineered honeycomb demonstrates superior energy absorption by effectively eliminating the peak load during the linear elastic stage of the load–displacement curve under impact loading, thereby preventing premature structural failure caused by excessive instantaneous loads. To systematically investigate the impact compression mechanics, energy absorption characteristics, and key influencing factors of aluminum HGTCWs, a three-factor orthogonal array of low-velocity impact experiments was designed. The design of experimental parameters for the impact test has taken into account the impact mass, impact velocity, and etching height. Comparative analysis assessed how these factors influence energy absorption performance. Results reveal that chemical etching-induced thickness gradient modification effectively suppresses peak load generation. Load–displacement curves exhibit distinct bilinear characteristics: an initial single linear phase when compression displacement is below the etching height, followed by a dual-linear phase with an inflection point at the gradient height. Time–velocity profiles during impact primarily consist of an initial nonlinear deceleration phase followed by a linear deceleration phase. Range analysis and analysis of variance identify impact velocity as the dominant factor influencing the energy absorption characteristics of HGTCWs. Full article

This study comprehensively compares the performance of two non-destructive testing (NDT) techniques—active thermography (AT) and digital shearography (DS)—for identifying various damage types in composite structures. Three distinct composite specimens were inspected: a carbon-fiber-reinforced polymer (CFRP) plate with flat-bottom holes, an aluminum honeycomb core sandwich plate with a circular skin-core disbond, and a CFRP plate with two low-energy impacts damage. The research highlights the significant role of post-processing methods in enhancing damage detectability. For AT, algorithms such as fast Fourier transform (FFT) for temperature phase extraction and principal component thermography (PCT) for identifying significant temperature components were employed, generally making anomalies brighter and easier to locate and size. For DS, a novel band-pass filtering approach applied to phase maps, followed by summing the filtered maps, remarkably improved the visualization and precision of damage-induced anomalies by suppressing background noise. Qualitative image-based comparisons revealed that DS consistently demonstrated superior performance. The sum of DS filtered phase maps provided more detailed and precise information regarding damage location and size compared to both pulsed thermography (PT) and lock-in thermography (LT) temperature phase and amplitude. Notably, DS effectively identified shallow flat-bottom holes and subtle imperfections that AT struggled to clearly resolve, and it provided a more comprehensive representation of the impacts damage location and extent. This enhanced capability of DS is attributed to the novel phase map filtering approach, which significantly improves damage identification compared to the thermogram post-processing methods used for AT. Full article

The use of aluminum honeycomb structures is fast expanding in advanced sectors such as the aeronautics, aerospace, marine, and automotive industries. However, processing these structures represents a major challenge for producing parts that meet the strict standards. To address this issue, an innovative manufacturing method using longitudinal ultrasonic vibration-assisted cutting, combined with a CDZ10 hybrid cutting tool, was developed to optimize the efficiency of traditional machining processes. To this end, a 3D numerical model was developed using the finite element method and Abaqus/Explicit 2017 software to simulate the complex interactions among the cutting tool and the thin walls of the structures. This model was validated by experimental tests, allowing the study of the influence of milling conditions such as feed rate, cutting angle, and vibration amplitude. The numerical results revealed that the hybrid technology significantly reduces the cutting force components, with a decrease ranging from 10% to 42%. In addition, it improves cutting quality by reducing plastic deformation and cell wall tearing, which prevents the formation of chips clumps on the tool edges, thus avoiding early wear of the tool. These outcomes offer new insights into optimizing industrial processes, particularly in fields with stringent precision and performance demands, like the aerospace sector. Full article

Aero-engine casings with excellent impact resistance are a practical requirement for ensuring the safe operation of aero-engines. In this paper, we report on numerical simulations of broken rotating blades impacting aluminum honeycomb sandwich casings under different temperatures and optimization of structural parameters. Firstly, an impact test system with adjustable temperature was established. Restricted by the temperature range of the strain gauge, ballistic impact tests were carried out at 25 °C, 100 °C, and 200 °C. Secondly, a finite element (FE) model including a pointed bullet and an aluminum honeycomb sandwich plate was built using LS-DYNA. The corresponding simulations of the strain–time curve and damage conditions showed good agreement with the test results. Then, the containment capability of the aluminum honeycomb sandwich aero-engine casing at different temperatures was analyzed based on the kinetic energy loss of the blade, the internal energy increment of the casing, and the containment state of the blade. Finally, with the design objectives of minimizing the casing mass and maximizing the blade kinetic energy loss, the structural parameters of the casing were optimized using the multi-objective genetic algorithm (MOGA). Full article

The design of automobile chassis structures is fundamentally linked to the optimization of mass and structural robustness. While conventional chassis structures predominantly utilize metals, achieving further mass reduction and enhanced rigidity necessitates the adoption of composite sandwich materials, typically comprising carbon fiber-reinforced polymer (C.F.R.P.) laminate skins bonded to an aluminum honeycomb core. This study focuses on presenting a framework methodology for minimizing the mass of a race car chassis by calculating an optimal baseline lamination sequence through the modification of the composite material parameters on either side of the aluminum core, using an optimization algorithm (O.A.), finite element (F.E.) analysis, composite mechanics theory, and failure criteria. Optimal solutions were derived by varying the laminae orientation and sequence parameters under two scenarios: unconstrained and constrained laminae angles. The optimization results indicate that the proposed lamination scheme reduces mass by 12.36 kg (41.66%) compared to the original lamination, with constraints imposed on laminae angles having no significant impact on the ultimate optimal outcome. Full article

With the continuous development of the new energy vehicle industry, in order to further improve the safety and range of electric vehicles, vehicle lightweighting has been a key focus of major car companies. However, research on lightweighting and the impact protection effect of battery pack protective plates is lacking. The bottom protective plate of the battery pack in this study has a sandwich-type multi-layer structure, which is mainly composed of upper and lower glass-fiber-reinforced resin protective layers, steel plate impact resistant layers, and honeycomb buffer layers. In order to study the relationship between the impact damage response and material characteristics of the multi-material battery pack protective plate, a matrix experimental design was adopted in this study to obtain the energy absorption ratio of different material properties when the protective plate is subjected to impact damage. This work innovatively used a low-cost equivalent model method. During the drop hammer impact test, a 6061-T6 aluminum plate in direct contact with the lower part of the bottom guard plate test piece was used to simulate the deformation of the water-cooled plate in practical applications. High-strength aluminum honeycomb was arranged below the aluminum plate to simulate the deformation of the battery cell. This method provides a scientific quantitative standard for evaluating the impact resistance performance of the protective plate. The most preferred specimen in this work had a surface depression deformation of only 8.44 mm after being subjected to a 400 J high-energy impact, while the simulated water-cooled plate had a depression deformation of 4.07 mm. Among them, the high-strength steel plate played the main role in absorbing energy during the impact process, absorbing energy. It can account for about 34.3%, providing reference for further characterizing the impact resistance performance of the protective plate under different working conditions. At the same time, an equivalence analysis of the damage mode between the quasi-static indentation test and the dynamic drop hammer impact test was also conducted. Under the same conditions, the protective effect of the protective plate on impact damage was better than that of static pressure marks. From the perspective of energy absorption, the ratio coefficient of the two was about 1.2~1.3. Full article

In this study, to optimize the lightweight design of power battery cases for new energy vehicles and meet impact resistance requirements, the mechanical properties of honeycomb sandwich composites were experimentally investigated by varying carbon/glass fiber hybrid ratios. Carbon fiber and glass fiber hybrid laminates were used as the panel, and the aluminum honeycomb was used as the core layer to prepare sandwich composite materials through vacuum-assisted resin infusion (VARI). Then, the flexural and impact properties of honeycomb sandwich composites with different hybrid ratios were tested, respectively. The damage morphology and the damage mechanism of the hybrid composites were analyzed by 3D profile scanning. The results demonstrated that compared to glass fiber-reinforced panels, hybrid panels significantly enhanced the flexural load-bearing capacity of the sandwich composites, exhibiting maximum increases of 26.5% and 34.38% in the L direction and W direction, respectively. Carbon fiber effectively improved the impact resistance of specimens, with the maximum impact load increasing by 53.09% and energy absorption showing measurable enhancement, while glass fiber improves toughness and reduces the severity of damage. This study includes damage analysis and mechanical behavior change analysis of composite materials, which can provide a reference for the application of composite materials in the battery box shell. Full article

Lightweighting is a critical focus in the transportation sector, directly enhancing efficiency and significantly reducing costs. In electric vehicle (EV) design, the body surrounding the battery must effectively absorb impact, especially during crashes. This study aims to improve the crash performance of the side profiles in the battery box of an M1 category vehicle. It is based on the crash test in Annex 8D of the ECE R100 regulation. In this study, the safe displacement at which the battery will not deform is set as 20 mm, and the maximum force and energy absorption at this displacement are compared. In total, 33 different electric and hybrid vehicle models were benchmarked in this study. L-shaped geometry and aluminum materials are generally preferred; this study focuses on using glass-fiber-reinforced polymer (GFRP) pultruded profiles to make batteries more durable and lighter. The GF800 material was selected for its superior mechanical strength among glass fiber composites. A virtual tensile test verified its properties. A unique hybrid model combining honeycomb and auxetic geometries was developed, showing a crash performance improvement of ~360% over honeycomb structures and ~88% over auxetic structures. Through multi-objective optimization using artificial neural networks (ANNs), 27 models were analyzed, leading to an optimized design. The final design resulted in the battery box side profile being 23.9% lighter and 38.6% cheaper, and exhibiting a performance 3% higher. This study demonstrates significant advancements in EV safety and cost efficiency, highlighting the practical benefits of innovative material and design approaches. Full article

This study presents a comprehensive structural performance analysis of a honeycomb-core substrate under normal pressure, highlighting the superior predictive accuracy of Artificial Neural Networks (ANNs) over Response Surface Methodology (RSM). The analysis focused on critical design parameters, such as material selection, coverage rate, and wall thickness, which significantly influence the substrate’s maximum deformation, elastic stress, and mass. The ANN model, trained on these parameters, optimized the design to achieve a cell size of 60 mm, a wall thickness of 12.5753 mm, a coverage rate of 64.38%, and selected aluminum as the material. This optimization resulted in a substrate with a maximum deformation of 7.21 × 10³ mm, an elastic stress of 1.9465 MPa, and a mass of 54.949 kg. The RSM-ANN method surpasses RSM in both optimization and accuracy, enhancing the understanding of how honeycomb design affects substrate properties. Full article

In this work, we focused on the characterization of closed-cell Al foams and aluminum honeycomb panels, in particular their energy absorption capacity under conditions of static compressive stress. Through experimental tests, the specific energy absorbed by different samples was evaluated: in the honeycomb panels the mechanical behavior was analyzed both for large assemblies and for structures with a reduced number of cells, and the effect of the number of cells was studied too. Furthermore, for larger structures, the specific energy absorbed was calculated from stress–strain compressive graphs. For the closed-cell Al foams, manufactured in the laboratory using the powder compaction method with different percentages of SiC and TiH₂ and characterized by different relative densities, the specific energy absorbed was evaluated too. The experimental results showed that the specific energy absorbed by the Al honeycomb was always higher than that of the different types of closed-cell foams. However, when selecting the material for each specific application, it is necessary to take into account numerous parameters such as the relative density, absorbed energy, peak stress, plateau stress, plateau extension, densification strain and so on. Consequently, the overall performance must be evaluated from time to time based on the type of application in which the best compromise between strength, stiffness and lightness can be achieved. Full article

This study investigates the compressive behavior of aluminum honeycombs partially filled with expanded polystyrene (EPS) foam, emphasizing the effects of filler area fractions and vertex contact locations on energy absorption and crush characteristics. Axial quasi-static compression tests evaluated energy absorption, mean crush force, specific energy absorption, and crush force efficiency. Results revealed that partially filled honeycombs significantly enhance energy absorption and mean crush force compared to their unfilled counterparts. However, higher filler area fractions increased mass, reducing specific energy absorption. Circular fillers exhibited lower energy absorption than hexagonal fillers due to their larger contact radius, which reduces stress concentration. The interaction between cell walls and fillers influenced densification strain, with wall–midpoint vertex contacts increasing peak force by reinforcing walls, while corner contacts reduced peak force but improved crush force efficiency. These findings underscore the potential of optimized, partially filled honeycombs for lightweight, energy-absorbing applications, particularly in automotive engineering. Full article

Given the requirement of high-efficiency thermal dissipation for large-aperture space optical remote sensors, a radiator based on single-walled carbon nanotubes (SWCNTs) filled with waterborne polyurethane (SWCNTs/WPU) coatings was proposed in this work. In situ polymerized SWCNTs/WPU coatings allowed for the uniform distribution of acid-purified SWCNTs in WPU matrix. Modified oxygen-containing groups on purified SWCNTs enhanced the interfacial compatibility of SWCNTs/WPU and enabled an improved tensile strength 9 (26.3 MPa) compared to raw-SWCNTs/WPU. A high electrical conductivity of 5.16 W/mK and thermal conductivity of 10.9 S/cm were achieved by adding 49.1 wt.% of SWCNTs. Only 2.85% and 4.2% of declined ratios for electric and thermal conductivities were presented after 1000 bending cycles, demonstrating excellent durability and flexibility. The designed radiator was composed of a heat pipe, SWCNTs/WPU coatings and an aluminum honeycomb core, allowing for −1.6~0.3 °C of temperature difference for the in-orbit temperature and thermal balance experimental temperature of the collector pipe. Moreover, the close temperature difference for the in-orbit and ground temperatures of the radiator indicated that the designed radiator with high heat dissipation met the mechanical environment requirements of a rocket launch. SWCNTs/WPU would be promising electric/thermal interface materials in the application of space optical remote sensors. Full article

The design and multi-objective optimization of auxetic sandwich panels (ASPs) are performed to enhance the blastworthiness of armored fighting vehicles (AFVs). Various metastructures in the form of four auxetic geometries are proposed as the sandwich core: re-entrant honeycomb (REH), double-arrow honeycomb (DAH), star honeycomb (SH), and tetra-chiral honeycomb (CH). This paper employs a combination of finite element and machine learning methodologies to evaluate blastworthiness performance. Optimization is carried out using the nondominated sorting genetic algorithm II (NSGA-II) method. The optimization results show significant improvements in blastworthiness performance, with notable reductions in permanent displacement and enhancements in specific energy absorption (SEA). Global sensitivity analysis using SHapley Additive exPlanations (SHAP) reveals that cell thickness is the most critical factor affecting blastworthiness performance, followed by the number of cells and corner angle or radius for CH. The application of optimized ASP on AFVs shows promising results, with no failure occurring in the occupant floor. Furthermore, AFVs equipped with the optimized ASP DAH significantly reduce maximum displacement and acceleration by 39.00% and 43.56%, respectively, and enhance SEA by 48.30% compared to optimized aluminum foam sandwich panels. This study concludes that ASPs have potential applications in broader engineering fields. Full article

Sandwich panels are widely used in the naval and aerospace industries to withstand the normal tensile, compressive, and shear stresses associated with bending. The faces of sandwich composites are usually made of metals such as aluminum and, in some studies with composites, using a polymeric matrix, but there are no studies in the literature using a castor oil polyurethane matrix. The core of the panel must keep the faces apart and be rigid perpendicular to them. To begin the work, a study was carried out on the influence of alkaline treatment on sisal fibers to increase the fibers’ adhesion to castor oil polyurethane. There are no relevant studies worldwide on the use of this resin and the adhesion of vegetable fibers to this polyurethane. In this work, a study was carried out through a three-point bending test of sandwich panels using faces of composite material with sisal fibers subjected to an alkaline treatment of 10% by weight of sodium hydroxide and an immersion time of 4 h in the dissolution, which was the best chemical treatment obtained initially in a castor oil polyurethane matrix. The honeycomb cores were made by 3D printer and in this study two different printing filament materials, PETG and PLA, and two different core heights were compared. As a result of a traction test, it was observed that sisal fibers with chemical treatment in a castor oil polyurethane matrix can be used in composites, although the stress levels obtained are 50% lower than the stresses obtained in other matrixes such as epoxy resin. The combination of sisal faces in a castor oil polyurethane matrix and honeycomb cores made in a 3D printer showed good properties, which allows the use of renewable, sustainable and less aggressive materials for the environment. In all tests, PETG was 21% to 32% stronger than PLA. Although there was no rupture in the test specimens, the PETG cores deformed 0.5% to 3.6% less than PLA. The composites with PLA were lighter, because the core density was 13.8% lower than the PETG cores. Increasing the height of the honeycomb increased its strength. Full article

The electrochemical performance of in-house developed, spark plasma-sintered, Aluminum metal–matrix composites (MMCs) was evaluated using different electrochemical techniques. X-ray diffraction (XRD) and Raman spectra were used to characterize the nanocomposites along with FE-SEM and EDS for morphological, structural, and elemental analysis, respectively. The highest charge transfer resistance (R_ct), lowest corrosion current density, lowest electrochemical potential noise (EPN), and electrochemical current noise (ECN) were observed for GO-reinforced Al-MMC. The addition of honeycomb-like structure in the Al matrix assisted in blocking the diffusion of Cl⁻ or SO₄⁻². However, poor wettability in between Al matrix and Al₂O₃ reinforcement resulted in the formation of porous interface regions, leading to a degradation in the corrosion resistance of the composite. Post-corrosion surface analysis by optical profilometer indicated that, unlike its counterparts, the lowest surface roughness (Ra) was provided by GO-reinforced MMC. Full article