Search Results (281)

Sustainability and the circular economy are increasingly recognized as global priorities, particularly in industrial waste management. This study explores the development of a sustainable composite material using wood waste and natural fibers, contributing to circular economy practices. Sandwich panels were manufactured with a green epoxy resin matrix, incorporating wood waste in the core and flax fibers in the outer layers. Mechanical tests on the sandwich panel revealed a facing bending stress of 92.79 MPa and a core shear stress of 2.43 MPa. The panel demonstrated good compressive performance, with an edgewise compressive strength of 61.39 MPa and a flatwise compressive strength of 96.66 MPa. The material’s viscoelastic behavior was also characterized. In stress relaxation tests (from an initial 21 MPa), the panel’s stress decreased by 20.2% after three hours. The experimental relaxation data were successfully fitted by the Kohlrausch–Williams–Watts (KWW) model for both short- and long-term predictions. In creep tests, the panel showed a 21.30% increase in displacement after three hours under a 21 MPa load. For creep behavior, the KWW model was preferable for short-term predictions, while the Findley model provided a better fit for long-term predictions. 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

Composite sandwich structures play a significant role in various engineering applications due to their excellent strength-to-weight ratio, durability, fatigue life, acoustic performance, damping characteristics, stealth performance, and energy absorption capabilities. The optimization of these structures results in enhancing their mechanical performance, weight reduction, cost-effectiveness, and sustainability. This review provides a comprehensive analysis of recent advancements in the optimization techniques applied in the case of composite sandwich structures, focusing on structural configuration, facesheets, and innovative cores design, loading conditions, analysis methodologies, and practical applications. Various optimization procedures, single- and multi-objective algorithms, Genetic Algorithms (GAs), Particle Swarm Optimization (PSO), and Machine Learning (ML)-based optimization frameworks, as well as Finite Element (FE)-based numerical simulations, are discussed in detail. It highlights the role of core material and geometry, face sheet material selection, and manufacturing limitations in achieving optimal performance under static, dynamic, thermal, and impact loads under various boundary conditions. Furthermore, challenges such as computational efficiency, experimental validation, and trade-offs between structural weight and performance are examined. The findings of this review offer insights into the recent and future research directions of optimizing sandwich constructions, emphasizing the integration of advanced numerical techniques for analysis and efficient structural optimization. Full article

Lightweight, layered wood-based panels are gaining attention due to favorable mechanical and physical properties. This study examined numerical modeling as a method to predict the strength of innovative three-layer sandwich panels with thermoplastic cores containing wood particles as the filler. Two core geometries (F and S) and two material formulations (60% HDPE + 40% sawdust, and 40% HDPE + 60% sawdust) were tested. The panels were produced without additional adhesives; bonding with high-density fiberboard (HDF) facings was achieved through the thermoplastic properties of the core. Mechanical properties such as bending strength (MOR), modulus of elasticity (MOE), and compressive strength perpendicular to the surface were measured. Results showed that both core geometry and material composition significantly influenced structural performance. Panels with the F profile showed better bending strength and stiffness (MOR—13.2 N/mm², MOE—2017 N/mm²), while the S profile had higher compressive strength (0.62 N/mm²). Numerical simulations using SolidWorks Simulation confirmed the experimental data, with stress and displacement distributions matching laboratory results. These findings demonstrate the potential of thermoplastically formed cores for creating lightweight, recyclable wood-based composites with tailored mechanical properties. 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

This paper presents an experimental investigation of six different types of composite sandwich panels manufactured from waste-based materials, which are comprised of two different types of skins (made from hemp and recycled PET (Polyethylene terephthalate) fabrics with bio-epoxy resin) and three different cores (composite wood, recycled plastic, and styrofoam) materials. The skins of these sandwich panels were investigated under five different environmental conditions (normal air, water, hygrothermal, saline solution, and 80 °C elevated temperature) over seven months to evaluate their durability performance. In addition, the tensile and dynamic mechanical properties of those sandwich panels were studied. The bending behavior of cores and sandwich panels was also investigated and compared. The results indicated that elevated temperatures are 30% more detrimental to fiber composite laminates than normal water. Composite laminates made of hemp are more sensitive to environmental conditions than composite laminates made of recycled PET. A higher-density core makes panels more rigid and less susceptible to indentation failure. The flexible plastic cores are found to be up to 25% more effective at increasing the strength of sandwich panels than brittle wood cores. Full article

Bamboo is a green, renewable material with high strength and low cost, but raw bamboo has limited application in residential buildings due to its irregular shape and dry cracking. In this regard, this work proposed a novel ecological sandwich panel to explore the potential combination of engineered bamboo and raw bamboo culms. Face sheets made of glued laminated bamboo panels were bonded to the bamboo culm core via epoxy resin and mortise–tenon joints. Two groups of specimens with height-to-thickness ratios of 4.63 and 5.37 were tested through edgewise compression to investigate the failure modes, strength and rigidity. The results revealed that the specimens had no overall stability problem under axial loading, but exhibited delamination and local bulging to the face sheets. When the height-to-thickness ratio increased from 4.63 to 5.37, but still belonged to the short member range, the area of the adhesive interface increased by 16.13%, and the edgewise compressive strength and rigidity increased by 17.57% and 35.04%, respectively. This indicated that the capacity and rigidity were mainly determined by the connection strength, which was obviously affected by the manufacturing and assembly errors. Accordingly, increasing the connection strength could be helpful for improving the load-carrying capacity and ductility of such panels. Full article

The development of sustainable and energy-efficient construction materials is crucial for mitigating the growing environmental impact of the building sector. This study introduces a new lightweight sandwich panel, featuring a core made of lightweight concrete with rice husk bio-aggregate (RHB) and faces constructed from foamed cementitious composites. The innovative design aims to promote sustainability by utilizing agro-industrial waste while maintaining satisfactory mechanical performance. Composites were produced with 4% short sisal fibers and matrices containing 15%, 20%, and 30% foaming agent. These composites were evaluated for density, direct compression, and four-point bending. It was found that the mixture with 20% foam volume demonstrated the highest efficiency for use in the production of sandwich panels. Concrete mixtures containing 50%, 60%, and 70% rice husk bio-aggregates were tested for density and compressive strength and used in the production of lightweight sandwich panels with densities ranging from 670 to 1000 kg/m³. Mechanical evaluation under flexion and shear indicated that the presence of fibers inhibited crack propagation in the face, enabling the creation of lightweight sandwich panels with deflection-hardening behavior. On the other hand, the increase in RHB content led to a reduction in the ultimate stress on the face, the core shear ultimate stress, and the toughness of the sandwich panels. Full article

The dynamic response and failure of rubber-coated sandwich composite structures with buoyancy material core (RC-BMC-SCS) subjected to high-energy low-velocity impacts were experimentally and numerically investigated. Six types of BMC-SCSs were designed and manufactured, and high-energy low-velocity impact experiments were performed. Based on the Mohr-Coulomb theory and the Ogden hyperelasticity constitutive model, a low-velocity impact finite element analysis model was developed. The results indicate that BMC-SCS damage stages could be divided into: (1) matrix damage, (2) core cracks, (3) debonding and fiber breakage. Three distinct damage stages of the RC-BMC-SCS were revealed: (1) rubber layer energy absorption, (2) core cracks, (3) debonding. The rubber layer can enhance the damage threshold by approximately 100% compared to BMC-SCS. However, rubber energy absorption capacity has an upper limit. Additionally, the larger the curvature of the BMC-SCS, the higher the initial stiffness of the structure and the larger the impact damage area. The results of this study provide valuable insights for the multifunctional design of composite deep-sea marine structures. Full article

3D-Kagome lattice sandwich panels are mainly composed of upper and lower panels and a series of symmetrically and periodically arranged lattices, known for their excellent high specific stiffness, high specific strength, and energy absorption capacity. The inherent geometrical symmetry of the 3D-Kagome lattice plays a crucial role in achieving superior mechanical stability and load distribution efficiency. This structural symmetry enhances the uniformity of stress distribution, making it highly suitable for automotive vibration suppression, such as battery protection for electric vehicles. In this study, a polyurethane foam-filled, symmetry-enhanced 3D-Kagome sandwich panel is designed following an optimization of the lattice structure. A novel fabrication method combining precision wire-cutting, interlocking core assembly, and in situ foam filling is employed to ensure a high degree of integration and manufacturability of the composite structure. Its mechanical properties and energy absorption characteristics are systematically evaluated through a series of experimental tests, including quasi-static compression, three-point bending, and low-speed impact. The study analyzes the effects of core height on the structural stiffness, strength, and energy absorption capacity under varying loads, elucidating the failure mechanisms inherent to the symmetrical lattice sandwich configurations. The results show that the foam-filled sandwich panels exhibit significant improvements in mechanical performance compared to the unfilled ones. Specifically, the panels with core heights of 15 mm, 20 mm, and 25 mm demonstrate increases in bending stiffness of 47.3%, 53.5%, and 51.3%, respectively, along with corresponding increases in bending strength of 45.5%, 53.1%, and 50.9%. The experimental findings provide a fundamental understanding of foam-filled lattice sandwich structures, offering insights into their structural optimization for lightweight energy-absorbing applications. This study establishes a foundation for the development of advanced crash-resistant materials for automotive, aerospace, and protective engineering applications. This work highlights the structural advantages and crashworthiness potential of foam-filled Kagome sandwich panels, providing a promising foundation for their application in electric vehicle battery enclosures, aerospace impact shields, and advanced protective systems. Full article

The growing demand for sustainable composites has increased interest in natural fiber reinforcements as alternatives to synthetic materials. This study evaluates the bending properties of sandwich structures with flax fibers and 3D-printed lightweight foaming PLA cores compared to conventional designs using glass fibers and traditional cores. Three-point bending tests (EN 310) and density profile analysis showed that, despite its lower density, the 3D-printed foaming PLA core achieved a modulus of elasticity of 2269.19 MPa and a bending strength of 31.46 MPa, demonstrating its potential for lightweight applications. However, natural fibers influenced resin absorption, affecting core saturation compared to glass fibers. The use of bio-based epoxy and foaming PLA contributes to a lower environmental footprint, while 3D printing enables precise material optimization. These findings confirm that 3D-printed cores offer a competitive and sustainable alternative, with future research focusing on further optimization of internal structure to enhance mechanical performance. Full article

The use of innovative insulating materials can contribute to an energy-efficient design by improving the thermal performance of building envelopes while also reducing the embodied energy of materials. Ultra-low carbon steel envelope solutions with bio-based insulations are aligned with this approach. However, fire safety aspects in general and smoldering issues in particular need to be considered when using bio-based insulations. Accordingly, this paper proposes a system-level assessment of the fire performance of steel envelopes with bio-based insulations, not only identifying potential smoldering issues of the core material but also defining and evaluating strategies that could address these concerns within the system design. For this purpose, the variables that could affect the fire performance of wood fiber insulation sandwich panels were identified while considering the different stages of the smoldering phenomena, such as the influence of the joint design or mounting provisions for the initiation, the existence of air cavities, oxygen entrances or physically continuous materials with a tendency to smolder for the continuation, or the inclusion of limiting elements or mitigation layers for spread limitation. Finally, strategies for fire-safe enclosures using bio-based insulations are proposed, assuming smoldering affections in wood-derived materials and analyzing possible mitigation elements at the system level. Full article

Thermal insulation layers between batteries are an effective way to reduce the propagation of thermal runaway in lithium-ion batteries. A flexible composite sandwich structure material has been designed for thermal insulation, featuring mica rolls (MRs) as the protective layers and a ceramic fiber felt (CFF) as the core layer. Experimental and numerical simulations demonstrate that at a hot-surface temperature of 900 °C, the cold-surface temperature of the sandwich structure with a 0.3 mm MR and 3.0 mm CFF layer is only 175 °C, which is significantly lower than the 350 °C observed for a standalone 3.0 mm CFF layer under the same conditions. The MR layer effectively shields against flames and impedes heat transfer, while the porous structure of the CFF, enhanced by microcracks and holes, increases heat transfer paths and scatters radiated heat. This synergistic interaction between the MR and CFF layers results in a superior thermal insulation performance. The findings highlight the potential of this sandwich structure in improving the safety and thermal management of lithium-ion batteries and other energy storage systems. Full article

Urbanization and population growth have heightened the need for sustainable, efficient building materials that combine acoustic and thermal insulation with environmental and economic sustainability. Sandwich composite panels have gained attention as versatile solutions, offering lightweight structures, high strength, and adaptability in construction applications. This study evaluates manual, semi-automatic, and automatic production methods, selecting the automatic process for its efficiency, precision, and suitability for large-scale production. Extensive characterization techniques, including field emission scanning electron microscopy (FE-SEM), thermogravimetric analysis (TGA), Differential Thermogravimetry (DTG), Differential Scanning Calorimetry (DSC), and flammability tests, were employed to evaluate the morphological, thermal, acoustic, and fire-resistant properties of the panels. The P200 sample, produced automatically, demonstrated high acoustic absorption in the mid–high frequencies (2000–4000 Hz), strong interlayer adhesion, and low thermal conductivity (2.75 W/mK), making it effective for insulation applications. The flammability tests confirmed compliance with EPA 1030 standards, with a low flame propagation rate (1.55 mm/s). The TGA-DTG and DSC analyses revealed the thermal stability of the panel’s components, with distinct degradation stages being observed for the polyurethane core and non-woven textile layers. The FE-SEM analysis revealed a compact and homogeneous structure with strong adhesion between the core and textile layers. These results highlight the potential of sandwich composites as eco-friendly, high-performance materials for modern construction. Full article

Triply periodic minimal surface (TPMS) sandwich structures were proposed based on the TPMSs. The test samples for the TPMS sandwich were prepared using Multi Jet Fusion (MJF) with PA12 as the base material. Their low-velocity impact responses were investigated using experimental tests and numerical simulation. The effect of structural parameters (relative density, panel thickness, impact energy, and TPMS core) on the impact performance of the sandwich structures was analyzed through parameter studies. The results indicate that the peak load and stiffness of the sandwich structure increase with the increase in relative density, panel thickness, and impact energy. Among three types of TPMS core sandwich structures, the Diamond sandwich structure exhibits the biggest peak load and best impact resistance. Full article