Sandwich panels using fibre-reinforced composite skins and low-density cores are being increasingly used in the aerospace industry due to their superior specific strength and stiffness, and increased design flexibility over traditional metallic and composite structures. However, it is well-known that sandwich panels are highly vulnerable to the effects of impact damage, with even low-energy impacts potentially causing very severe reductions in the in-plane compressive strength of these structures. The objective of this project was to produce a faithful and reliable numerical model for the simulation of the compression-after-impact strength of composite sandwich panels. An in-depth literature review revealed that delamination within the skins of a sandwich panel is a damage mechanism that has gone almost entirely neglected in previous efforts at modelling this problem, despite the proven significance of this mechanism in the failure of impact damaged sandwich panels in compression. Consequently, the use of the cohesive zone model for delamination initiation and propagation is the key unique feature of this model, with Hashin s criteria being used for intra-laminar damage formation, and a simple plasticity response capturing core crushing. An experimental study is performed to produce a thorough dataset for model validation, featuring differing levels of damage induced via quasi-static indentation, and novel asymmetric panels with skins of unequal thickness (the thinner skin being on the unimpacted side). The experimental study revealed that the use of a thinner distal (undamaged) skin could improve the strength of mildly damaged sandwich panels over undamaged sandwich panels using the same asymmetric configuration. It is believed that this effect is due to the movement of the neutral plane of the sandwich panel caused by the reduction in the stability of the damaged skin through stiffness reduction and geometric imperfections. This removes the eccentricity of the compressive loading that exists in the undamaged asymmetric panels, which has mismatched axial stiffness between the indented skin and the thinner distal skin, and thus a noticeably lower ultimate strength than the undamaged symmetric panels. The sandwich model is developed using pre-existing experimental and material data, and trialled for a variety of different skin lay-ups, core thicknesses and indenter sizes. The numerical model generally agreed well with the ultimate stress found in the experiments for these different configurations, but is quite poor at estimating the magnitude of the damage induced by the indentation. When used to model the experimental study, the model gave generally good, conservative estimates for the residual compressive strength of both the symmetric and asymmetric panels. The tendency of the asymmetric panels to become stronger with mild damage was not captured by the model per se, with the numerical results instead showing an insensitivity to damage in the asymmetric panels, which was not shared by the symmetric panels. However, the numerical model did exhibit erroneous strain-stress responses for both panel configurations, particularly for the undamaged and mildly damaged cases. Investigations revealed that this erroneous behaviour was caused by inconsistency in the material data, which had been collected partially via experimentation and partly from literature sources. Overall, the model developed here represents a promising advancement over previous efforts, but further development is required to provide accurate damage states.

This thesis will present the experimental and numerical analysis of composite sandwich structures under monotonic and fatigue loading. The sandwich skins were made of fiberglass and the core used was a closed cell PVC foam. Initial delaminations were introduced into the sandwich structures during manufacturing to see the effect of delamination size on the ultimate strength and monotonic fracture. Fiberglass rods, called shear keys, added to the foam core to determine whether or not they increased the strength of the test specimens. Furthermore, shear key locations were also varied and their effects noted. The fixed rate static behavior for all of the above cases listed were determined. The fatigue life and behavior were determined for sandwich structures with no initial delamination, 0.5 inch initial delamination, and 0.5 inch initial delamination with a shear key 0 inch from the delamination depth. The fatigue specimens were tested at various percentages of the ultimate monotonic failure loads to determine the fatigue life. A static numerical analysis was performed using Abaqus/CAE 6.7.1 to observe at the monotonic behavior of the test specimens with no initial delamination and with 0.5 inch initial delamination. The sandwich structures with an initial delamination and/or a shear key in the foam core experienced over a 70% reduction in the ultimate monotonic failure load. The two delamination lengths had no significant effect on the ultimate monotonic failure load, but the presence of an initial delamination corresponded to a material response dominated by plastic behavior. The experimental testing also showed that the location of the shear key in the sandwich structure had little effect on the monotonic strength, but moving the shear keys further away from the back edge of the delamination caused a reduction in strength. The monotonic testing determined that composite sandwich structures containing shear keys had approximately a 7% reduction in the monotonic failure load of test specimens with an initial delamination. Numerical analysis results matched the ultimate failure loads within 5% for the test specimens with a 0.5 inch an initial delamination and within 15% for the test specimens with no initial delamination. The fatigue testing showed that sandwich structures containing shear keys had life reduction of approximately 33%. Preliminary experiments involved with rotating the shear keys 90° showed increased ultimate monotonic failure loads of the composite sandwich structures by as much as 30%. Future funding and research would be necessary to verify the increased structural performance of the newly oriented shear keys.

No description available.

No description available.

The use of composite sandwich structures is rapidly increasing in the aerospace industry because of their increased strength-to-weight and stiffness-to-weight characteristics. The effects of low velocity impacts on these structures, however, are the main weakness that hinders further use of them in the industry because the damages from these loadings can often be catastrophic. Impact behavior of composite materials in general is a crucial consideration for a designer but can be difficult to describe theoretically. Because of this, experimental analysis is typically used to attempt to describe the behavior of composite sandwiches under impact loads. Experimental testing can still be unpredictable, however, because low velocity impacts can cause undetectable damage within the composites that weaken their structural integrity. This is an important issue with composite sandwich structures because interlaminar damage within the composite facesheets is typical with composites but the addition of a core material results in added failure modes. Because the core is typically a weaker material than the surrounding facesheet material, the core is easily damaged by the impact loads. The adhesion between the composite facesheets and the core material can also be a major region of concern for sandwich structures. Delamination of the facesheet from the core is a major issue when these structures are subjected to impact loads. This study investigated, through experimental and numerical analysis, how varying the core and facesheet material combination affected the flexural strength of a composite sandwich subjected to low velocity impact. Carbon, hemp, aramid, and glass fiber materials as facesheets combined with honeycomb and foam as core materials were considered. Three layers of the same composite material were laid on the top and bottom of the core material to form each sandwich structure. This resulted in eight different sandwich designs. The carbon fiber/honeycomb sandwiches were then combined with the aramid fiber facesheets, keeping the same three layer facesheet design, to form two hybrid sandwich designs. This was done to attempt to improve the impact resistance and post-impact strength characteristics of the carbon fiber sandwiches. The two and one layer aramid fiber laminates on these hybrid sandwiches were always laid up on the outside of the structure. The sandwiches were cured using a composite press set to the recommended curing cycle for the composite facesheet material. The hybrid sandwiches were cured twice for the two different facesheet materials. The cured specimens were then cut into 3 inch by 10 inch sandwiches and 2/3 of them were subjected to an impact from a 7.56 lbf crosshead which was dropped from a height of 38.15 inches above the bottom of the specimen using a Dynatup 8250 drop weight machine. The impacted specimen and the control specimen (1/3 of the specimens not subjected to an impact) were loaded in a four-point bend test per ASTM D7250 to determine the non-impacted and post-impact flexural strengths of these structures. Each sandwich was tested under two four-point bend loading conditions which resulted in two different extension values at the same 100 lbf loading value. The span between the two supports on the bottom of the sandwich was always 8 inches but the span between the two loading pins on the top of the sandwich changed between the two loading conditions. The 2/3 of the sandwiches that were tested after being impacted were subjected to bending loads in two different ways. Half of the specimens were subjected to four-point bending loads with the impact damage on the top facesheet (compressive surface) in between the loading pins; the other half were subjected to bending loads with the damage on the bottom facesheet (tensile surface). Theoretical failure mode analysis was done for each sandwich to understand the comparisons between predicted and experimental failures. A numerical investigation was, also, completed using Abaqus to verify the results of the experimental tests. Non-impacted and impacted four-point bending models were constructed and mid-span deflection values were collected for comparison with the experimental testing results. Experimental and numerical results showed that carbon fiber sandwiches were the best sandwich design for overall composite sandwich bending strength; however, post-impact strengths could greatly improve. The hybrid sandwich designs improved post-impact behavior but more than three facesheet layers are necessary for significant improvement. Hemp facesheet sandwiches showed the best post-impact bending characteristics of any sandwich despite having the largest impact damage sizes. Glass and aramid fiber facesheet sandwiches resisted impact the best but this resulted in premature delamination failures that limited the potential of these structures. Honeycomb core materials outperformed foam in terms of ultimate bending loads but post-impact strengths were better for foam cores. Decent agreement between numerical and experimental results was found but poor material quality and high error in material properties testing results brought about larger disagreements for some sandwich designs.

No description available.

No description available.

O presente trabalho objetivou desenvolver e implementar, em escala laboratorial, uma rotina experimental com base em Imageamento por Ressonância Magnética Nuclear (IRMN) de modo a verificar seu potencial como metodologia não-destrutiva aplicável à inspeção quali- e quantitativa de água e hidrocarbonetos líquidos aprisionados no interior de células de núcleos-colméia utilizados na confecção de painéis-sanduíche compósitos estruturais de grau aeronáutico. Tentativas foram também realizadas no sentido de se observarem e caracterizarem danos por amassamento de núcleos-colméia, assim como de se detectar a presença de resina polimérica na forma sólida, visando, desta feita, verificar o uso do IRMN na inspeção de componentes previamente reparados e/ou contendo excesso de resina por falha do processo de manufatura. Concluiu-se que IRMN é uma poderosa ferramenta para a detecção e a quantificação de líquidos puros e compostos, ricos em hidrogênio, contidos nas células de núcleos de amostras extraídas de painéis-sanduíche compósitos. O potencial do IRMN na identificação, e, portanto, na discriminação entre os diversos fluidos se mostrou bastante promissor, desde que se empreguem ferramentas de processamento e análise computadorizada de imagens a partir de programas computacionais de reconhecimento de padrões via redes neurais artificiais e/ou sistemas com base em conhecimento. A técnica de IRMN utilizada neste estudo não permitiu a captura de imagens de resina polimérica sólida, nem mesmo quando à esta foram adicionadas cargas de elementos intensificadores de sinais de RMN, tais como ferro e gadolíneo. Danos no núcleo-colméia tão pequenos quanto 1,0 mm de profundidade e 1,8 mm de diâmetro foram clara e inequivocamente imageados e delineados pela técnica IRMN, desde que estivessem permeados por fluido hidrogenado (ex. água). A quantificação de líquidos nos núcleos-colméia por intermédio de ferramentas computacionais simples (processadores e analisadores de imagens) foi muito bem sucedida no caso dos líquidos com relativamente alto ponto de fulgor, pois as massas fluidas se mantiveram constantes por períodos de tempo significativamente longos no interior das células analisadas. / This work intended to develop and implement in laboratorial scale an experimental routine funded in Nuclear Magnetic Resonance Imaging (NMRI) in order to verify its potential as a non-destructive methodology for quali- and quantitative inspection of liquid water and hydrocarbons entrapped in honeycomb core cells utilized to build up aeronautical grade structural composite sandwich panels. Attempts were also carried out to observe and characterize crush damage of honeycomb core, as well as to detect solid polymer resin towards the use of NMRI to assess previously repaired components and/or containing in excess resin amount due to manufacturing process faults. It has been concluded that NMRI is a powerful tool in detecting and quantifying hydrogen-rich pure and compound liquids contained in core cells of composite sandwich samples. The NMRI potential in identifying and, therefore, discriminating several fluids has shown very promising as long as computed image processing and analysis tools are employed from pattern recognition software via artificial neural networks and/or knowledge-based systems. The utilized NMRI technique failed in imaging solid polymer resin, even when the latter was loaded with NMR-signal intensifier elements such as iron and gadolinium. Honeycomb core damages as small as 1.0 mm in depth and 1.8 mm in diameter were clearly and unambiguously imaged and delineated by the NMRI technique since they were permeated with hydrogenated fluid (ex., water). The quantification of liquids in honeycomb cores by means of simple computational tools (image processor and analyzer) was very successful in case of relatively high flash point fluids, insofar as their masses remained constant within the analyzed cells for significantly long periods of time.

A lightweight carbon fiber reinforced polymer (CFRP) sandwich panel has been developed for floor use in commercial office building construction. CFRP laminate skins were combined with low-density rigid polyurethane foam to create a composite sandwich panel suitable for floor use. The CFRP sandwich panel was optimized to withstand code prescribed office-building live loads using a 3D finite element computer program called SolidWorks. The thickness of the polyurethane foam was optimized to meet both strength and serviceability requirements for gravity loading. Deflection ultimately was the controlling factor in the design, as the stresses in the composite materials remained relatively low. The CFRP sandwich panel was then subjected to combined gravity and lateral loading, which included seismic loads from a fictitious 5-story office building located in a region of high seismic risk. The results showed that CFRP sandwich panels are a viable option for use with floors, possessing sufficient strength and stiffness for meeting code prescribed design loads, while providing significant benefits over traditional construction materials.

O presente trabalho objetivou desenvolver e implementar, em escala laboratorial, uma rotina experimental com base em Imageamento por Ressonância Magnética Nuclear (IRMN) de modo a verificar seu potencial como metodologia não-destrutiva aplicável à inspeção quali- e quantitativa de água e hidrocarbonetos líquidos aprisionados no interior de células de núcleos-colméia utilizados na confecção de painéis-sanduíche compósitos estruturais de grau aeronáutico. Tentativas foram também realizadas no sentido de se observarem e caracterizarem danos por amassamento de núcleos-colméia, assim como de se detectar a presença de resina polimérica na forma sólida, visando, desta feita, verificar o uso do IRMN na inspeção de componentes previamente reparados e/ou contendo excesso de resina por falha do processo de manufatura. Concluiu-se que IRMN é uma poderosa ferramenta para a detecção e a quantificação de líquidos puros e compostos, ricos em hidrogênio, contidos nas células de núcleos de amostras extraídas de painéis-sanduíche compósitos. O potencial do IRMN na identificação, e, portanto, na discriminação entre os diversos fluidos se mostrou bastante promissor, desde que se empreguem ferramentas de processamento e análise computadorizada de imagens a partir de programas computacionais de reconhecimento de padrões via redes neurais artificiais e/ou sistemas com base em conhecimento. A técnica de IRMN utilizada neste estudo não permitiu a captura de imagens de resina polimérica sólida, nem mesmo quando à esta foram adicionadas cargas de elementos intensificadores de sinais de RMN, tais como ferro e gadolíneo. Danos no núcleo-colméia tão pequenos quanto 1,0 mm de profundidade e 1,8 mm de diâmetro foram clara e inequivocamente imageados e delineados pela técnica IRMN, desde que estivessem permeados por fluido hidrogenado (ex. água). A quantificação de líquidos nos núcleos-colméia por intermédio de ferramentas computacionais simples (processadores e analisadores de imagens) foi muito bem sucedida no caso dos líquidos com relativamente alto ponto de fulgor, pois as massas fluidas se mantiveram constantes por períodos de tempo significativamente longos no interior das células analisadas. / This work intended to develop and implement in laboratorial scale an experimental routine funded in Nuclear Magnetic Resonance Imaging (NMRI) in order to verify its potential as a non-destructive methodology for quali- and quantitative inspection of liquid water and hydrocarbons entrapped in honeycomb core cells utilized to build up aeronautical grade structural composite sandwich panels. Attempts were also carried out to observe and characterize crush damage of honeycomb core, as well as to detect solid polymer resin towards the use of NMRI to assess previously repaired components and/or containing in excess resin amount due to manufacturing process faults. It has been concluded that NMRI is a powerful tool in detecting and quantifying hydrogen-rich pure and compound liquids contained in core cells of composite sandwich samples. The NMRI potential in identifying and, therefore, discriminating several fluids has shown very promising as long as computed image processing and analysis tools are employed from pattern recognition software via artificial neural networks and/or knowledge-based systems. The utilized NMRI technique failed in imaging solid polymer resin, even when the latter was loaded with NMR-signal intensifier elements such as iron and gadolinium. Honeycomb core damages as small as 1.0 mm in depth and 1.8 mm in diameter were clearly and unambiguously imaged and delineated by the NMRI technique since they were permeated with hydrogenated fluid (ex., water). The quantification of liquids in honeycomb cores by means of simple computational tools (image processor and analyzer) was very successful in case of relatively high flash point fluids, insofar as their masses remained constant within the analyzed cells for significantly long periods of time.