Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
Biographies
Introduction
Chapter 1 Sandwich Structural Core Materials and Properties
1.1 Rigid Structural Plastic Foams
1.1.1 Requirements of Foam Core Materials
1.1.2 Polyvinyl Chloride (PVC) Foam
1.1.3 Polyethylene Terephthalate (PET) Foam
1.1.4 Polyurethane (PUR) Foam
1.1.5 Poly (Styrene-co-Acrylonitrile) (SAN) Foam
1.1.6 Polymethacrylimide (PMI) Foam
1.1.7 Polyetherimide (PEI) and Polyethersulfone (PES) Foam
1.1.8 Syntactic Foam Core
1.2 Wood-Based Core Materials
1.2.1 Balsa Wood-Based Core Material
1.2.1.1 Balsa Tree
1.2.1.2 Milling, Kiln Dry, and Make Block
1.2.1.3 Microstructure
1.2.1.4 Mechanical Properties of Balsa Lumber
1.2.1.5 Mechanical Properties of Lumber-Based End-Grain Core
1.2.1.6 Homologation and Density Variation
1.2.1.7 Humidity, Moisture, and Its Effect on Mechanical Properties
1.2.1.8 Miscellaneous Properties
1.2.1.9 Product and Format
1.2.1.10 Applications
1.2.2 Cork-Based Sandwich Core
1.2.2.1 Plantation and Harvest
1.2.2.2 Mechanical Properties
1.2.2.2 Other Properties and Applications
1.3 Honeycomb Cores
1.3.1 Thermoplastics Honeycombs
1.3.2 Metal Honeycombs
1.3.3 Honeycombs Made from Composite Materials
1.3.4 Paperboard Honeycombs
1.4 Special Foam Cores
1.4.1 Metallic Foams
1.4.2 Ceramic Foams
1.4.3 Carbon Foams
1.5 Other Core Materials
1.5.1 Corrugated and Lattice Truss Cores
1.5.1.1 Corrugated Core
1.5.1.2 Lattice Truss Core
1.5.2 3D Fabric Woven Cores
1.5.3 Core Mats
1.6 Sheet Formats of Core Materials
References
Chapter 2 Special Properties and Characterization Methods of Core Materials
2.1 Specialties of Sandwich Core Materials
2.2 Flatwise Compressive Properties
2.3 Flatwise Tensile Properties
2.4 Plate Shear Properties
2.5 Other Important Properties
References
Chapter 3 Face Sheet Materials for Sandwich Composites
3.1 Metal, Plastics, and Plywood Face Sheet Materials
3.1.1 Metallic Face Sheet Materials
3.1.1.1 Steel
3.1.1.2 Aluminum
3.1.1.3 Magnesium
3.1.1.4 Titanium
3.1.1.5 Miscellaneous Alloys
3.1.2 Plastics
3.1.2.1 Thermoplastics
3.1.2.2 Commodity Plastics (PE, PP, PET, and PVC)
3.1.2.3 Engineered Thermoplastics (PA6, PEI, PPS, etc.)
3.1.2.4 High-Performance Thermoplastics (PAEK, PEEK, and PI)
3.1.3 Wood
3.2 Reinforcement Fiber Materials for Composite Face Sheets
3.2.1 Glass and Basalt Fibers
3.2.1.1 E-Glass and ECR-Glass
3.2.1.2 H-Glass and R-Glass
3.2.1.3 Basalt
3.2.1.4 S-Glass
3.2.1.5 Quartz (Silica)
3.2.1.6 A-Glass, C-Glass, and AR-Glass
3.2.2 Carbon Fibers
3.2.2.1 PAN-Based Carbon
3.2.2.2 Pitch-Based Carbon
3.2.3 Natural Fibers
3.2.3.1 Bast
3.2.3.2 Leaf
3.2.4 Synthetic Fibers
3.2.4.1 Para-Aramid
3.2.4.2 High-Modulus Polypropylene
3.2.4.3 UHMWPE, PBO, and LCP
3.2.5 Boron and Ceramic Fibers
3.2.5.1 Boron
3.2.5.2 SiC and Alumina
3.2.6 Architectural Forms of Reinforcement Materials
3.3 Plastic Matrix Materials for Composite Face Sheets
3.3.1 Unsaturated Polyester and Vinyl Ester Resin
3.3.1.1 Unsaturated Polyester (UPR)
3.3.1.2 Vinyl Esters
3.3.2 Epoxy Resin
3.3.3 Phenolic Resin
3.3.4 Polyurethane Resin
3.3.5 High-Temperature Application Resins
3.3.6 Thermoplastic Matrix
3.4 Composite Face Sheet Material Properties and Characterization
3.4.1 Unidirectional Laminae
3.4.2 Biaxial Laminates
3.4.3 Quasi-Isotropic Laminates
3.4.4 Test Methods for Laminated Composite Face Sheets
3.4.4.1 Tensile Strength and Modulus
3.4.4.2 Compressive Strength and Modulus
3.4.4.3 In-Plane Shear Strength and Modulus
3.4.4.4 Flexural Strength and Modulus in Sandwich
3.4.4.5 Interlaminar Shear Strength
3.4.4.6 Damage Tolerance and Impact Properties
References
Chapter 4 Laminating Processes of Thermoset Sandwich Composites
4.1 Dry Laminating Process
4.1.1 Facing Materials
4.1.2 Adhesives
4.1.3 Laminating Processes
4.2 Wet Laminating Process
4.2.1 Hand Layup Process
4.2.2 Spray Layup Lamination
4.2.3 Prepreg Lamination, Press or Autoclave Curing
4.2.4 Closed Mold Lamination
4.2.4.1 Vacuum Infusion
4.2.4.2 Resin Transfer Molding (RTM)
4.2.5 Pultrusion
4.2.6 3D Printing and Additive Manufacturing
References
Chapter 5 All-Thermoplastic Sandwich Composites
5.1 Concept and Specialties
5.2 Thermoplastic Core Materials
5.3 Thermoplastic Face Materials
5.4 Sandwich Structure Process Methods
5.4.1 Compression Molding
5.4.2 Continuous Laminating β Double Belt and Pultrusion
5.4.3 In-situ Core Foaming
5.4.4 Diaphragm Forming
5.4.5 Manufacturing of 3D Thermoplastic Sandwiches by One-Step Forming
5.5 Postprocessing and Recycling
References
Chapter 6 Characterizations of Sandwich Structures
6.1 Face to Core Bonding Strength Tests
6.1.1 Drum Peel Test
6.1.2 Flatwise Tensile Test
6.1.3 Other Tests for Evaluating Strength of Skin and Core Bonding
6.2 Flexural Strength and Bending Stiffness Evaluations
6.2.1 Core Shear Properties of Sandwich Constructions by Beam Flexure Test
6.2.2 Facing Properties of Sandwich Constructions by Long-Beam Flexural Test
6.2.3 Test for Determining Sandwich Beam Flexural and Shear Stiffness
6.3 Flatwise and Edgewise Compressive Test
6.3.1 Flatwise Compressive Test
6.3.2 Edgewise Compressive Strength
6.4 Concentrated Load and Wave Impact Tests
6.4.1 Concentrated Load Impact Tests
6.4.2 Wave Impact Tests
6.4.3 Air and Water Blast Tests by Shock Tubes
6.4.4 Air and Water Blast Tests by Full-Scale Explosion
6.5 Dynamic Fatigue Evaluation
6.5.1 Flexural Fatigue Tests
6.5.2 Other Fatigue Tests
6.5.2.1 Flatwise Compressive Fatigue Test
6.5.2.2 Edgewise Compression β Compression Fatigue Test
6.5.2.3 Two-Dimensional Simply Supported Distributed Load Flexural Static and Fatigue Test
6.6 Fracture Toughness Test
6.7 Thermal Mechanical Tests
6.8 Nondestructive Tests
6.8.1 Visual Inspection
6.8.2 Tap Tests
6.8.3 Pitch-Catch Swept Method
6.8.4 Ultrasonic Tests
6.8.5 Shearography Test
6.8.6 Infrared Thermography Method
6.8.7 Industrial-Scale Inspection
References
Chapter 7 Sandwich Structure Design and Mechanical Property Analysis
7.1 Structure and Load Distribution of Sandwich Composites
7.1.1 Rigidity, Stress, and Deflection of a Sandwich Beam Subjected to Bending Moment
7.1.1.1 Flexural Rigidity and Shear Rigidity
7.1.1.2 Face Tensile/Compressive Stress
7.1.1.3 Core Shear Stress
7.1.1.4 Deflection of Sandwich Beam Subjected to Bending Moment and Shear Force Caused by Bending
7.1.2 Stress, Strain, and Rigidity in a Sandwich Beam Subjected to Tension or Compression
7.2 Strength and Deflection of Simple Sandwich Elements at Different Supports and Loads
7.3 Edgewise Damage Prediction and Prevention
7.3.1 General Buckling
7.3.2 Local Buckling in the Sandwich
7.4 Design Principles of a Simple Sandwich Element
7.4.1 Design for Strength of Facings and Core
7.4.2 Design for Rigidity
7.4.3 Design for Minimum Weight
7.4.3.1 Minimum Weight for Given Stiffness
7.4.3.2 Minimum Weight for Given Strength
7.4.4 Other Design Considerations
7.5 Design Procedure from Simple Element to Large Complex Structure
7.5.1 Determine Thicknesses of Simple Sandwich Element
7.5.2 Design Routine of Simple Sandwich Element
7.5.3 Scaling Up to Large Complex Structure
7.5.3.1 Multilevel Scaling
7.5.3.2 Similarity Theory Scaling
7.6 Effects of Core Formats, Process Methods, and Application Conditions on Design Parameters
7.6.1 Influence of the Core Formats on Design Parameters
7.6.2 Influence of Laminating Methods on Design Parameters
7.6.3 Influence of Product Application Conditions on Design Parameters
7.7 Principles and Examples of Using Hybrid Cores, Regional Reinforcements, Transitions, and Connection Elements
7.7.1 Use Intelligent Combinations of Hybrid Core Materials for a Large Complex Product
7.7.2 Regional (Local) Reinforcements
7.7.3 Fasteners and Connections
7.7.3.1 Connect to Solid Structure
7.7.3.2 Straight Connect Sandwich Structures
7.7.3.3 Right Angle Connection
7.7.3.4 T-Joint Connection
7.7.3.5 Fasten Sandwich Panel to Solid Structural Component
References
Chapter 8 Sandwich Composite Structure Modeling by Finite ElementΒ Method
8.1 Basics on Finite Element Analysis
8.1.1 Purpose
8.1.2 General Steps and Considerations of Performing Finite Element Analysis When Using Commercial Software
8.2 Skin/Face Sheet Modeling: Material Models and Parameter Characterization
8.2.1 Hashin Damage Model and Parameter Characterization
8.3 Continuous Surface Core Modeling: Material Models and Parameter Characterization
8.3.1 Crushable Foam Material Model and Parameter Characterization
8.3.2 J2 Elastoplasticity Material Model
8.3.3 End-Grain Balsa Wood Material Model and Parameter Characterization
8.4 Discontinuous (Honeycomb, Truss) Core Modeling Approaches
8.5 Adhesive and Debonding/Delamination Modeling Approaches
8.5.1 Cohesive Zone Method
8.5.2 Surface Separation Approach
8.5.3 Connector Element Approach
8.6 Foam Core Sandwich Composite Modeling Example: Debonding of Foam Core Sandwich Composite Beam
8.7 Honeycomb Core Sandwich Composite Modeling Example: Nonlinear Response of Honeycomb Sandwich Composite Beam Subject to Four-Point Bending
8.8 Optimization of Sandwich Composite Design Based on Finite Element Analysis
8.9 Fatigue Life Modeling of Sandwich Composite via Finite Element Analysis
8.9.1 The S-N Curve Method for Sandwich Composites
Appendix: Octave/Matlab code for transferring foam strengths for crushable foam material model in ABAQUS
References
Chapter 9 Application of Sandwich Structural Composites
9.1 Marine Industry
9.1.1 Recreational Boat Building
9.1.2 Military Ship Constructions
9.1.3 Commercial Marine Industry
9.2 Wind Energy Industry
9.3 Airplane and Aerospace
9.3.1 Applications in Airplanes
9.3.2 Applications in Helicopters
9.3.3 Applications in Space
9.3.4 Future of Aeronautic Sandwich Structures
9.4 Transportation
9.4.1 Rail Car Application
9.4.2 Bus Body Application
9.4.3 Truck and Semitrailer Body Application
9.4.4 Automotive Industry
9.5 Building and Civil Industries
9.5.1 Housing and Building Construction
9.5.2 Bridge Building
9.5.3 Bridge and Dock Protective Systems
9.5.4 Challenges and Issues
9.6 Miscellaneous
9.6.1 Sandwich Structure for Radome Construction
9.6.2 Medical Equipment
9.6.3 Acoustic Barriers
9.6.3.1 Sound Transmission through Sandwich Structures
9.6.3.2 Sound Transmission Reduction by Adding a Layer of Membrane-Type Acoustic Meta-Materials
9.6.3.3 Reduce the Sound Transmission by Acoustic Separation of the Layers of Sandwich
9.6.3.4 Introduce Air or Sound Insolation Gap to Core or between Panels
9.6.3.5 Honeycomb Sandwich Panels with Micro-perforated Facings
9.6.3.6 Use Damping Core and Perforated Facing
9.6.4 Sports and Leisure
9.6.4.1 Sporting Boards on the Water
9.6.4.2 3D Printing Sport Boards
9.6.4.3 Skis and Snowboard
9.6.4.4 Sandwich Construction for Making Canoes, Kayaks and Paddleboards
References
Chapter 10 Sandwich Composite Damage Assessment and Repairing
10.1 Detection and Estimation of Defects and Damages
10.1.1 Personal and Visual Inspections
10.1.2 Inspect by Instruments
10.1.3 Damage Estimation
10.2 Different Type of Damages
10.2.1 General Clarifications of the Damages
10.2.2 Detail Damages of Special Products
10.3 Repairing Procedures and Methods
10.3.1 Repair Plan Design and Option Selection
10.3.2 Damage Cleaning
10.3.3 Repairing Materials and Preparation
10.3.4 General Repair Processes
10.3.4.1 Repair of Type A Damage
10.3.4.2 Repair of Type B Damage
10.3.4.3 Repair of Type C Damage
10.3.5 Special Repair Processes
10.3.5.1 Surface Repair
10.3.5.2 Brief or Short-Term Repair
10.3.5.3 Structural Repair
10.3.5.4 Vacuum Bagging Pressure Curing
10.3.5.5 Repair of Structure Face with Cracks or Surface Defects
10.3.5.6 Re-bonding Delaminated Skin to a Core by Resin Injection
10.3.5.7 Vacuum Infusion Bag Pressure Curing Repair Technology
10.3.5.8 Temperature Control During Repair Curing
10.4 Quality Inspection During and After Repairing
References
Index