The nature of quasi-static indentation damage is studied in aluminum honeycomb core sandwich panels with eight ply, quasi-isotropic, graphite/epoxy face sheets. Parameters that are varied include the core thickness, core density, face sheet layup, and indentor diameter. The majority of induced damage is in the vicinity of the barely visible threshold. The permanent dent in the panel is found to be always larger than the contact area of the indentor, and specimens with denser cores exhibit smaller dent diameters for a given dent depth. Regardless of specimen layup, delaminations occur essentially only at the 3rd, 5th, 6th, and 7th interfaces. Stiffer cores, either in terms of a higher density or, for those cores considered, a smaller thickness, result in lower dent depths, smaller dent diameters, and more face sheet delamination for a given indentation event. The manner in which core orthotropy influences the size and pattern of the delaminations is shown to depend on face sheet layup. Regardless of the core, larger delaminations occur in face sheets that contain 90° angle changes between the adjacent plies in comparison to those that contain only 45° angle changes. Results are compared to those previously reported in the literature, and mechanisms that are related to plate boundary conditions are described that reconcile what would appear to be conflicting results obtained by different studies. Findings are then discussed in the context of choosing the most damage-resistant structural configuration and how this translates to damage tolerance.

The damage resistance of composite sandwich structures with eight and 16 ply quasi-isotropic, carbon/epoxy face sheets and aluminum honeycomb core is evaluated. The external damage is induced quasi-statically, using spherical steel indentors under displacement control, to be in the vicinity of the barely visible threshold. In addition to the face sheet thickness, other parameters that are varied include the core thickness, core density, face sheet layup, and indentor diameter. The effect of these parameters on the extent of damage is evaluated using the damage metrics of dent depth, dent diameter, and planar area of delamination. When dent depth or dent diameter is considered as the damage metric, specimens containing a higher density core are always found to be the most damage resistant. When planar area of delamination is considered as the damage metric, the eight ply configuration comprised of a lower density core and face sheets containing only small ply angle changes are found to be the most damage resistant. However, this configuration is found to be the least damage resistant when this damage metric is applied to the 16 ply specimens. Rather, the best delamination resistance is provided by a 16 ply configuration with a high density core and face sheets that have AE45 ply groups at the beginning and ending of their stacking sequence.

An innovative concept for a multifunctional structural battery using lithium-ion battery materials as load bearing elements in a sandwich panel construction has been demonstrated. The structural battery prototype has exhibited an initial capacity of 17.85 Ah, an energy density of 248 Wh L 21 , a specific energy of 102 Wh kg 21 , and a capacity retention of 85.8% after 190 charge-discharge cycles at~C/3 rate and eight mechanical loading cycles (upto 1060 N). The mechanical stiffness in three-point bend tests follows expectations based on sandwich beam theory, proving that the battery materials are sharing in the load-carrying function of the sandwich panel. While areas for improvement of the fabrication and performance of the prototype still exist, the results of the current investigation demonstrate the promising potential of the proposed structural battery concept for the efficient use of space and mass in an electric vehicle.

Tension–tension fatigue tests in a combustion environment were performed on double-edge notched oxide/oxide ceramic matrix composite specimens. The composite, designated as N720/A, constituted woven 0°/90° Nextel™720 fibers in alumina matrix. Monotonic tensile and cyclic loads at a frequency of 1 Hz and a stress ratio of 0.05 were applied on the specimens in a combustion environment. The maximum specimen temperature due to combustion flame impingement in the notch region was 1250 ± 50℃. A stiffness reduction of less than 10% evaluated for the run-out specimens showed the harsh combustion environment had a minimal effect on specimen degradation. The residual strength was evaluated to be ∼75%–85% the strength of non-fatigued (virgin) double-edge notch specimens in room temperature. The monotonic tensile strength and the fatigue limit for 90,000 cycles (run-out) were found to be ∼40 MPa less in the combustion environment when compared to published results for 1200℃ laboratory air environment. The damage mechanisms were also the same in the two environments. Finite element analyses showed that the reduction in strength and fatigue limit in the combustion environment (as compared to the laboratory air environment) was due to the presence of thermal gradient stresses because of non-uniform specimen temperature distribution.

This study examines the parametric effects of core density, core thickness, face-sheet stacking sequence, and indentor diameter on the compressive strength of aluminum honeycomb-core sandwich panels stiffened with eight-ply, quasi-isotropic, graphite/epoxy face sheets. The sandwich panels contained damage at the threshold of visual detectability created through quasi-static indentation with 25.4 mm or 76.2 mm-diameter spherical indentors. During compression-after-indentation testing, failure occurred due to: dent deepening followed by localized, compressive micro-buckling of fibers in the 0° plies; localized buckling of the near-free-surface sub-laminates; or unstable dent growth in the direction lateral to the applied compressive load. Regardless of failure mode or face-sheet type, the compression-after-indentation strength increased with increasing core thickness and with decreasing core density. Additionally, panels containing face sheets with the 0° plies near the mid-plane and 45° angle change between subsequent plies exhibited greater undamaged compressive strength and higher compression-after-indentation strength relative to panels containing 90° angle changes between subsequent plies and 0° plies near the free surface. The compression-after-indentation strength was found to be relatively unaffected by the indentor diameter size and the resulting variations in the face sheet and core damage. These results imply that precise representation of the damage state in models to predict the post-indentation response of sandwich panels may not be necessary in order to make accurate average residual strength predictions.