Sandwich structures are a class of multifunctional high-performance structural composites that have the advantages of being lightweight, of a high strength-to-weight ratio, and of high specific energy absorption capabilities. The creative design of the core along with the apposite material selection for the fabrication of the face sheet and core are the two prerequisites with encouraging areas for further expedition towards the fabrication of advanced composite sandwich structures. The current review work focused on different types of core designs, such as truss, foam, corrugated, honeycomb, derivative, hybrid, hollow, hierarchical, gradient, folded, and smart core along with different composite materials accessible for face sheet fabrication, including fiber-reinforced composite, metal matrix composite, and polymer matrix composite are considered. The joining method plays a major role for the performance evolution of sandwich structures, which were also investigated. Further discussions are aligned to address major challenges in the fabrication of sandwich structures and further enlighten the future direction of the advanced composite sandwich structure. Finally, the work is summarized with a brief conclusion. This review article provides wider guidelines for researchers in designing and manufacturing next-generation lightweight multilayer core sandwich structures.
Polymer nanocomposites have been gaining attention in recent years. The addition of a low content of nanomaterials into the matrix improves mechanical, wear, thermal, electrical, and flame-retardant properties. The present work aimed to investigate the effect of graphene and hexagonal boron nitride nanoparticles on Kevlar and hybrid fiber-reinforced composites (FRP). Composites are fabricated with different filler concentrations of 0, 0.1, 0.3, and 0.5 wt.% by using a hand layup process. Characterizations like tensile, flexural, hardness, and impact strength were evaluated separately, heat deflection and viscosity properties of the epoxy composites. The dynamic viscosity findings indicated that a higher concentration of filler material resulted in nano-particle agglomeration. Graphene filler showed superior properties when compared to hexagonal boron nitride filler. Graphene showed optimum mechanical properties at 0.3 wt.%, whereas the hBN filler showed optimum properties at 0.5 wt.%. As compared to Kevlar composites, hybrid (carbon–Kevlar) composites significantly improved properties. As compared to graphene-filled composites, hexagonal boron nitride-filled composites increased scratch resistance. Digimat simulations were performed to validate experimental results, and it was observed that hybrid fabric composites exhibited better results when compared to Kevlar composites. The error percentage of all composites are within 10%, and it was concluded that hybrid–graphene fiber composites exhibited superior properties compared to Kevlar composites.
The utility of polymers in the present decade is consistently increasing, giving scope to many applications from automobiles to prosthetics. Polymers used for solid free-form fabrication (SFFF), also known as 3D printing, comprise a quick fabrication process adopted by many industries to increase productivity and decrease the run time to cope with the market demands. In this research work, pure polyethylene terephthalate glycol (PETG) and multi-walled carbon nanotube (MWCNT)-PETG with an electroless metal layer coating and without a coating are discussed. The effect of the electroless metal layer coating on the reinforced PETG-MWCNT results in improved mechanical, tribological, and other surface properties. Pure PETG was incorporated with MWCNT nanofillers at 0.3 wt.% and extruded as a filament through a twin screw extruder with a 1.75 mm diameter and printed on ASTM standards. Tensile testing was performed on all four types of un-coated pure PETG, PETG-MWCNT, and metal-layer-coated PETG and PETG-MWCNT with a coating thickness of 26, 32, 54, and 88 μm. Dynamic mechanical analysis (DMA) showed that the coated PETG-MWCNT had the highest storage and loss modulus. The heat deflection temperature was improved to 88 °C for the coated PETG-MWCNT. The wear volume against the sliding distance at a load of 40, 50, and 60 N showed that the coefficient of friction decreased with an increase in the load. The scratch test results revealed the lowest penetration depth and lowest friction coefficient for the coated PETG-MWCNT sample. The water contact angle test showed that a greater coating thickness makes the sample surface more hydrophobic, and the microhardness test indicated that the indentation hardness value for the PETG-MWCNT was 92 HV. The study revealed that the metal-layer-coated PETG-MWCNT had better performance compared to the other specimens due to a good metal layer bonding on the PETG substrate. It was concluded that adding MWCNTs to a metal layer electroless coating improved the surface and mechanical properties of the PETG, and this may be suitable for many applications.
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