In materials science, a sandwich-structured composite is a special class of composite materials that is fabricated by attaching two thin-but-stiff skins to a lightweight-but-thick core. The core material is normally of low strength, but its greater thickness provides the sandwich composite with high bending stiffness with overall low density.
Open- and closed-cell-structured foams like polyethersulfone, polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, and honeycombs are commonly used core materials. Sometimes, the honeycomb structure is filled with other foams for added strength. Open- and closed-cell metal foam can also be used as core materials.
Laminates of glass or carbon fiber-reinforced thermoplastics or mainly thermoset polymers (unsaturated polyesters, epoxies...) are widely used as skin materials. Sheet metal is also used as skin material in some cases.
The core is bonded to the skins with an adhesive or with metal components by brazing together.
A summary of the important developments in sandwich structures is given below. [1]
Metal composite material (MCM) is a type of sandwich formed from two thin skins of metal bonded to a plastic core in a continuous process under controlled pressure, heat, and tension. [3]
Recycled paper is also now being used over a closed-cell recycled kraft honeycomb core, creating a lightweight, strong, and fully repulpable composite board. This material is being used for applications including point-of-purchase displays, bulkheads, recyclable office furniture, exhibition stands, wall dividers and terrace boards. [4]
To fix different panels, among other solutions, a transition zone is normally used, which is a gradual reduction of the core height, until the two fiber skins are in touch. In this place, the fixation can be made by means of bolts, rivets, or adhesive.
With respect to the core type and the way the core supports the skins, sandwich structures can be divided into the following groups: homogeneously supported, locally supported, regionally supported, unidirectionally supported, bidirectionally supported. [5] The latter group is represented by honeycomb structure which, due to an optimal performance-to-weight ratio, is typically used in most demanding applications including aerospace.
The strength of the composite material is dependent largely on two factors:
Sandwich structures can be widely used in sandwich panels, with different types such as FRP sandwich panel, aluminium composite panel, etc. FRP polyester reinforced composite honeycomb panel (sandwich panel) is made of polyester reinforced plastic, multi-axial high-strength glass fiber and PP honeycomb panel in special antiskid tread pattern mold through the process of constant temperature vacuum adsorption & agglutination and solidification.
Sandwich theory [8] [9] describes the behaviour of a beam, plate, or shell which consists of three layers - two face sheets and one core. The most commonly used sandwich theory is linear and is an extension of first order beam theory. Linear local buckling sandwich theory is of importance for the design and analysis of Sandwich plates or sandwich panels, which are of use in building construction, vehicle construction, airplane construction and refrigeration engineering.
Reinforced concrete, also called ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having higher tensile strength or ductility. The reinforcement is usually, though not necessarily, steel bars (rebar) and is usually embedded passively in the concrete before the concrete sets. However, post-tensioning is also employed as a technique to reinforce the concrete. In terms of volume used annually, it is one of the most common engineering materials. In corrosion engineering terms, when designed correctly, the alkalinity of the concrete protects the steel rebar from corrosion.
A composite material is a material which is produced from two or more constituent materials. These constituent materials have notably dissimilar chemical or physical properties and are merged to create a material with properties unlike the individual elements. Within the finished structure, the individual elements remain separate and distinct, distinguishing composites from mixtures and solid solutions. Composite materials with more than one distinct layer are called composite laminates.
Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.
Engineered wood, also called mass timber, composite wood, human-made wood, or manufactured board, includes a range of derivative wood products which are manufactured by binding or fixing the strands, particles, fibres, or veneers or boards of wood, together with adhesives, or other methods of fixation to form composite material. The panels vary in size but can range upwards of 64 by 8 feet and in the case of cross-laminated timber (CLT) can be of any thickness from a few inches to 16 inches (410 mm) or more. These products are engineered to precise design specifications, which are tested to meet national or international standards and provide uniformity and predictability in their structural performance. Engineered wood products are used in a variety of applications, from home construction to commercial buildings to industrial products. The products can be used for joists and beams that replace steel in many building projects. The term mass timber describes a group of building materials that can replace concrete assemblies.
A structural insulated panel, or structural insulating panel, (SIP), is a form of sandwich panel used in the construction industry.
Seismic retrofitting is the modification of existing structures to make them more resistant to seismic activity, ground motion, or soil failure due to earthquakes. With better understanding of seismic demand on structures and with recent experiences with large earthquakes near urban centers, the need of seismic retrofitting is well acknowledged. Prior to the introduction of modern seismic codes in the late 1960s for developed countries and late 1970s for many other parts of the world, many structures were designed without adequate detailing and reinforcement for seismic protection. In view of the imminent problem, various research work has been carried out. State-of-the-art technical guidelines for seismic assessment, retrofit and rehabilitation have been published around the world – such as the ASCE-SEI 41 and the New Zealand Society for Earthquake Engineering (NZSEE)'s guidelines. These codes must be regularly updated; the 1994 Northridge earthquake brought to light the brittleness of welded steel frames, for example.
Wood–plastic composites (WPCs) are composite materials made of wood fiber/wood flour and thermoplastic(s) such as polythene (PE), polypropylene (PP), polyvinyl chloride (PVC), or polylactic acid (PLA).
Syntactic foams are composite materials synthesized by filling a metal, polymer, cementitious or ceramic matrix with hollow spheres called microballoons or cenospheres or non-hollow spheres as aggregates. In this context, "syntactic" means "put together." The presence of hollow particles results in lower density, higher specific strength, lower coefficient of thermal expansion, and, in some cases, radar or sonar transparency.
In materials science, a metal foam is a material or structure consisting of a solid metal with gas-filled pores comprising a large portion of the volume. The pores can be sealed or interconnected. The defining characteristic of metal foams is a high porosity: typically only 5–25% of the volume is the base metal. The strength of the material is due to the square–cube law.
Isogrid is a type of partially hollowed-out structure formed usually from a single metal plate with triangular integral stiffening ribs. It was patented by McDonnell Douglas . It is extremely light and stiff. Compared to other materials, it is expensive to manufacture, and so it is restricted to spaceflight applications and some particularly critical parts of more general aerospace use.
Glass fibre reinforced concrete (GFRC) is a type of fibre-reinforced concrete. The product is also known as glassfibre reinforced concrete or GRC in British English. Glass fibre concretes are mainly used in exterior building façade panels and as architectural precast concrete. Somewhat similar materials are fibre cement siding and cement boards.
Honeycomb structures are natural or man-made structures that have the geometry of a honeycomb to allow the minimization of the amount of used material to reach minimal weight and minimal material cost. The geometry of honeycomb structures can vary widely but the common feature of all such structures is an array of hollow cells formed between thin vertical walls. The cells are often columnar and hexagonal in shape. A honeycomb-shaped structure provides a material with minimal density and relative high out-of-plane compression properties and out-of-plane shear properties.
A sandwich panel is any structure made of three layers: a low-density core, and a thin skin-layer bonded to each side. Sandwich panels are used in applications where a combination of high structural rigidity and low weight is required.
Sandwich theory describes the behaviour of a beam, plate, or shell which consists of three layers—two facesheets and one core. The most commonly used sandwich theory is linear and is an extension of first-order beam theory. The linear sandwich theory is of importance for the design and analysis of sandwich panels, which are of use in building construction, vehicle construction, airplane construction and refrigeration engineering.
A thermoset polymer matrix is a synthetic polymer reinforcement where polymers act as binder or matrix to secure in place incorporated particulates, fibres or other reinforcements. They were first developed for structural applications, such as glass-reinforced plastic radar domes on aircraft and graphite-epoxy payload bay doors on the Space Shuttle.
Plascore Incorporated manufactures honeycomb core, cleanrooms, and composite panels marketed under the brand Plascore. Honeycomb is used in aerospace, marine, military, safety, transportation, and other applications. When honeycomb is sandwiched between two surfaces, it effectively creates a distance between the two surfaces more or less like an I-beam. The resulting composite structure exhibits a high strength-to-weight ratio and shear strength. Shear strength is the measured ability of a material to resist structural failure. Plascore honeycomb is designed to increase shear strength while adding minimal additional weight. Plascore is a global organization, with a 185,000 sq. ft. headquarters and three additional manufacturing facilities in Zeeland, Michigan. Those three facilities are 50,000, 40,000 and 80,000 sq. ft. in size. The company also has an 85,000 sq. ft. manufacturing plant in Waldlaubersheim, Germany; and sales offices throughout the world. Plascore is AS/EN/JISQ9100, ISO 14001:2004, and ISO 9001:2008 Certified, and the company's PP Honeycomb has received a Lloyds Register Certificate of Approval of a Core Material. Plascore is also AS9100 certified, an industry standard required by the majority of major aircraft manufacturers that provides verification of consistent aerospace product quality.
Aluminium foam sandwich (AFS) is a sandwich panel product which is made of two metallic dense face sheets and a metal foam core made of an aluminium alloy. AFS is an engineering structural material owing to its stiffness-to-mass ratio and energy absorption capacity ideal for application such as the shell of a high-speed train.
This glossary of structural engineering terms pertains specifically to structural engineering and its sub-disciplines. Please see glossary of engineering for a broad overview of the major concepts of engineering.
Hybrid wood or wood hybrid systems (WHS) is a multilayer composite material, composed on the surface of a skin made of composite wood (WPC) adhering to an underneath structural core, in general aluminum. Invented in Japan in 2008, this technological evolution is based on wood composite technology which was conceived in 1972 by Sadao Nishibori and patented in 1983 to substitute threatened exotic wood species. WHS are not fibre-reinforced plastic (FRP).