Review of composite sandwich structure in aeronautic applications

Abstract This paper presents a review of the issues concerning sandwich structures for aeronautical applications. The main questions raised by designers are first recalled and the complexity of sandwich structure design for aeronautics is highlighted. Then a review of applications is presented, starting with early examples from the 1930s and the Second World War. The growth in the use of sandwich materials in civil and military applications is then developed. Recent research and innovations conclude the paper.

[1]  Hyunbum Park,et al.  A study on low velocity impact damage evaluation and repair technique of small aircraft composite structure , 2011 .

[2]  Julien Aubry,et al.  Study of Medium Velocity Impacts on the Lower Surface of Helicopter Blades , 2014 .

[3]  Jörg Feldhusen,et al.  Development of a Mechanical Technology for Joining Sandwich Elements , 2009 .

[4]  Ole Thybo Thomsen,et al.  New Peel Stopper Concept for Sandwich Structures , 2007 .

[5]  Ramesh Talreja,et al.  Modeling of Wrinkling in Sandwich Panels under Compression , 1999 .

[6]  James Kratz,et al.  Vacuum-bag-only co-bonding prepreg skins to aramid honeycomb core. Part II. In-situ core pressure response using embedded sensors , 2015 .

[7]  R. Morishima,et al.  Numerical analysis and experiment of composite sandwich T-joints subjected to pulling load , 2011 .

[8]  P. Thevenet,et al.  Damage Tolerance of Aeronautical Sandwich Structures , 1998 .

[9]  William R. Pogue,et al.  Multifunctional structure-battery composites for marine systems , 2013 .

[10]  Philippe Le Grognec,et al.  Exact analytical solutions for the local and global buckling of sandwich beam-columns under various loadings , 2013 .

[11]  Isabelle L. Paris,et al.  Exploratory investigation of failure mechanisms in transition regions between solid laminates and X-cor® truss sandwich , 2002 .

[12]  Chai Gin-Boay,et al.  Stress distribution in sandwich beams under tension , 1999 .

[13]  Douglas T. Queheillalt,et al.  A multifunctional heat pipe sandwich panel structure , 2008 .

[14]  Dan Zenkert,et al.  Effects of Anisotropy and Multiaxial Loading on the Wrinkling of Sandwich Panels , 2005 .

[15]  Salim Belouettar,et al.  Multi-scale techniques to analyze instabilities in sandwich structures , 2013 .

[16]  Ole Thybo Thomsen,et al.  Modeling of Tapered Sandwich Panels Using a High-Order Sandwich Theory Formulation , 2002 .

[17]  Anthony J. Vizzini,et al.  A Feasible Methodology for Engineering Applications in Damage Tolerance of Composite Sandwich Structures , 2004 .

[18]  Stefanie Feih,et al.  Performance of bio-inspired Kagome truss core structures under compression and shear loading , 2014 .

[19]  Jean-François Ferrero,et al.  Nonlinear Response of Symmetric Sandwich structures Subjected to in-plane loads , 2012 .

[20]  Thomas E. Lacy,et al.  Numerical modeling of impact-damaged sandwich composites subjected to compression-after-impact loading , 2003 .

[21]  Li Ma,et al.  Modeling and reliability of insert in composite pyramidal lattice truss core sandwich panels , 2019, Composite Structures.

[22]  Ole Thybo Thomsen,et al.  The effect of temperature on the failure modes of polymer foam cored sandwich structures , 2015 .

[23]  Dan Zenkert,et al.  Imperfection-induced Wrinkling Material Failure in Sandwich Panels , 2005 .

[24]  Xinwei Wang,et al.  On stability and damage behavior of asymmetric sandwich panels under uniaxial compression , 2020 .

[25]  Sebastian Heimbs,et al.  Failure behaviour of honeycomb sandwich corner joints and inserts , 2009 .

[26]  Bruno Castanié,et al.  Non-linear finite element analysis of inserts in composite sandwich structures , 2008 .

[27]  Dai Gil Lee,et al.  Development of a satellite structure with the sandwich T-joint , 2010 .

[28]  Li-Qun Chen,et al.  A multifunctional lattice sandwich structure with energy harvesting and nonlinear vibration control , 2019, Composite Structures.

[29]  Steven Marguet,et al.  Impact damage prediction in thin woven composite laminates – Part II: Application to normal and oblique impacts on sandwich structure , 2018 .

[30]  Bruno Castanié,et al.  Insert of sandwich panels sizing through a failure mode map , 2020 .

[31]  Christian Hühne,et al.  Validity check of an analytical dimensioning approach for potted insert load introductions in honeycomb sandwich panels , 2018, Composite Structures.

[32]  D.A. Crump,et al.  The Manufacturing Procedure for Aerospace Secondary Sandwich Structure Panels , 2010 .

[33]  Tu Delft,et al.  Research on sailplane aerodynamics at Delft University of Technology. Recent and present developments. , 2006 .

[34]  Onur Çoban,et al.  Experimental investigation of single and repeated impacts for repaired honeycomb sandwich structures , 2017 .

[35]  Axel Fink,et al.  Discrete tailored asymmetric sandwich structures , 2020 .

[36]  Erik Kappel,et al.  Spring-in of curved CFRP/foam-core sandwich structures , 2015 .

[37]  Hao-Ming Hsiao,et al.  Core Crush Problem in the Manufacturing of Composite Sandwich Structures: Mechanisms and Solutions , 2006 .

[38]  Jean-Jacques Barrau,et al.  Theoretical and experimental analysis of asymmetric sandwich structures , 2002 .

[39]  Trevor M. Young,et al.  Bonded repair of composite aircraft structures: A review of scientific challenges and opportunities , 2013 .

[40]  John H. Fogarty,et al.  Honeycomb Core and the Myths of Moisture Ingression , 2010 .

[41]  Zhongwei Guan,et al.  Experimental and numerical study on the mechanical response of Nomex honeycomb core under transverse loading , 2015 .

[42]  Sebastian Heimbs,et al.  Virtual testing of sandwich core structures using dynamic finite element simulations , 2009 .

[43]  B. Castanié,et al.  Experimental and Numerical Analysis of Inserts in Sandwich Structures , 2005 .

[44]  Kicki F. Karlsson,et al.  Manufacturing and applications of structural sandwich components , 1997 .

[45]  J. Hamer Honeycomb structure and its application to the Concorde rudder , 1971 .

[46]  Kenneth E. Evans,et al.  The design of doubly curved sandwich panels with honeycomb cores , 1991 .

[47]  N. J. Hoff,et al.  The Buckling of Sandwich-Type Panels , 1945 .

[48]  James Kratz,et al.  Vacuum bag only co-bonding prepreg skins to aramid honeycomb core. Part I. Model and material properties for core pressure during processing , 2015 .

[49]  Tian Jian Lu,et al.  Recent advances in hybrid lattice-cored sandwiches for enhanced multifunctional performance , 2017 .

[50]  Daining Fang,et al.  Frequency-selective-surface based sandwich structure for both effective loadbearing and customizable microwave absorption , 2020 .

[51]  Jean-Claude Grandidier,et al.  Discrete modelling of low-velocity impact on Nomex® honeycomb sandwich structures with CFRP skins , 2019, Composite Structures.

[52]  Yulfian Aminanda,et al.  Spring-back simulation of unidirectional carbon/epoxy flat laminate composite manufactured through autoclave process , 2015 .

[53]  Rushabh Kothari,et al.  Design and analysis of multifunctional structures with embedded electronics for thermomechanical loads , 2012 .

[54]  Julien Aubry,et al.  Study of impact on helicopter blade , 2012 .

[55]  Vincent Caccese,et al.  Elastic Coupling Effects in Tapered Sandwich Panels with Laminated Anisotropic Composite Facings , 2005 .

[56]  Lionel Leotoing,et al.  Nonlinear interaction of geometrical and material properties in sandwich beam instabilities , 2002 .

[57]  Lorenzo Dozio,et al.  Buckling and wrinkling of anisotropic sandwich plates , 2018, International Journal of Engineering Science.

[58]  Roderic S. Lakes,et al.  Moisture Ingression in Honeycomb Core Sandwich Panels: Directional Aspects , 1997 .

[59]  H. G. Allen I. Evolution et développement , 1989 .

[60]  A. Boudjemai,et al.  Effect of position of tension-loaded inserts on honeycomb panels used for space applications , 2018 .

[61]  Yancheng Zhang,et al.  Multifunctional structural lithium-ion battery for electric vehicles , 2017 .

[62]  Christophe Bouvet,et al.  Experimental investigation of compression and compression after impact of wood-based sandwich structures , 2019, Composite Structures.

[63]  Jean-Jacques Barrau,et al.  Multi-level experimental and numerical analysis of composite stiffener debonding. Part 2: Element and panel level , 2009 .

[64]  T. Kevin O'Brien,et al.  Water intrusion in thin-skinned composite honeycomb sandwich structures , 1990 .

[65]  Kevin Retz The Road to Large Scale Composite Application on Wide Body Commercial Transports , 2003 .

[66]  Thomas Pardoen,et al.  Multifunctional sandwich structure for electromagnetic absorption and mechanical performances , 2014 .

[67]  Mark Battley,et al.  Strength Variability of Inserts in Sandwich Panels , 2009 .

[68]  Berend G. van der Wall,et al.  From ERATO Basic Research to the Blue Edge Rotor Blade , 2016 .

[69]  Göran Fernlund Spring-in of angled sandwich panels , 2005 .

[70]  Ole Thybo Thomsen,et al.  Sandwich Plates with "Through-the-Thickness" and "Fully-Potted" inserts: Evaluation of Differences in Structural Performance , 1997 .

[71]  B. Castanié,et al.  Experimental Analysis and Modeling of the Crushing of Honeycomb Cores , 2005 .

[72]  Marc Sartor,et al.  ANALYTICAL TWO-DIMENSIONAL MODEL OF A HYBRID (BOLTED/BONDED) SINGLE-LAP JOINT , 2007 .

[73]  Daining Fang,et al.  Fire protection design for composite lattice sandwich structure , 2017 .

[74]  Ole Thybo Thomsen,et al.  Conceptual Design Principles for Non-Circular Pressurized Sandwich Fuselage Sections – a Design Study Based on a High-Order Sandwich Theory Formulation , 2001 .

[75]  Yulfian Aminanda,et al.  Modelling of low-energy/low-velocity impact on Nomex honeycomb sandwich structures with metallic skins , 2008 .

[76]  Heslehurst Rikard Benton Engineered Repairs of Composite Structures , 2019 .

[77]  Jack C. Joanides,et al.  Mach 3 Wing Structures Stiffened Skin versus Sandwich , 1961 .

[78]  Emmanuel E. Gdoutos,et al.  Compression facing wrinkling of composite sandwich structures , 2003 .

[79]  Kevin D Potter,et al.  Experimental investigation into the thermoelastic spring-in of curved sandwich panels , 2013 .

[80]  John Dugundji,et al.  Buckling and Failure of Sandwich Plates with Graphite-Epoxy Faces and Various Cores , 1988 .

[81]  B. W. Flynn,et al.  Advanced Technology Composite Fuselage-Structural Performance , 1997 .

[82]  Bruno Castanié,et al.  Spring-in prediction for carbon/epoxy aerospace composite structure , 2017 .

[83]  Bruno Castanié,et al.  Dynamic failure of composite and sandwich structures , 2013 .

[84]  U. V. R. S. Turaga,et al.  Failure Modes and Load Transfer in Sandwich T-Joints , 2000 .

[85]  Jianxun Zhang,et al.  The initial plastic failure of fully clamped geometrical asymmetric metal foam core sandwich beams , 2016 .

[86]  Elena Bozhevolnaya,et al.  Local effects at core junctions of sandwich structures under different types of loads , 2006 .

[87]  Joachim L. Grenestedt,et al.  Development of a new peel-stopper for sandwich structures , 2001 .

[88]  B. Castanié,et al.  Combined shear/compression structural testing of asymmetric sandwich structures , 2004 .

[89]  L. M. Smith,et al.  Bonded Bomber - B-58 , 1962 .

[90]  S. Smidt,et al.  Bending of curved sandwich beams, a numerical approach , 1996 .

[91]  Chun H. Wang,et al.  Optimum shapes of scarf repairs , 2009 .

[92]  Onera,et al.  Blue Edge: The Design, Development and Testing of a New Blade Concept , 2011 .

[93]  J. Månson,et al.  Ultra-light asymmetric photovoltaic sandwich structures , 2009 .

[94]  S. Tsai,et al.  Composite Materials: Design and Applications , 2002 .

[95]  Jan-Anders E. Månson,et al.  Assessment of semi-impregnated fabrics in honeycomb sandwich structures , 2010 .

[96]  Yulfian Aminanda,et al.  Core crush criterion to determine the strength of sandwich composite structures subjected to compression after impact , 2008 .

[97]  Chun H. Wang,et al.  Improved design methods for scarf repairs to highly strained composite aircraft structure , 2006 .

[98]  Lu Zhang,et al.  Manufacture and mechanical properties of sandwich structure-battery composites , 2019, Journal of Polymer Engineering.

[99]  George A. Kardomateas,et al.  Structural and Failure Mechanics of Sandwich Composites , 2011 .

[100]  Y Y Chen,et al.  Wave propagation and absorption of sandwich beams containing interior dissipative multi‐resonators , 2017, Ultrasonics.

[101]  Bruno Castanié,et al.  Manufacturing and quasi-static bending behavior of wood-based sandwich structures , 2017 .

[102]  Christophe Bouvet,et al.  Experimental and numerical analysis of the shear nonlinear behaviour of Nomex honeycomb core: Application to insert sizing , 2018, Composite Structures.

[103]  Christophe Bouvet,et al.  Experimental analysis of impact and post-impact behaviour of inserts in Carbon sandwich structures , 2019 .

[104]  Joseph Morlier,et al.  Fabrication and mechanical testing of glass fiber entangled sandwich beams: A comparison with honeycomb and foam sandwich beams , 2009 .

[105]  S. Heimbs Foldcore Sandwich Structures and Their Impact Behaviour: An Overview , 2013 .

[106]  Jan-Anders E. Månson,et al.  Hybrid processing of thick skins for honeycomb sandwich structures , 2011 .

[107]  Ramazan Asmatulu,et al.  Effects of moisture ingressions on mechanical properties of honeycomb-structured fiber composites for aerospace applications , 2017 .

[108]  W. A. Spivak XB-70A Mach 3 Design and Operating Experience , 1966 .

[109]  Dieter Krause,et al.  Numerical modelling of partially potted inserts in honeycomb sandwich panels under pull-out loading , 2018, Composite Structures.

[110]  Ole Thybo Thomsen,et al.  Crack deflection analyses of different peel stopper designs for sandwich structures , 2009 .

[111]  A Tropis,et al.  Certification of the Composite Outer Wing of the ATR72 , 1995 .

[112]  Bambang K. Hadi,et al.  Development of Benson–Mayers theory on the wrinkling of anisotropic sandwich panels , 2000 .

[113]  E. H. Hooper III. Le Starship : un modèle pour les avions futurs , 1989 .

[114]  A. Marques,et al.  Multifunctional Material Systems: A state-of-the-art review , 2016 .

[115]  Anthony J. Vizzini,et al.  Failure of Sandwich to Laminate Tapered Composite Structures , 1995 .

[116]  D. Chaumette,et al.  Flight qualification of composite structures at AMD-BA , 1982 .

[117]  R. Heslehurst Defects and Damage in Composite Materials and Structures , 2014 .

[118]  Jan-Anders E. Månson,et al.  Non-autoclave processing of honeycomb sandwich structures: Skin through thickness air permeability during cure , 2010 .

[119]  Yulfian Aminanda,et al.  Experimental and numerical study of compression after impact of sandwich structures with metallic skins , 2009 .

[120]  M. E. Ibrahim Nondestructive evaluation of thick-section composites and sandwich structures: A review , 2014 .

[121]  Steven Nutt,et al.  Process diagnostics for co-cure of sandwich structures using in situ visualization , 2019, Composites Part A: Applied Science and Manufacturing.

[122]  Thomas M. Krivanek,et al.  Composite Payload Fairing Structural Architecture Assessment and Selection , 2012 .

[123]  Christophe Bouvet,et al.  Damage Mechanics Modelling of the shear nonlinear behavior of Nomex honeycomb core. Application to sandwich beams , 2018, Mechanics of Advanced Materials and Structures.

[124]  Frédéric Lachaud,et al.  On the Potential Static Strength of Hybrid (Bolted/Bonded) Lap Joints with Functionally Graded Adhesives , 2019, AIAA Journal.