A heat shield called the thermal protection system (TPS) is an important structure in hypersonic vehicles as it prevents hot air from entering vehicles and potential impacts from space debris. With the increase in demand for low-cost reusable launch vehicles as well as for searching and exploration of new planets in both unmanned and manned missions, the need for developing an effective TPS has increased across many countries. The structural design of TPSs has become more prominent in the early stage of hypersonic vehicle development. Sandwich structures that have the advantages of low density and high performance are integrated into the structural design of an effective TPS. This paper provides a comprehensive review of recent research efforts on sandwich structures for TPSs. The topics discussed in this paper include aspects of structural and material design, mechanical and thermomechanical performances, and manufacturing methods. In particular, we review and discuss the structural design as well as the material design of sandwich structures for different TPS types with various configurations, including corrugated cores, lattice cores, multilayer cores, foams, honeycomb cores, bio-inspired cores. The materials used for the sandwich structures, such as various types of laminated composite, ceramic matrix composite, and metals, are included. We also discuss the performance of the TPS sandwich structures in terms of temperature gradients, deformation limits, and mechanical strengths and provide a discussion on the manufacturing methods of TPS sandwich structures for hypersonic vehicles. Finally, further research directions and challenges of sandwich structures for TPSs are presented.

Advanced sandwich structures for thermal protection systems in hypersonic vehicles: A review

The current paper is intended to provide an overview on the current state of the art for sandwich structures marine applications to support their wider application and identify the key issues to de...

Lightweight sandwich structures for marine applications: a review

Dual-mechanism auxetic-core protective sandwich structure under blast loading

In this work, structural design and manufacturing of sandwich composite floor for automobile was performed The tensile and compression strength of specimen were investigated Based on this, structural design of floor board was performed The sandwich composite floor board are subject to payload The maximum load was analyzed in consideration of the safety factor The structural design and analysis were performed in consideration of applied load The finite element analysis method was applied to investigate structural safety The stress, displacement, and buckling analysis was carried out Through the structural analysis, it was confirmed that the designed floor board structure is safety Based on the result, the manufacturing of prototype was conducted Finally, test and evaluation of composite floor board was performed

Study on Structural Design and Manufacturing of Sandwich Composite Floor for Automotive Structure.

Mechanical behaviors and fracture mechanisms of CFRP sandwich composite structures with bio-inspired thin-walled corrugated cores

Review of current trends for metal-based sandwich panel: Failure mechanisms and their contribution factors

This paper investigates the adhesive effect between the surface layer of sandwich panel with three different core surface configurations by using a peel simulation approach. The sandwich panels with cavity on the core structure can potentially be highly vulnerable to debonding phenomenon when subjected to extreme loading. The three-dimensional sandwich panels based on ASTM D1876 were developed with a finite element modelling and subjected to a constant loading magnitude of 100 MPa in two force directions of 90° and 180°. The result shows that the sandwich panel with a honeycomb core and a dimpled surface core showed increments in stress distributions at bonding area (85 % and 12.8 % at the force direction of 90°; 69.9 % and 11.6 % at the force direction of 180°) compared to that with a solid plate core. Nevertheless, the high shear stress was revealed at a large adhesive area, indicating the high potential for debonding to occur at the adhesive area between panel surface layers. This stress was directly proportional to the total deformation. The size of the adhesive area influences the bonding strength, but an extra reduction in the core density could lead to the early failure of the sandwich panel.

Evaluating an adhesive effect on core surface configuration for sandwich panel with peel simulation approach

This paper presents the effect of sandwich panel with two types of dimple core surface and solid plate core on its ballistic properties and strength . The current core such as foam, honeycomb, and lattice cores have cavity and porosity on its structure which made them vulnerable to catastrophic failure due to high impact. This paper aims to enhance the ballistic resistance of panel using enhanced core configuration. A simulation was conducted using computational method of explicit dynamic under high-speed projectile impact at 980 m/s of 7.62 mm armour-piercing metal. A half-symmetric of three-dimensional sandwich panel with 27 mm thickness including adhesive material was modelled with a mesh refinement of 1 mm and added with the modified Johnson–Cook parameters to describe the ballistic behaviour of each materials. The results show that the use of dimple surface as the core for sandwich panel has increased the ballistic performance by approximately 30% from the solid core. No macrocrack or petal showed at the back layer except of bulges effect. Magnesium alloy as core material showed high potential to be used as main core for sandwich panel on protection application by decrement in projectile penetration about 4.5% compared to aluminium alloy. This study proposed that the structural integrity of the metal sandwich panel with proposed core configuration has improved with no significant reduction in ballistic performance compared to the sandwich panel with solid core.

M. K. Faidzi

Papers

Review of current trends for metal-based sandwich panel: Failure mechanisms and their contribution factors

Evaluating an adhesive effect on core surface configuration for sandwich panel with peel simulation approach

Computational analysis on the different core configurations for metal sandwich panel under high velocity impact