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<p>Internal thermal expansion molding is a cost-effective composite fabrication technique that enables the integrated formation of complex, enclosed structures. In sandwich structures, interfacial delamination critically affects bearing capacity, making interface performance a key concern. Thus, this study primarily focuses on integrated multilayer sandwich structures to investigate the mechanism of mode I interfacial fracture toughness. The research findings firstly demonstrate that the expansion ratio (ER) systematically influences various parameters, including compliance, delamination length, fracture propagation mode, and final loading. The interface between carbon fiber reinforced polymer (CFRP) and thermal expansion foam (TEF) (C-T interface) exhibits an initial fracture toughness of ~ 0.53&#xa0;kJ/m², which exceeds the TEF itself by ~ 235.7%. Similarly, the interface between polymethacrylimide (PMI) and TEF (P-T interface) achieves a synergistic enhancement, with interfacial toughness surpassing that of the individual base materials. These improvements are attributed to co-curing-induced bonding, increased interfacial contact, reduced thermal stress, the formation of mechanical interlocks, and mitigation of stress concentrations. The results demonstrate that the integrated multilayer sandwich composite structures fabricated via the internal thermal expansion technique not only enable efficient, integrated manufacturing, but also achieve superior interfacial properties relative to traditional three-layer structures.</p>

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Interfacial Delamination and Corresponding Mechanisms of Integrated Sandwich Composite Structure Fabricated Via Internal Thermal Expansion Technique

  • 期刊论文

  • 发表日期：

    2025年11月20日

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  • Yunfei Peng,
  • Maojun Li,
  • Xujing Yang,
  • Hanting Zuo,
  • Bingjie Sun,
  • Shilong Lv

摘要

Internal thermal expansion molding is a cost-effective composite fabrication technique that enables the integrated formation of complex, enclosed structures. In sandwich structures, interfacial delamination critically affects bearing capacity, making interface performance a key concern. Thus, this study primarily focuses on integrated multilayer sandwich structures to investigate the mechanism of mode I interfacial fracture toughness. The research findings firstly demonstrate that the expansion ratio (ER) systematically influences various parameters, including compliance, delamination length, fracture propagation mode, and final loading. The interface between carbon fiber reinforced polymer (CFRP) and thermal expansion foam (TEF) (C-T interface) exhibits an initial fracture toughness of ~ 0.53 kJ/m², which exceeds the TEF itself by ~ 235.7%. Similarly, the interface between polymethacrylimide (PMI) and TEF (P-T interface) achieves a synergistic enhancement, with interfacial toughness surpassing that of the individual base materials. These improvements are attributed to co-curing-induced bonding, increased interfacial contact, reduced thermal stress, the formation of mechanical interlocks, and mitigation of stress concentrations. The results demonstrate that the integrated multilayer sandwich composite structures fabricated via the internal thermal expansion technique not only enable efficient, integrated manufacturing, but also achieve superior interfacial properties relative to traditional three-layer structures.