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<p>This study investigates the enhancement of impact resistance of conventional honeycomb structures through the incorporation of an aluminium grid and polyurethane foam, resulting in the development of a hybrid honeycomb core (HHC) sandwich panel. Impact testing was conducted using a drop-weight method at energy levels of 30 and 45&#xa0;J to compare the impact performance of HHC panels with the honeycomb core (HC) panels. The response of the sandwich panels in terms of force–displacement and force–time was recorded. Damage characterization was performed on the impacted panels to evaluate both visible and invisible damage and to determine damage mechanisms such as delamination, matrix cracking, core crushing, and core buckling. The experimental results demonstrated that the HHC sandwich panels exhibited up to 28% higher peak force and 35% lower indentation depth compared to HC core panels, indicating significantly enhanced impact resistance and energy absorption. The location of impact also played an important role in the impact resistance of the panels as the underlying damage mechanisms changed based on the impact on the foam area or on the reinforcement grid. The findings provide practical guidance for engineers in selecting or designing sandwich cores based on performance needs such as perforation resistance, stiffness, or energy dissipation.</p>

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Low-Velocity Impact Response of Composite Sandwich Structure with Hybrid Honeycomb Core

  • 期刊论文

  • 发表日期：

    2025年9月24日

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  • Usman Ayub,
  • Aamir Mubashar,
  • Manzar Masud,
  • Muhammad Mughees Abbas Dogar,
  • Muhammad Saad,
  • Sadaqat Ali

摘要

This study investigates the enhancement of impact resistance of conventional honeycomb structures through the incorporation of an aluminium grid and polyurethane foam, resulting in the development of a hybrid honeycomb core (HHC) sandwich panel. Impact testing was conducted using a drop-weight method at energy levels of 30 and 45 J to compare the impact performance of HHC panels with the honeycomb core (HC) panels. The response of the sandwich panels in terms of force–displacement and force–time was recorded. Damage characterization was performed on the impacted panels to evaluate both visible and invisible damage and to determine damage mechanisms such as delamination, matrix cracking, core crushing, and core buckling. The experimental results demonstrated that the HHC sandwich panels exhibited up to 28% higher peak force and 35% lower indentation depth compared to HC core panels, indicating significantly enhanced impact resistance and energy absorption. The location of impact also played an important role in the impact resistance of the panels as the underlying damage mechanisms changed based on the impact on the foam area or on the reinforcement grid. The findings provide practical guidance for engineers in selecting or designing sandwich cores based on performance needs such as perforation resistance, stiffness, or energy dissipation.