Composite Materials and Testing: Research Paper on Sandwich Panels

Composite Materials and Testing 1
Research Paper on the Composite Materials and Testing
A Research Paper on Sandwich Panels By
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Composite Materials and Testing 2
TABLE OF CONTENT
Item Page
Abstract............................................................................................3
INTRODUCTION................................................................................4
METHODOLOGY........................................................................................................4
Overview..................................................................................4
Panel Option..............................................................................6
Use of Different Cores and Ply counts................................................7
Method of Construction..................................................................9
Test Methods.............................................................................10
ANALYSIS.......................................................................................11
Overview..........................................................................................................11
Testing and Performance vs Theory.................................................................11
Motorsport Applications...............................................................14
Likely Failure Applications ............................................................16
Cost of Components ...................................................................16
CONCLUSION...................................................................................16
RECOMMENDATION..........................................................................17
Bibliography.......................................................................................18

Composite Materials and Testing 3
Abstract
The objective of this paper is to discuss the process and method of manufacture, test
and relation to motorsports of the sandwich panels. A sandwich panel is any structure made
of thin skin-layer, a low-density core, and three layers bonded to each side. Sandwich panels
are utilized in areas where a combination of low weight and high structural rigidity is a
necessity. There are numerous options for the panel depending on the material used for
stiffeners of the sandwich panels, the panel options include fibre, resin, and fabrics. The
major core materials used in the construction of the sandwich panels include honeycomb
material and polystyrene foam. The polystyrene foam should not be used together with
polyester resin since the styrene in the compound dissolves the foam. The honeycombs are
normally made from either Nomex paper of aluminium and it is important to note that these
materials are virtually weightless but effectively the increases the laminate's thickness
without adding any weight.

Composite Materials and Testing 4
INTRODUCTION
This report paper is about the practising and learning the construction of sandwich
panels through testing different panels to determine their sandwich core material and ply
count. The objective of this paper is to discuss the process and method of manufacture, test
and relation to motorsports of the sandwich panels. For these objectives to be achieved, there
is need to research areas of motorsports application in which the sandwich panels will be
used. Some of the subtopics discussed in this research paper include construction of diverse
sandwich panel types, materials used for ply and core quantities, cons and pros of different
methods, tests method used, and data gained.
The sandwich panels are types of laminated composite material. Composite structures
in various forms have been used for hundreds of years. Technically, composite means a
combination of materials, the early ships used the combination of metal and wood just like
the early cars and aircraft. A sandwich panel is any structure made of thin skin-layer, a low-
density core, and three layers bonded to each side. Sandwich panels are utilized in areas
where a combination of low weight and high structural rigidity is a necessity. There are two
types of sandwich panels, namely Aluminium composite panels (ACM) and Structural
Insulated Panels (SIP) (Akovali, 2013).
METHODOLOGY
Overview
Fibre Reinforced Plastics (FRP) have been adopted widely in the industry of
motorsport for numerous motives, but the major reason being because they can be moulded
into a virtually limitless variety of shapes comparatively easy. The top team have invested in
a great deal of equipment to subject their composites material and components in the quest
for increased knowledge that they hope will enable improved competitiveness. The