Low-velocity impact properties of foam sandwich composites with different thicknesses prepared via thermal expansion molding process
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摘要: 热膨胀工艺能够一体化成型各种泡沫夹芯复合材料。选择初始厚度为1 mm的可膨胀环氧泡沫预浸胶，通过控制模具型腔尺寸以控制不同成型压力制备4种不同厚度的泡沫夹芯板。以10 J和42 J冲击能量研究热膨胀工艺和芯材厚度对泡沫夹芯复合材料低速冲击性能的影响。通过ABAQUS有限元分析、超声C扫描对比试验数据分析了不同试样的损伤模式。通过冲击后压缩试验分析了不同试样的损伤容限。结果发现更高膨胀倍率的泡沫芯子，产生更低的膨胀力，泡沫夹芯板的抗冲击强度降低，但结构具有更优异的吸能效果。高能量和低强度的泡沫芯子都会导致蒙皮更高的损伤程度。试样在10 J能量冲击后的压缩强度衰减率为8.2%，而42 J能量冲击后的压缩强度衰减率达到38.2%。成型压力和芯子的厚度对泡沫夹芯板的损伤容限影响很小。研究确定了热膨胀工艺成型泡沫夹芯复合材料具有高的结构和抗冲击性能可设计性。Abstract: Thermal expansion molding process is expected to be integrated to form various foam sandwich composites. The expandable epoxy foam prepreg with an initial thickness of 1 mm was selected, and four kinds of foam sandwich panels with different thicknesses were prepared by controlling the mold cavity size and different molding pressures. The impact energies of 10 J and 42 J were used to study the effects of thermal expansion process and core thickness on the low-velocity impact properties of foam sandwich composites. The damage patterns of different specimens were investigated by ABAQUS finite element analysis, ultrasonic C-scan and the test data. Compression after impact tests were conducted to investigate the damage tolerance of different specimens. The results show that the foam core with higher expansion rate produces lower expansion force, and the impact strength of the foam sandwich board is reduced, but the structure has better energy absorption effect. Both high impact energy and low strength foam cores lead to higher damage degree of the skin. The compression strength decay rate of the sample at 10 J impact energy is 8.2%, and the compression strength decay rate of the sample at 42 J impact energy is 38.2%. The forming pressure and the thickness of the core have little effect on the damage tolerance of the foam sandwich plate. The high designability of structural and impact resistance properties of foam sandwich composites formed by thermal expansion process was determined.
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图 1 (a) 热膨胀成型工艺制备泡沫夹芯复合材料示意图；(b) 模具及试样铺层示意图；(c) 泡沫膨胀不同倍率制备的夹芯复合材料断面图
Figure 1. (a) Schematic diagram of foam sandwich composites prepared via thermal expansion molding process; (b) Schematic diagram of mold and sample lay-up; (c) Sectional diagram of sandwich composites prepared by foam expansion at different ratios
图 2 热膨胀泡沫膨胀力测试方法：(a) 高低温试验箱和万能试验机；(b) 试验箱内加载示意图；(c) 试验试样及模具示意图
Figure 2. Test method of expansion pressure of thermal expansion foam: (a) High and low temperature test box and universal testing machine; (b) Schematic diagram of loading in the test box; (c) Schematic diagram of test sample and mold
图 3 不同泡沫夹芯板(X1、X2、X3、X4 )制备工艺曲线
Figure 3. Preparation process curves of different foam sandwich panels (X1, X2, X3, X4 )
图 4 (a) 冲击实验试样；(b) 冲击实验试样夹持示意图；(c) 冲击后试样超声C扫描示意图
Figure 4. (a) Impact test samples; (b) Clamping diagram of the impact test samples; (c) Ultrasonic C-scan diagram of the samples after impact
图 6 冲击后压缩(CAI)试验示意图
Figure 6. Schematic diagram of compression after impact (CAI) test
图 7 X1~X4试样在10 J冲击能量下得到的载荷-位移曲线(a)、冲击能量-时间曲线(b)、位移-时间曲线(c)、峰值载荷和吸收能量的柱形图(d)
Figure 7. Load-displacement curves (a), impact energy-time curves (b), displacement-time curves (c) and bar graph of peak load and absorbed energy (d) obtained for X1-X4 samples at 10 J impact energy
图 8 X1~X4试样在42 J冲击能量下得到的载荷-位移曲线(a)、冲击能量-时间曲线(b)、位移-时间曲线(c)、峰值载荷和吸收能量的柱形图(d)
Figure 8. Load-displacement curves (a), impact energy-time curves (b), displacement-time curves (c) and bar graph of peak load and absorbed energy (d) obtained for X1-X4 samples at 42 J impact energy
图 9 X1~X4试样在10 J冲击能量下的宏观表面失效模式、局部放大图和应力云图
Figure 9. Macroscopic surface failure modes, local magnification and stress clouds of X1-X4 samples at 10 J impact energy
S—Stress (MPa); SNEG—Surface negative
图 10 X1~X4试样在42 J冲击能量下的宏观表面失效模式、局部放大图和应力云图
Figure 10. Macroscopic surface failure modes, local magnification and stress clouds of X1-X4 samples at 42 J impact energy
图 11 10 J冲击能量得到的试样正面位移云图：(a) X1；(b) X2；(c) X3；(d) X4
Figure 11. Pit depth on the front obtained by 10 J impact energy: (a) X1; (b) X2; (c) X3; (d) X4
U—Displacement (mm)
图 12 42 J冲击能量得到的试样正面位移云图：(a) X1；(b) X2；(c) X3；(d) X4
Figure 12. Pit depth on the front obtained by 42 J impact energy: (a) X1; (b) X2; (c) X3; (d) X4
图 13 X1~X4试样超声C扫表面损伤形貌：(a) 10 J正面；(b) 42 J正面；(c) 42 J反面
Figure 13. Surface damage morphologies of ultrasonic C-scan for X1-X4 samples: (a) 10 J front; (b) 42 J front; (c) 42 J back
图 14 不同试样在10 J冲击能量下的表面损伤云图(纤维拉伸、纤维压缩、基体拉伸和基体压缩)
Figure 14. Surface failure modes of different samples under 10 Jimpact energy (Fiber tensile, fiber compression, matrix tensile and matrix compression)
图 15 不同试样在42 J冲击能量下的表面损伤云图(纤维拉伸、纤维压缩、基体拉伸和基体压缩)
Figure 15. Surface failure modes of different samples under 42 J impact energy (Fiber tensile, fiber compression, matrix tensile and matrix compression)
图 16 X1~X4试样在冲击前(a)、10 J冲击能量(b)、42 J冲击能量(c)下得到的压缩载荷-位移曲线和峰值载荷柱形图(d)
Figure 16. Compression load-displacement curves of X1-X4 samples obtained at before impact (a), 10 J impact energy (b), 42 J impact energy (c) and bar graph of peak load (d)
图 17 不同试样冲击后压缩试验得到的宏观表面失效图
Figure 17. Macroscopic surface failure modes obtained from compression after impact tests for different samples
图 18 不同试样冲击后压缩试验得到的宏观断面失效图
Figure 18. Failure modes of macroscopic sections obtained from compression after impact tests for different samples
表 1 有限元分析(FEA)相关的材料参数
Table 1. Material parameters related to finite element analysis (FEA)
Materials Density/
(kg·m−3)Tensile strength/MPa Young's modulus/MPa Compressive strength/MPa Poisson's
ratio vShear strength τ/MPa Shear modulus G/MPa X1 M-1 318 7.98 395 3.47 0 3.91 62.28 X2 M-1 162 4.68 201 2.31 0 1.95 39.29 X3 M-1 109 2.23 170 1.95 0 1.64 31.26 X4 M-1 78 1.34 113 0.99 0 1.08 21.17 805 (XT) 61340 (E1) 509 (XC) 0.04 (v12) 112 (S12) 7600 (G12) CFRP 1580 805 (YT) 61340 (E2) 509 (YC) 0.30 (v13) 59 (S13) 2700 (G13) 50 (ZT) 6900 (E3) 170 (ZC) 0.30 (v23) 59 (S23) 2700 (G23) Cohesive 2000 — 1200 — 0.32 — 385 Notes: XT, YT, ZT—Tensile strength of the three directions of CFRP; E1, E2, E3—Young's modulus of the three directions of CFRP; XC, YC, ZC—Compressive strength of the three directions of CFRP; v12, v13, v23—Poisson's ratio; S12, S13, S23—Shear strength; G12, G13, G23—Shear modulus; CFRP—Carbon fber reinforced polymer; M-1—Epoxy resin based rigid foam with thermal expansion function. 
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表 2 冲击有限元分析模型数据
Table 2. Finite element analysis model data of impact test
Sample number Part Thickness Mesh style Mesh number X1 CFRP 2 mm+2 mm
2 mm
0SC8R 141880 Foam C3D8R 14188 Cohesive COH3D8 7094 X2 CFRP 2 mm+2 mm
4 mm
0SC8R 141880 Foam C3D8R 14188 Cohesive COH3D8 7094 X3 CFRP 2 mm+2 mm
6 mm
0SC8R 141880 Foam C3D8R 14188 Cohesive COH3D8 7094 X4 CFRP
Foam
Cohesive2 mm+2 mm
8 mm
0SC8R
C3D8R
COH3D8141880
28376
7094Notes: SC8R—8-node quadrilateral in-plane general continuous shell elements; C3D8R—Linear 3D reduced integration solid elements; COH3D8—Cohesive element.
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表 3 X1~X4试样冲击试验损伤数据对比
Table 3. Comparison of impact test damage data for X1-X4 samples
Sample number Stress/MPa (FEA) Displacement/mm Area of damage/mm2 Experiment FEA Error/% Experiment FEA Error/% C-scan Error/% X1-10 J 960 2.71 2.45 9.59 39.57 45.23 14.30 44.16 11.60 X2-10 J 971 2.92 2.68 8.22 47.76 54.37 13.84 54.08 13.23 X3-10 J 1086 3.20 3.16 1.25 58.06 67.89 16.93 65.01 11.97 X4-10 J 1111 3.26 3.38 3.68 69.36 80.21 15.64 76.94 10.93 X1-42 J 1119 6.91 6.76 2.17 114.93 136.64 18.89 134.71 17.21 X2-42 J 1067 7.67 7.63 0.52 145.19 167.59 15.43 160.52 10.56 X3-42 J 1028 9.04 9.19 1.65 206.02 238.96 15.99 229.54 11.42 X4-42 J 1055 11.44 11.08 3.15 298.49 353.25 18.35 320.31 7.31
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