Investigation into high-speed impact response of composite sandwich structures

Sandwich structures composed of top and bottom face sheets and an inner core are commonly used for energy-absorbing applications, mainly because of their superior stiffness-to-weight ratio and crashworthiness. Despite extensive studies on the ballistic behavior of monolithic and composite materials, limited research has focused on hybrid sandwich structures combining lightweight and ductile materials like thermoplastic polyurethane (TPU) with high-strength aluminum. This study aimed to numerically establish the ballistic limit velocities and the penetrating and perforation resistances of composite sandwich structures to address this gap. The sandwich panels were manufactured from thermoplastic polyurethane (TPU) and aluminum (Al) 2024-T351 as core and face sheets/skins, respectively. The panels were subjected to an impact to investigate the effects of various thicknesses of their face skins and core on high-speed impact resistance. From the results obtained, it was evident that the numerical models simulated experiments with high accuracy. The impact and damage resistances of the composite sandwich structures increased with the thicknesses of their core and face sheets. The resistance of the structure increased by 19% by increasing the thickness of face sheets from 1.2 to 2.0 mm. Similarly, the resistance of the composites can be increased by 44% by increasing the core thickness from 20 to 50 mm. Therefore, it can be established that the impact resistance of the composite sandwich structures depended on the thicknesses of their core and skins. The investigated performances of the different composite sandwich structures should guide their choice for various industrial applications.