Failure analysis of metal-polymer-metal sandwich panels with wire mesh interlayers: Finite element modeling and experimental validation

Vacuum hot pressing of a thermoplastic core and metal skin sheets resistance welded to wire meshes is used to fabricate high interface strength metal-polymer-metal sandwich panels. The wire mesh strongly bonds with polymer core from material interlocking and it bonds with metal skin from welding. A finite element (FE) model is developed for characterizing the deformation behavior and failure of fabricated sandwich panels. While, a continuum ductile damage model is used to characterize failure of layers in stretching, a cohesive zone model is used to characterize interface failure. The FE model is validated using tensile tests, peel tests, double lap shear tests, and V-bending experiments. Good match is seen between simulations and experiments. In V-bending, spring back as well as debonding is correctly predicted. Sandwich panels fabricated in this work form an attractive alternative to adhesively bonded panels. The developed finite element model can be used for forming analysis of developed sandwich panels and for optimizing the panel architecture.