Cell-filling reinforced materials for improving the low-velocity impact performance of composite square honeycomb sandwiches: Polymethacrylimide foam vs. aluminum foam

In this study, PMI foam and aluminum foam are used as reinforcement materials for filling the cells of carbon fiber-reinforced composite square honeycomb sandwiches (CSHSs), forming two new sandwich structures, namely, PMI foam-reinforced CSHS (PRCSHS) and aluminum foam-reinforced CSHS (AFRCSHS). The impact resistance and residual flexural performance of the composites is compared by using low-velocity impact (LVI) and three-point bending (3 PB) experiments. The different impact energy levels of 25 J, 50 J, 65 J, and 100 J are applied. The impact and bending failure process and failure mechanism are analyzed using a combination of industrial computed tomography (ICT) and scanning electron microscopy (SEM). PRCSHS and AFRCSHS are compared for various enhancement effects and their resulting lightweight features. The residual flexural and impact resistance properties of the two sandwiches improved significantly. Compared with CSHS, the maximum impact load of PRCSHS and AFRCSHS increased by 115.6% and 78.9%, respectively. Moreover, the impact energy absorption, residual flexural load, and residual flexural energy absorption increased by 30.9% and 21.3%, 80.7% and 58.5%, and 173.1% and 84.3%, respectively. The PRCSHS was noticeably lightweight, but AFRCSHS was not sufficiently lightweight. The qualitative results of comparison of the two reinforcement materials in this study can be extended to other carbon fiber-reinforced all-composite 2D honeycomb sandwiches.