ABSTRACT

Sandwich composites are used for Variety of applications and

uses in modern days. The main advantage of composite is
lightweight, more durability and corrosion free material.
Sandwich composites generally composed of hard core materials
covered by face sheets of any fiber. The main disadvantage of the
sandwich composite are the separation of the face sheets away
from the core materials.
In this paper some new ways are discussed to improve the
characteristics of sandwich composite and to overcome the
problems mentioned above i.e. infusion of carbon Nano fibers. In
this experiment polyurethane foam is used as a core along with
CSM and WRM glass fiber for the face sheets. Sheet 1 –
conventional sheet, sheet 2- sheet with core modification and
sheet 3- sheet with core modification and infusion of carbon Nano
fiber into glass fiber using vacuum infusion process. After the
vacuum infusion process, the sample sheet are cut into pieces as
per the guidelines of ASTM standards and they will be tested in
universal testing machine for compressive, flexural and shear
strength. The addition of carbon Nano fiber has increased the
mechanical characteristics and strength of the composite and it
also reduces the problem of de-bonding as compared to the
conventional sheet.
 CHAPTER 1
INTRODUCTION
1.1 Composite Material
Composite materials are made of 2 and more dissimilar material having
different chemical or mechanical characterization combined together to
produce a material with properties different than the individual
components that are used. The individual component don’t lose its effect
but combines together effectively to improve the overall characteristics of
the product. They are generally made by attaching two or more thin and
stiff layers to a relatively light cores,it is attached to the skin with
combining compounds. A different number of core material are used in
composites.
Composite materials are mainly used to increase the strength, efficiency
and durability. Composite materials are currently being preferred over
traditional materials because they are less expensive, have better strength-
weight ratio and are more efficient.They are used for different number of
applications such as aerospace, marine, transport, construction and wind
energy etc.
 Figure 1.1: composite sheet

1.1.2 Benefits of composites

Reducedweight:
Composites provide good mechanical properties with much lower weight
than traditional materials. Less weight equals better efficiency and lower
transport costs.

(a)
 (b)
Figure 1.2: (a) & (b) examples of weight loading in sandwich
composite

Figure 1.3: comparison of strength of different materials

Increasedstrength

For applications that require high strength materials at low weight

composites can be made to be strong as well as light in these situations.
Composites can be made to be strong in one specific region or direction
whereas metals are uniformly strong throughout in all directions which
only increases its weight and makes it more heavy.

Design flexibility
Composites can be made into any shape with the help of the mould. Its
shape depends only on the shape of mould. This give composites the
freedom of design, its shape can be changed until the last stage of
manufacture where the get their final shape. This helps in making smooth
and nonlinear designs.
Corrosion resistance
Composites can withstand damage from harsh weather and corrosive
chemicals. The components built with sandwich composites require very
low maintenance.
Reduced environmental impact
Composites benefit the environment in many ways. They require very
less raw materials compared to traditional materials. Less raw materials
means less transportation and reduced fuel consumption. They also
require lower maintenance and have longer lifespans hence less raw
material required for repair and renewal of the parts.
Nonmagnetic
Composites are nonmagnetic because they don’t contain any metal and
can be used around magnetic materials.
Radar transparent
Composite materials are transparent and allow radar signals to pass
through them which them good for use with radar both in ground and in
air.
Low thermal conductivity
Naturally the composite materials are lower thermal conductivity
specimens, so they are extensively used in the insulation of cold storage
containers.
High impact strength
Due to the inter molecular arrangement of the composite and the hardness
of composite gives it high impact strength to withstand higher forces.
Customized surface finish
The surface of the composite can be decided according to the application
and the need of the work or users decision.
1.2 Classification of composites
1.2.1 Classification based on matrix material
1.2.1.1 Polymer Matrix Composite (PMC)
Polymers have established them as engineering structuralal because they
are light in weight, have good mechanical properties and can also be
processed very easily. They have a simple fabrication method and are low
in cost. They are composed of matrix medium mostly thermoset or
thermoplastic and dispersed phase. Thermosets are usually liquid and are
mostly moulded to get their solid form. Upon curing they develop a three
dimensional well bonded structure. Once they are hardened they will
decompose other than melting. Thermosets are usually stronger than
thermoplastic because of their well bonded three dimensional structure.

1.2.1.2 Metal Matrix Composites (MMC)

Metal Matrix Composite is a composite having two or more constituent
parts with one part being an organic material or ceramic and the other part
strictly being a metal. Metal matrix is dispersed by a reinforcing material
to make an MMC. The matrix can react with the reinforcement material
so to prevent it the surface of the reinforcement material is coated. To
synthesise aluminium matrices carbon fibre are mostly used because
aluminium matrices have low density and more strength. The matrix
material will be mostly a lighter material with good strength like
aluminium or titanium for structural applications. For usage in high
temperatures cobalt alloys are mostly used.
1.2.1.3 Ceramic Matrix Composites
Ceramics matrix composites belong to group of composite materials as
well as ceramics. Their matrices contain ceramic fibers like carbon and
carbon fibers. Ceramics have strong ionic bonds in most cases and in few
covalent bonds. For structural applications above temperatures of 1500c
mostly ceramic matrices is employed because of their high compressive
strength and stability at higher temperatures. This makes ceramic matrices
good for higher temperature applications.
1.4 SANDWICH COMPOSITES:
Sandwich composite is made up of two thin & stiff sheets that surrounds
a thick and lightweight core. These composites are low in weight but also
stiff. The core is attached to the skins with the help of an adhesive. Some
of the properties of sandwich composites are
They have high strength to weight ratio
They are very light weight
They are very cost effective compared to other materials

Need for sandwich composites:

Sandwich composite is coming popular because they provide the same
mechanical properties of conventional materials with relatively less
weight. They are more efficient when compared to traditional materials.
They have reduced impact over the environment and they require much
less raw materials when compared to traditional materials. Two separating
materials with a light weight material in between increases the strength
and stiffness. The strategic selection of core material can change the
characteristic of the material such as low water absorption, thermal
insulation and sound properties etc.

Figure 1.4: sandwich laminate

Advantages of sandwich composites:
 Corrosion resistance
 Sound insulation
 Thermal insulation
 Light weight
 Freedom in design
 Sandwich composites consists of :
 Face(outer and inner skins):
The faces surround and protect the light weight core. The faces take up
the tensile & compressive stresses over the sandwich composite. In
conventional materials steel & aluminium are used as faces. Fibre glass
or glass reinforced plastics is mostly used as faces in composite materials.
 Core:
The purpose of the core is to support the skin so they do not break under
pressure. The core is usually very thick and also light in weight in a typical
sandwich composite. To maintain the rigidity of the composite the core
must be stiff more to maintain equal distance between the skins.

 Adhesive:
Adhesive is the material that attaches the face with the core and keeps
them intact. The adhesive must be able to carry shear and tensile stresses.
An adhesive should be able to withstand the same amount of shear stress
as the core. It is of most importance that the skins adhere properly to the
core.
1.5 MANUFACTURING TECHNIQUES:
1.5.1 Resin infusion process:
Resin infusion moulding (RTM) is also known as liquid moulding. It is a
simple process. It has a two part closed mould that is either made of metal
or a composite material. The reinforcement material is placed in the mould
and it is closed. Then the resin & catalyst is mixed together and pumped
into the mould at low pressure through the ports for preforming. Low
viscosity resin are used for this process to preform quickly and for even
spreading of the resin before curing. The resin and mould can be heated if
it is necessary. This method produces a mould without the need for an
autoclave. Most applications use 2 part epoxy formula. The 2 parts is
mixed before they are inject into the mould. This method produces
dimensionally accurate parts with good surface finish and surface detail.
Void content on RTM parts is low measuring up to 0 to 2 percentage.

1.5.2 Vacuum assisted resin transfer moulding:

In this type of moulding the resin drawn to through vacuum only and not
through the pump which is under pressure. VARTM does not need heat
or pressure. It also requires low cost tools and large parts can be produced
in a single attempt. In this process the fibre reinforcements are placed
along the mould and it is covered and sealed to form a vacuum. The resin
enters the setup with the help of carefully laid out tubes to and from the
setup. The vacuum fills the resin towards the setup through the tubes that
are placed. Fibre content in the finished product can be up to 75 percent.
Two bags can also be used in this process known as double bag infusion.
This method is used by NASA and boeing to produce quality aerospace
parts.

Figure 1.5: preparing of the sandwich composite using vacuum

1.6 Applications of composites:

Composite materials have a number of applications because of different
characteristic properties. They are used in variety of fields as transport,
wind energy, marine, construction, subsea etc. Since it has a many range
with applications it is used and manufacturering according to the needs
and demands. Plywood is one of best examples for the application of
sandwich composites. Sandwich structures are currently being used in
railways for interior panels as structural panel that separates coaches and
as an energy absorbing material. It is also being used in space technology.
The sandwich composites can be used in many platforms and ways:
 As energy withstand material
 For carriage interior panels and for decoration of automobile interiors
 As structural panels for the separating floor of coaches.

(a) (b)
Figure 1.6: applications of sandwich composites in
cars and aircrafts
 CHAPTER 2
LITERATURE REVIEW
U.K Vaidya et al. This paper tells about an new way of infused hollow
epoxy infused core sandwich composite structure that gives several
purposed benefits to addition of advantages of lightweight and bending
stiffness. with comparison to conventional foam and honeycomb shaped
cores, infused core gives a route rods, electronic assemblies, and storage
of fuel and fire resistant foam, are among the other provided benefits. In
this research, the low speed impact response of infused sandwich core
composite was studied. The thickness of infused and function of embed
glass epoxy sandwich cores are considered in this research. The low speed
impact result showed that hollow and function embedded integrated core
suffer a local damage level limited to system of core of the members in
the aftermath of impact. The highest forces raises under compression and
low speed impact were in going along Euler column buckling statement.
Stack arrangement of the core was an efficient way of developing
functions and limit to the low speed impact causes in the sandwich plate.
The function embedded cores provides heightened low speed impact
resistance because of more addition of energy absorption methods.

Nitin Kulkarni et al. Sandwich boards are produced utilizing another

infusion pitch utilizing exchange forming technique. glass fiber with
epoxy saps are utilized as face sheets in a poly urethane froth center.
Testing is performed in a 3 point flexure mode utilizing another structure
apparatus in which the confined harm was insignificant. more exhaustion
information are created for the S– N chart and split improvement was
observed as building up an example for froth life expectation technique.
The primary indication of harm event is center layer partition parallel to
hub of the pillar. This detachment spreads gradually to the top surface and
in the long run reaches profoundly while shear opening happen and after
that create in shaky manner which results in example harm. A weariness
investigation dependent on the break advancement is created and
dissected with different trials.
V.Rizov et al. Due to the high firmness and quality weight proportion
composite sandwich structures is demonstrating their utilization in a huge
no. of utilizations in different fields, for the most part in car, air
transportation and structural building. The fundamental burdens of
sandwich structure is the disappointment of burden minding vitality
because of harms. The primary motivation behind the present thing is the
investigation of consequence of PU froth sandwich composite plates to
harm. Test tests are performed by a ball formed Intron general test
machine in removal control by cross head speed of 2 millimeter for each
moment. The test examples are fabricated by utilizing hardened froth with
thickness of about 50millimeter and glass fiber strengthened composite
material sheets of thickness 2.4 mm. The heap removal result for stacking
alongside emptying steps are recorded along the testing. width of harmed
zone on the sheet was estimated in the emptying. A numerical esteem
demonstrating of the space reaction in symmetrical conditions are
performed utilizing the limited component PC examination. The reaction
of the froth material is characterized by crushable from hanging
alternative. The geometrical linearity was considered utilizing the choice.
The principle part of the examination is to know the burdens and strain
and chiefly greatness of the split of the center. A decent likeness between
the limited component demonstrating examination and the test
information investigation was gotten. The present work ought to be
considered as a one stage towards building up a progressively right
numerical model equipped for improving mechanical conduct of
sandwich structures.
Nikhil gupta, Eyassu Woldesenbet Particles of a similar size however
with 5 distinctive span esteems are mostly used to create 5 kinds of
various manufactured sheets. These five sorts of sheets are utilized as the
center material to make sandwich composites. 3 and 4 point bowing and
short bar shear quality tests are done to discover the flexural normal for
syntactic center sandwich composites. The reasons for change in empty
particles sweep in flexural property of the sandwich composite are found.
The outcomes are demonstrated that the 3 and 4 point twisting test,
disappointment is kept up by ductile property of the center and the quality
isn't diminished by the empty particles sweep proportion. Shear split
happen in short bar amid shear test, which makes the empty particles span
a significant point in finding the shear quality of the sandwich composites.

Basir shafiq, Amilcar Quispitupa microscopic analysis of the crack and

sheet has been observed to the core. The more and more crack is propagate
through the core there will br more Multiple crack starting sites are
observed under fatigue loading conditions in the observation of the notch
tip. Both modes one and 2 cracks was core observed between the spaces
of sheets and core

CHAPTER 3
SCOPE AND OBJECTIVE
Sandwich composites composed of layer of core and face sheets which offers high
stiffness, better strength, and has high strength to weight ratio, offers flexibility,
resistance to corrosion, nonmagnetic, low thermal conductivity and high impact
strength. It has also few limitations like delamination’s and failure due to out of plain
loading. This project aims at improving mechanical characteristics of the sandwich
composite such as compressive and shear strength and reduce the debonding that
takes place between the core and the face sheets are separated during loading. In the
current work it is proposed to fabricate three types of sheets by vacuum infusion
process as mentioned below

Sheet 1: conventional sandwich composite

Sheet 2 : sandwich composite with infused nanoparticles

Sheet 3 : Nano phased sandwich foam with Nano phased resin

The core is to be modified by the infused nanoparticles which act as a barrier to the
propagation of the cracks. Also the Nano phased resin added in the sheet 3 also
improves the mechanical characteristics of the composite.

The manufactured sheets are tested for different findings such as shear strength,
flexural strength, compressive strength. The impact and the reason of the
nanoparticles in increasing the strength also to be studied.

mechanical properties of 3 type of sheets are to be compared and analyzed to

understand the effect of core modification and carbon Nano fiber addition.

CHAPTER - 4
METHODOLOGY
4.1 MATERIAL SELECTION:
4.1.1 CORE:-
Polyurethrene belongs to the family of plastics and polymers and its foam
is used as the core for the sandwich composites. Its foam structure can be
either be rigid or flexible. It is manufactures by mixes two chemicals
polyol and isocyanate in a ratio of 2:2.5. Polyol has a density of 36 kg/m3
and isocyanate has a density of 40 kg/m3. Wax is applied on the surface
of the mould used to prevent the foam from sticking to it during the
removal of the foam. They are mixed together and poured in a mould of
required dimensions (200*200*26) and closed. They are allowed to stay
in the mould for up to 15 minutes after which the PU foam hardens . It
then rises up and takes the shape of the mould. The foam is removed
from the mould and cut into the desired shape.

FIGURE 4.1: POLYURETHANE FOAM

4.1.2 FACE SHEETS:-

Three glass fibres are stacked upon the PU foam on both the sides
of the sheet. CSM and WRM are two types of glass fibres used
.
CSM(Chopped Strand Mat) has a value of 450 gsm and is used in
the middle layer and WRM(Woven Roving Mat) which has a
value of 600 gsm is used in the outer two layers on each side of
the foam. They are used to increaseing the high impact strength
and flexural strength of composites. They are very compatible
with resins. They are also very permeable to resin flow. Woven
Roving Mat is available in different widths , weights and weaves
for different applications. It is made by continuous roving and
interweaving of glass fibres.

CSM is made by random reinforcement of fibres. It uses a

monomer of styrene to hold its Chopped Strands together in one
place. Unlike Woven Roving Mat it is not compatible with resins
and not very permeable to resins.

Figure 4.2:woven roving mat figure 4.3:chopped strand

mat

4.1.3 RESIN AND HARDENER:-

The resin and hardener used were Araldite LY556 epoxy resin and
HY951 respectively as they are most suitable for vaccum infusion
process. The properties of which are as follows:
Table 4.1: properties of araldite LY 556

Properties of hardener(HY951):-
Improvement of mechanical strength.
more resistance to chemical and atmospheric degradation.
Excellent electrical properties.

4.1.4 CARBON NANO FIBER:-

Carbon has great bonding ability. They are simply able to raise the
strength of any structure due to their bonding properties. It also has great
bonding flexibility. which helps in the formation of various stable Organic
and Inorganic Molecules. . Carbon has different number of allotropes like
graphite and diamond. The arrangement of carbon widely changes the
properties of the compound. CNF are microscopic particles which are
present in the nanometre scale. They are mostly used with composite
materials because of their ability to increase the mechanical strength.
They are also very flexible and used for a variety of applications like
electromagnetic protecting and enhancement of mechanical strength. The
properties of carbon Nano fibre are as follows:
 Figure 4.4: cell structure at Figure 4.5: cell structure
10000x at 5000x

4.2 FABRICATION OF SHEETS

4.2.1 TYPES OF SHEETS
Three types of sheets are manufactured using Vacuum infusion
process. They are
TYPE 1:-PU foam with cavities with cavities in them using resin
and hardener.
TYPE 2:-Carbon Nano fibre infused PU foam along with resin and
hardener.
TYPE 3:-Carbon Nano fibre infused PU foam with resin and
hardener infused with Carbon Nano fibre.
The schematic diagram for the layers of sandwich composite:

CSM
WRM
CSM
PU FOAM
(Thickness : 20 mm)
CSM
WRM
CSM

Figure 4.6: schematic diagram of composite sheets

4.2.2 VACCUM INFUSION PROCESS:-
It is a process that uses pressure to force the resin into the composite.
The materials are arranged together in the mould and vacuum is applied
on it before the resin is allowed to flow through it. The resin is sucked
into the composite once the vacuum is completed through well laid out
tubes.
Vacuum infusion process has some advantages over other processes
due to a number of reasons. They are:-
Even flow of resin:-
Vacuum infusion process ensures even flow of resin throughout the
composite by the laying of tubes carefully at the centre of the mould. The
pressure also is a factor in the even spreading of mould throughout the
mould. It also prevents the wastage of resin by using it efficiently. No
amount of resin is wasted in the process as it is carefully spread across the
entire mould evenly.

FASTER PROCESS:-
Vacuum infusion is a faster process compared to other process. One of the
key reasons to this is because of the vacuum which allows the faster flow
of resin throughout the mould. The composite also dries relatively fast in
this process. So it is more faster and efficient as the resin is spread out
uniformly throughout.
 STEP 1:-
The setup is cleaned by pouring acetone on it and allowing it to dry for a
few seconds after which it is removed using a scrapping plate along with
the impurities. This is done twice or three until the setup is clean. Then
wax is applied on the glass setup for 10 mins after which it is removed
and re applied again. Then the entire mould region is sealed off using a
sealant tape.

 STEP 2:-
The PU foam is drilled with small 5mm holes throughout the entire
dimension of the sheet in regular intervals. This is done to ensure the
proper flow of resin through the sheet. Three glass fibers are stacked upon
the PU foam on both the sides of the sheet. CSM and WRM are two types
of glass fibres used.
CSM(Chopped Strand Mat) has a value of 450 gsm and is used in the
middle layer and WRM(Woven Roving Mat) which has a value of 600
gsm is used in the outer two layers on each side of the foam.

 STEP 3:-
1 kg of resin is used along with 250 grams of hardener for the infusion of
each composite. The resin is mixed along with the hardener and poured in
a container to which a tube is laid out which goes to the sheet. The entire
setup is covered and tightly air sealed to prevent any leakage and to
increase the vacuum pressure which should be kept at a value above 90 to
ensure proper flow of resin.

 STEP 4:-
The resin is sucked into the setup by vacuum by means of a motor until it
is emptied. Two tubes are laid out to and from the motor and the container
to ensure even flow of the resin throughout the sheet. The setup is left to
cure for two days after which the composite is removed from the setup.
 Figure 4.7 : basic layout for vacuum infusion

CHAPTER 5

MECHANICAL CHARACTERIZATION

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) is an

organization that provides technical testing standards for wide range of
materials to ensure the safety and the performance of the materials.
according to the ASTM standards the dimensions, model type, face sheet
constituents, and the type of test are mentioned in the tabular 5.1.

TABLE 5.1: Dimensions of the specimens

The purpose of the ASTM standards are the development of testing
techniques for many industries with idea of improving the performance and
safety for wide amount of material and services.

In each specimen three samples will be cut out and the samples are tested
according to the ASTM standards and the results are obtained for each
sample of each specimen and they are compared and the results were
analyzed.

5.2 CORE SHEAR CHARACTERS OF SANDWICH CONSTRUCTION BY

FLEXURE TEST (ASTM C393)

The ASTM C393 gives the procedure to find the properties of the flat
composites. The test method contains of 3 or 4 point bending
configurations for load and deflection tests and measurement. Using
flexure test many properties can be found such as stiffness, the shear
strength and modulus and the facing strength. This can also be used to
calculate the ratio of core to face bond strength. the tangent modulus of
elasticity, often called the MOE.

For this experiment UTM machine of capacity of 100KN and the

crosshead speed of 2.5mm/min. the span length is 150mm, width is 60mm
and thickness 24mm according to ASTM guidelines
 (a) (b)
Figure 5.1: 3 point beam flexure test (a) general layout (b) testing picture

Figure 5.2 universal testing machine for beam flexure test

The point of failure and the type of failure are determined and the flexural
value is found from the provided formulas and the graphs value provided.
 (a) (b)
Figure 5.3: specimen for beam flexure test (a) top view (b) side view

5.3 Edgewise Compression Test (ASTM C364)

This test gives a determined method of getting sandwich compressive
strength for designing the panel properties, material objectives, and it also
gives the quality of the sandwich panels. This experiment will find the
compression of the sandwich sheets by applying force parallel to the facing
sheets. This experiment is suitable for both continuous & discontinuous
bonding surfaces.

This test gives a load bearing capacity of specimen. The values are
represented either in the SI units or pounds. This test is done to inspect
nondestructive test, dimensions, accuracy measurement, failure mode and
analysis.
 Figure 5.4 : edgewise compression test

In this experiment in a universal testing machine with a capacity of

100KN and the crosshead speed of 2.5mm/min. In this test the crack
propogation and deforming of the sandwich composites are studied and
determined.
 Figure 5.5: specimen pictures for compression test

5.4 SHEAR TEST CHARACTERIZATION OF SANDWICH CORE FACE

MATERIALS (ASTM C273)

This experiment is done to find the shear strength of the sandwich

composite by using plates with load joined to outer skins. This test is also
done for discontinuous and continuous core surfaces.

First the specimen are attached to the fixtures with adhesive, then the
specimen is placed in a UTM machine with the metal attached to machine
and the specimen is sheared about 3 to 6 min or about the point of breaking

Things that can be found using shear test:

 Ultimate shear strength

 Failure mode and analysis
 Shear modulus
 Crack propagation

The universal machine with capacity of 100KN is used for the testing
with the crosshead feed of 2.5mm/min.

Figure 5.6: shear test

This experiment requires a special setup to join the specimen to the UTM
machine.

figure 5.7: shear test apparatus

 (a) (b)

figure 5.8: shear test (a) tested shear material (b)general picture

CHAPTER 6

RESULTS AND DISCUSSIONS

6.1 COMPRESSIVE TEST (ASTM C364)

The below load v/s displacement graph given below gives the
information about the comparison of compressive strength of sheet-1,
sheet-2 and sheet-3. It is clearly seen that the compressive strength of
sheets 2 &3 shows higher compressive strength than the conventional
PU foam. The nanophased foam composite shows increase in the
compressive strength than the conventional composite and the
nanophased PU foam with nanophased resin shows further increase in
compressive strength than the nanophased foam composite. Thus it is
clearly seen that the carbon nano fibers shows an incredible increase in
the compressive strength of the composites when added as an
reinforcement.

Another important change is that the addition of carbon nano fibers

makes the composite more brittle. As seen from graph the rate of
displacement is maximum for the sheet-3 composite and minimum for
the conventional type composite. Thus the addition of carbon nano
fibers makes the composite more brittle but can withstand high
compressive strength .

The compressive experiment was conducted as per the guidelines of the

ASTM standards C364 with length of 120mm, width 60mm and thickness
of 24mm.

compression test
12

10

8
LOAD(KN)

conventional
6
nano ppufoam
nano pufoam+resin
4

0
0.1 0.3 0.5 0.7 0.9 1.1 1.3 1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9
 Axial displacement (mm)

Figure 6.1 load v/s axial displacement curve for compression test

The compressive strength was calculated using the following formula as

shown in eq. (1)

….. (1)

The compressive test results from the experiment is calculated using the
above formula and corresponding bar graph is drawn below. The bar
graph shows the ultimate load for all three types of sandwich
composites. It is clear that the sheet-3 shows better ultimate load than
the conventional sandwich composite due to modification of the core
and infusion of the carbon nanofiber.
12

10
ULTIMATE LOAD(KN)

0
sheet-1 sheet-2 sheet-3
SHEET

Figure 6.2: bar graph depicting comparison of ultimate load for

compressive test
In conventional sandwich composite, it can be seen that the core and
sheet layer gets de-bonded due to compressive force. But due to infusion
of the Nano carbon fibers there is no de-bonding between core and the
face sheets and only crack was propagated through the core in the 2nd
and 3rd composites. By calculating the compressive strength using the
formula and the provided ultimate load the compressive strength of each
sandwich composite is calculated and represented in the bar graph
below. By observing the graph , it is known that the sheet-3 shows higher
compressive strength than the conventional sandwich composites.
8

7
COMPRESSIVE STRENGTH(MPa)

0
sheet-1 sheet-2 sheet-3
SHEET

Figure 6.3: Bar graph for comparison of compressive strength

As shown in the figure 6.4(a)there is a complete de-bonding of face

sheets from the core is occurred in the conventional sandwich composite
(b) due to the addition of nano particles it can be observed that there is
no de-bonding of sheets from the core but crack is propagated through
the core.

This

Figure 6.4: crack after compression test (a) type1 (b) type 2

6.2 BEAM FLEXURE TEST (ASTM C393)

The below load v/s displacement graph given below gives the
information about the comparison of flexural strength of sheet-1, sheet-
2 and sheet-3. It is clearly seen that the flexural strength of sheet-2
shows higher flexural strength than the sheet-1. The sheet-2 shows
increase in the flexural strength than the sheet-1 and the sheet-3 shows
further increase in flexural strength than the sheet-2 Thus it is clearly
seen that the carbon Nano fibers shows an incredible increase in the
flexural strength of the composites when added as an reinforcement.

From the graph details it is found that the sheet-2 shows better flexural
strength than the conventional composites. On the sheet-2, it is noted
that the rate of displacement is minimum thus, it is ductile in nature and
have more flexural strength . in case of sheet-3 , it is observed that it has
highest flexural strength than the other two composites but it is also
noted that the Nano phased resin makes the composite more brittle,
since the rate of displacement is maximum for type3 than the other two
type of composites.

The flexural experiment was conducted as per the guidelines of the

ASTM standards C393 with the length of sample as 200mm, width as
60mm and thickness as 24mm in a UTM at a constant cross head speed
of 2.5mm/min.

flexural test
2
1.8
1.6
1.4
1.2
LOAD(KN)

coventional
1
nanophased foam
0.8
nanophased foam+resin
0.6
0.4
0.2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Axial displacement (mm)

Figure 6.5: load v/s axial displacement curve for beam flexure test

The required formula for finding the flexural strength from the ultimate
load readings taken from the graph given above and the bar graph is
obtained from the found ultimate flexural load .

…(2)

1.4

1.2

1
ULTIMATE L OAD(KN)

0.8

0.6

0.4

0.2

0
sheet-1 sheet-2 sheet-3
SHEET

Figure 6.6: bar graph for comparison of ultimate flexural load

In conventional sandwich composite, it can be seen that the core and
sheet layer gets de-bonded due to flexural load. But due to infusion of
the Nano carbon fibers there is no deboning between core and the face
sheets and only crack was propagated through the core in the 2nd and 3rd
composites. By calculating the ultimate flexural load using the formula
and the provided ultimate load the flexural strength of each sandwich
composite is calculated and represented in the bar graph below. By
observing the graph , it is known that the sheet-3 shows higher flexural
strength than the conventional sandwich composites.

9
8
FLEXURAL STRENGTH(MPa)

7
6
5
4
3
2
1
0
sheet-1 sheet-2 sheet-3
SHEET

Figure 6.7: bar graph comparing flexural strength

As shown in the figure 6.4(a)there is a complete de-bonding of face

sheets from the core is occurred in the conventional sandwich composite
(b) due to the addition of Nano particles it can be observed that there is
no de-bonding of sheets from the core but crack is propagated through
the core.
 (a) (b)

Figure 6.8: specimen after beam flexure test (a) type 1 (b) type 2 sheet
6.3 SHEAR TEST (ASTM C273)

The below load v/s displacement graph given below gives the
information about the comparison of shear strength of sheet-1, sheet-2
and sheet-3. It is clearly seen that the shear strength of Nano phased
composites shows higher shear strength than the sheet-1. The sheet-2
shows increase in the shear strength than the sheet-1 and the sheet-3
shows further increase in shear strength than the Nano phased foam
composite. Thus it is clearly seen that the carbon Nano fibers shows an
incredible increase in the shear strength of the composites when added
as an reinforcement.

From the graph details it is found that the carbon Nano fiber infused
composites shows better shear strength than the conventional
composites. On the sheet-2, it is noted that the rate of displacement is
minimum thus, it is ductile in nature and have more flexural strength . in
case of sheet-3 , it is observed that it has highest flexural strength than
the other two composites. The rate of displacement is maximum for
conventional than the other two type of composites. The sheet-3 has the
minimum rate of displacement than the other two composites.
The flexural experiment was conducted as per the guidelines of the
ASTM standards C393 with the length of sample as 380mm, width as
60mm and thickness as 24mm in a UTM at a constant cross head speed
of 2mm/min and the maximum capacity of 100KN.

shear strength
3.5

2.5
LOAD(KN)

2 conventional
nanophased foam
1.5
nanophased foam and resin
1

0.5

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

AXIAL DISPLACEMENT(MM)

Figure 6.9: load v/s displacement cure for shear test

…… (3)
 3.5
3
ULTIMATE LOAD(KN)

2.5
2
1.5
1
0.5
0
sheet-1 sheet-2 sheet-3
SHEET

Figure 6.10: bar graph depicting ultimate shear load

In conventional sandwich composite, it can be seen that the core and

sheet layer gets de-bonded due to flexural load. But due to infusion of
the Nano carbon fibers there is no deboning between core and the face
sheets and only crack was propagated through the core in the 2nd and 3rd
composites. By calculating the ultimate shear load using the formula and
the provided ultimate load the shear strength of each sandwich
composite is calculated and represented in the bar graph below. By
observing the graph , it is known that the sheet-3 shows higher shear
strength than the sheet-1.
 3.5
3
SHEAR STRENGTH(MPa)

2.5
2
1.5
1
0.5
0
sheet-1 sheet-2 sheet-3
SHEET

Figure 6.11: bar graph comparing shear strength

(a) (b) (c)

 Figure 6.12: shear test specimen after test (a)conventional
(b)Nano phased foam (c) Nano phased foam with Nano phased
resin

From the above images that each Samples has each type of failures. In
the figure (a), it is observed that the there is a complete de-bonding of
the sheets due to no change to the core structure, so there is no locking
mechanism to prevent the deboning. In figure (b) and (c) it is observed
that the de-bonding is reduced and the crack is only propagated within
the core which improve the shear strength of the Nano phased
composites as the carbon Nano fibers act as a barrier to the propagation
of crack within the core.

CHAPTER 7

CONCLUSION

Sandwich composites with modified core and nano phased epoxy resin
was successfully manufactured using vacuum infusion process. The
modification in the core and infusion of nanofiber resulted in better
properties in comparison with the conventional sheet. The de-bonding
issue was resolved to a great extent in Type 2 and Type 3 as the core
modification and infusion of nanofiber provided locking mechanism and
enhanced mechanical performance. Type 3 sheet showed better
resistance to the plane loading. The crack in Type 1 propagated along
the face sheet but in Type 2 and Type 3 it propagated through the core.
  A 66% growth in compressive strength in Type 2 was observed as
compared to the Type 1, also 68.29% increase was observed In
Type 3 as compared to Type 1.
 A 24.72% growth in flexural strength in type 2 was observed as
compared to the type 1, also 88% increase was observed in type 3
as compared to type 1.
 A 60% growth in shear strength in type 2 was observed as
compared to type 1, also 52% increase was observed in type 3 as
compared to type 1.
Further by changing the core material, varying the weight % of the
nanofiber, introducing new type of cavities and using different
fabrication techniques, the mechanical properties can be enhanced.