Fabrication and mechanical properties of thermoplastic corrugated sandwich panel with enhanced face‐core interface.

Thermoplastic sandwich structures are widely utilized in engineering fields due to their high specific strength and stiffness, recyclability, and impact toughness. The face‐core interface strength is crucial to maximize the performance benefits of sandwich structures. Two sizes of corrugated sandwich panels with hot‐melt bonding and resistance welding connection methods were fabricated. The mechanical properties of sandwich panels were compared using a combination of experimental, numerical, and analytical investigation. Edgewise compression (EC) and 3‐point bending (3 PB) tests were conducted to obtain load–displacement curves and investigate different failure modes of sandwich panels. The peak edge compression and bending loads of the resistance welded structures were 42% and 92% higher, respectively, and the face‐core interface was always well‐connected compared to those of the hot‐melt bonding. The results indicate that the resistance welding method can be utilized as a core bonding technique for thermoplastic composite sandwich structures and has great potential for aerospace application. Highlights: A method that includes hot‐melt bonding and resistance welding are develop to produce thermoplastic composite corrugated sandwich panels (TPC‐CSPs).The TPC‐CSPs fabricated by resistance welding exhibit superior interface connection performance compared to hot‐melt bonding and this method enhance the structural load bearing capacity.The numerical and analytical method were presented to investigate the failure model, which was consistent with the experimental results. [ABSTRACT FROM AUTHOR]