Strength of asymmetric tapered composite foam core sandwich structures subjected to thermomechanical loading

An experimental test program and companion analytical study were designed and conducted to gain understanding of the tensile failure mechanisms in asymmetrical tapered sandwich core structures at cold temperatures. Representative test coupons were subjected to a tensile load in an environmental chamber to induce foam tensile failure in the core. Finite-element modeling with a proposed maximum principal stress criterion was used to predict the failure loads of the tapered test coupon design at the test temperatures. The predicted failure loads were in good agreement with test results. An important finding is that the cure stresses in the foam are significant and should not be ignored. Additionally, the analysis correctly predicted the failure initiation location, which was verified using high speed photography during the tensile test. The study identified the critical failure regions of asymmetrical tapered sandwich core designs and the failure load dependence on the temperature gradient in the structure.