Novel High Performance and Multifunctional Sandwich Composite Structures

The U.S. Navy is seeking the development of high-performance, multifunctional sandwich composite structures to enhance the mission capabilities of composite aircraft systems. The performance and multifunctionality of these advanced structures are critically influenced by the tailored properties of the core materials and the interfacial bonding strength between the face sheet and the core. Achieving the desired levels of performance requires innovative core design, strategic material selection for both the core and face sheet, and robust methods to enhance interfacial bonding strength. Traditional sandwich constructions utilizing aluminum or Nomex honeycomb cores have been widely adopted in aerospace applications; however, these legacy solutions are inadequate for environments involving aggressive multiaxial loading, dynamic impacts, and extreme thermal conditions. Furthermore, their conventional designs limit applicability in complex, curved sandwich structures. A significant barrier to progress in this area is the lack of comprehensive modeling and simulation tools capable of guiding the exploration of novel materials, geometries, and fabrication techniques aimed at achieving superior performance while reducing structural weight. To address this technology gap, Global Engineering and Materials, Inc. (GEM), in collaboration with its partner, proposes the development, design, and fabrication of next-generation composite sandwich structures that incorporate additively manufactured (AM) metallic and fiber-reinforced polymer composite cores. By integrating advanced AM techniques with precision-controlled fabrication processes, this effort will demonstrate enhanced coreñface sheet bond strength and embedded multifunctionality under both static and dynamic loading conditions. The Phase I program will be guided by the following key technical objectives and innovations: 1. Enhancement of existing modeling capabilities to enable rapid identification of AM process windows and to support rational tailoring of core topology based on mission-driven performance criteria, including structural strength, stiffness, and thermal management. 2. Fabrication of composite sandwich panels featuring both metallic and composite cores in two carefully selected geometric configurations, demonstrating the flexibility of the proposed approach for different application scenarios. 3. Demonstration of superior mechanical performance of the newly fabricated sandwich composites, benchmarked against conventional counterparts using aluminum and Nomex cores. 4. Evaluation of multifunctional capabilities, highlighting improvements in both mechanical and thermal performance.