Advancing the Understanding of Sandwich Structures through Mechanical Behaviour Modelling and Failure Analysis of FSSW-Joined Honeycomb Core

Abstract

The modern automotive industry is increasingly focused on addressing global energy and environmental challenges by developing lightweight vehicles, particularly electric cars, whose performance and range are heavily influenced by weight. Sandwich structures, especially those with honeycomb cores, have gained prominence due to their lightweight nature, high bending stiffness, energy absorption, and strength. These structures are highly customizable, offering superior mechanical and crash-worthiness properties. However, joining these components effectively remains a critical challenge. Traditional methods like adhesive bonding (AB) and mechanical fastening have limitations, such as sensitivity to environmental conditions, stress concentrations, and added weight. Additive manufacturing (AM) offers potential but faces material and cost barriers.