Design of New Hybrid Composites using Metal Embedded in Polymer Foam and Foam Composite

Abstract

Adhesion and loading bearing properties of polyurethane (PU) foams and sandwich composite with metallic inserts are studied. Metal or solid polymer anchors are used as the load transfer components for PU foam and sandwich composites when they are used as the structural element in design. The traditional method of fixation of these components in foams is gluing and fastening. In this work, the anchors are in the form of inserts and are imbedded in the PU during the foaming process. Flexural testing was conducted on PU with and without metallic inserts to establish typical interaction trends. The load-deflection response, mode of failure, and fracture stresses of the PU structures are elucidated. Results show that long taper and leaf inserts imbedded in foam and sandwich composite provide better load carrying capacity. Comparisons between the taper and leaf inserts are documented. Leaf inserts inside a foam and sandwich composite show better results as compared to taper inserts in terms of adhesion and failure stresses. A linear elastic fracture model is also developed for the foam beam, and the fracture toughness is calculated. FEA analyses of the interaction between the inserts and the PU and sandwich composites under different loads were carried out. The FEA modeling results coincide with the experimental ones, hence validating the model.