EXPERIMENTAL ANALYSIS ON THE IMPACT

BEHAVIOUR OF H-130 PVC FOAM BASED

SANDWICH COMPOSITES

A PROJECT REPORT

Submitted by

RONY SHIELA. S (2016110032)

RENITH KUMAR. C (2016110031)

LOGESH. R (2016110016)

in partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING
in
MATERIALS SCIENCE AND ENGINEERING

COLLEGE OF ENGINEERING, GUINDY

ANNA UNIVERSITY, CHENNAI-600025

NOVEMBER 2019
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “EXPERIMENTAL ANALYSIS ON THE

IMPACT BEHAVIOUR OF H-130 PVC FOAM BASED SANDWICH
COMPOSITES” is the bonafide work of
RONY SHIELA S (2016110032)
RENITH KUMAR C (2016110031)
LOGESH R (2016110016)
who carried out the project work under my supervision.

Dr. S. Rajendra Boopathy Dr. S. Senthil Kumaran

HEAD OF THE DEPARTMENT SUPERVISOR

Professor

Department of Mechanical Engineering Department of Mechanical Engineering

College of Engineering Guindy College of Engineering Guindy

Chennai 600025 Chennai 600025
 ABSTRACT

The impact behaviour of H130 PVC Foam core-based sandwich composites

was studied using experimental analysis, involving the use of Ball Dot Impact

Testing Machine. Two different types of skin materials were used, namely E-

glass fibres and Basalt fibres. The effect of introduction of Non-Newtonian fluid

as a reinforcement on the impact behaviour of sandwich composites was also

studied and a comparative analysis between sandwich composites with E-Glass

fibre and Basalt fibre skins was established.

Experimental Analysis showed that the composites with basalt fibre skin

showed a substantially greater resistance to impact when compared to composites

with E-Glass fibre skin. It was also found that the composites with Non-

Newtonian fluid reinforcements expressed maximum resistance to impact among

the various types of composites fabricated.

Thus, it was proved that the addition of Non-Newtonian Fluid

reinforcement enhanced the impact property of sandwich composites. The

experimental results well complemented the predicted outcomes of the behaviour

of sandwich composites.
 TABLE OF CONTENTS

CHAP. DESCRIPTION PAGE NO.

NO.
Abstract iii
List of Tables iv
List of Figures v
List of Symbols, Abbreviations and vi
Nomenclature

1 Introduction 1
1.1 General 1
1.2 Sandwich Composites 2
1.2.1 Structure of a Sandwich Composite 2
1.2.2 Applications 2
1.3 Composites in the Aviation Industry 3
1.3.1 Materials used as skins 4
1.3.1.1 Basalt Fibers 4
1.3.1.2 E-Glass Fibers 6
1.3.2 Core Materials 9
1.3.2.1 H-130 PVC Foam 9
1.3.3 Adhesives used 10
1.4 Non-Newtonian Fluid - Dilatant 11
1.5 Problems Identified 12
1.6 Impact of the problem 12
1.7 Objectives of the Study 13
2 Literature Survey 14
3 Experimental Procedure 17
3.1 Materials 17
3.2 Foam Cutting and Drilling 17
3.3 Introduction of Non-Newtonian Fluid 18
3.3.1 Method of Preparation 18
3.3.2 Method of Reinforcing the Fluid 19
3.4 Fabrication Processes 19
3.4.1 Hand Lay-up 19
3.4.1.1 Issues faced in the fabricated Samples 20
3.4.2 Vacuum Bag Moulding 20
4 Impact Testing 23
4.1 Ball Dot Impact Tester 23
5 Experimental Results and Analysis 25
5.1 Sample 1 25
5.2 Sample 2 26
5.3 Sample 3 27
5.4 Sample 4 28
5.5 Results and Interpretation 29
6 Conclusion 29
7 References 30
 LIST OF TABLES

SL. CONTENT PAGE NO.

NO.
1 Physical Properties of Basalt fibres 5
2 Properties of E-Glass Fibre 7
3 Properties of PVC Foams 10
4 Major Physical Properties of Corn Starch Dilatant 12
5 Composition of the Sandwich Composites 13
6 Specifications of the Testing Equipment 24
7 Test Observations for Sample 1 25
8 Test Observations for Sample 2 26
9 Test Observations for Sample 3 27
10 Test Observations for Sample 4 28
 LIST OF FIGURES

SL.NO. CONTENT PAGE

NO.
1 Schematic Diagram of a typical Sandwich 2
Composite
2 Various applications of Sandwich Composites in an 3
Aircraft
3 Graph between Shear Stress and Shear Strain of 11
fluids
4 Materials Procured 17
5 Foam Cutting 17
6 Foam Drilling 18
7 Non-Newtonian Fluid 18
8 Hand lay-up process 19
9 Sandwich Composite Fabricated using Hand Lay-up 20
process
10 Vacuum bag molding process 21
11 Vacuum bag molding fabrication steps 22
12 Sandwich Composites fabricated using 22
Vacuum Bag Molding

13 Ball dot impact testing equipment 23

14 Photograph of Sample 1 25
15 Photograph of Sample 2 26
16 Photograph of Sample 3 27
17 Photograph of Sample 4 28
 LIST OF SYMBOLS, ABBREVIATIONS AND
NOMENCLATURE

PVC – Poly Vinyl Chloride

GRP – Glass Fibre reinforced Polymer
FRP – Fibre Reinforced Polymer
IPN – Interpenetrating Polymer Network
BVID – Barely Visible Impact Damage
ASTM – American Society of Testing and Materials
EG – E-Glass fibre
BS – Basalt fibre
 INTRODUCTION

1.1 GENERAL

Composite materials are being extensively used in the aviation industry. Bird
Strike events, highly prevalent in the aviation industry, causes not only
catastrophic damage, but also causes significant downtime of an aircraft due to
maintenance, during which the damaged part has to be repaired or even replaced
as a whole. Bird impact on a vulnerable component, such as an engine or
windscreen, can result in serious damage to the aircraft and even loss of life.
Aircraft components are also liable to be hit by hail stones during heavy rains.
Severe convection weather such as hail has long been the potential threat to the
safety of aircraft. Even a short while passing through the hailstone regions, it is
sufficient to cause damage to aircraft structure such as depression, cracking and
even piercing if crushed with hailstone at a high speed.
The impact may not be visible from outside i.e. the fuselage may seem
unaffected, but the inner packaging of sandwich composite structures would be
severely damaged. The current crops of Commercialised composites such as
Glass Fibre Composite and Carbon Fibre Composite may well result in BARELY
VISIBLE IMPACT DAMAGE and eventually, delamination of the structure.
So, the materials used for inner packaging (Sandwich composites) should be
designed in such a way that it withstands High and Low velocity impacts without
causing BVID so as to increase the reliability and Life span of the Aircraft.
Thus, the aim of this experiment is to analyse and study the impact
behaviours of H-130 PVC Foam based Sandwich composites, when subjected to
events such as a bird strike, hailstorm or other low velocity impacts and their
potential in replacing the existing composite structures. Sandwich Composites
are highly preferred due to their High Strength to Weight ratio and structural
versatility.
1.2 SANDWICH COMPOSITES

1.2.1 Structure of a Sandwich Composite:

Figure 1: Schematic Diagram of a typical Sandwich Composite

A sandwich composite essentially consists of 3 main layers:

➢ Skin or Face layers
➢ Bonding layers
➢ Core material

The skin layers are usually two thin and stiff layers, which are attached on both
sides of a thick, light-weight core material. Both the skin and core are bonded to
each other using an adhesive or bonding material.

1.2.2 Applications

Sandwich composite panels are being widely used in various fields such as:

➢ GRP Terrain Vehicles and Trucks

➢ Transportation Applications- in cars, subway cars and trains
 ➢ In Flooring, Interior and Exterior Panels
➢ In Decks and Hulls of Pleasure boats and ships
➢ Civil Engineering applications and Windmills
➢ Aerospace and Marine Industry
➢ Radar Equipment, due to exclusive property of Radar Transparency

1.3 SANDWICH COMPOSITES IN THE AVIATION INDUSTRY

Figure 2: Various applications of Sandwich Composites in an Aircraft

The use of composite materials in the aerospace industry has been one
of the most remarkable innovation, as these enable designers to overcome the
shortcomings created by using metallic components.

The foremost advantage of using composites is the reduction in weight, and

hence they are used for both structural applications and components of all
spacecraft and aircraft vehicles, starting from gliders and hot air balloon gondolas
to fighter planes, space shuttle and passenger airliners.
 Some of the key advantages of using sandwich composites for aerospace
applications include the following:

• Weight reduction up to 20 to 50%.

• Provide higher strength at lower weight.
• Have High impact resistance.
• Have High thermal stability
• Corrosion and Fatigue Resistant
• Design flexibility
• Reduced environmental impact

1.3.1 MATERIALS USED AS SKIN LAYERS:

• Carbon Fibres
• Kevlar/Aramid fibres
• Glass Fibres
• Basalt fibres, etc.

1.3.1.1 BASALT FIBRES:

Basalt fibre is a relative newcomer to fibre reinforced polymers (FRPs)

and structural composites. It has a similar chemical composition as glass fibre but
has better strength characteristics, and unlike most glass fibres, it is highly
resistant to alkaline, acidic and salt attack, thus, making it a good candidate for
concrete, bridge and shoreline structures.

It is used as a fireproof textile in the aerospace and automotive industries

and can also be used as a composite to produce products such as camera tripods.
Some of the important properties of the fibre are as follows:

1. High strength and high modulus fiber

2. Excellent shock resistance - good for ballistic applications

3. Low cost alternative and can replace carbon fiber in some applications
including filament winding

4. High temperature resistance and good light resistance

5. Good fatigue and corrosion resistance properties

6. No need for special processing equipment

7. Easy to handle and process

8. Environment friendly and can be recycled

9. Exhibits no health and safety risks

10. Compatible with many resins - unsaturated polyester, vinyl ester, epoxy,
phenolic, etc.

11. Better chemical resistance than E-glass

Table 1: Physical Properties of Basalt fibres

Property Value

Tensile strength 2.8–3.1 GPa

Elastic modulus 85–87 GPa

Elongation at break 3.15%

Density 2.67 g/cm³

1.3.1.2 E-GLASS FIBRES:

E-Glass or electrical grade glass was originally developed for stand off
insulators for electrical wiring. It was later found to have excellent fibre forming
capabilities and is now used almost exclusively as the reinforcing phase in the
material commonly known as fibreglass.

Properties that have made E-glass so popular in fibreglass and other glass
fibre reinforced composite include:

• Low cost

• High production rates

• High strength and stiffness

• Relatively low density

• Non-flammable

• Resistant to heat

• Good chemical resistance

• Relatively insensitive to moisture

• Able to maintain strength properties over a wide range of conditions

• Good electrical insulation

 Table 2: Properties of E-Glass Fibre

Material: E-Glass Fibre

Composition: 54%SiO2-15%Al2O3-12%CaO

Minimu Maximu Minimu Maximu

m Value m Value Units m Value m Value
Property (S.I.) (S.I.) (S.I.) (Imp.) (Imp.) Units (Imp.)

Atomic 0.0088 0.009 m3/kmol 537.009 549.213 in3/kmol

Volume
(average)

Density 2.55 2.6 Mg/m3 159.191 162.313 lb/ft3

Energy 100 120 MJ/kg 10833.9 13000.6 kcal/lb

Content

Bulk Modulus 43 50 GPa 6.23662 7.25188 106 psi

Compressive 4000 5000 MPa 580.151 725.189 ksi

Strength

Ductility 0.026 0.028 null 0.026 0.028 NULL

Elastic Limit 2750 2875 MPa 398.854 416.984 ksi

Endurance 2970 3110 MPa 430.762 451.067 ksi

Limit

Fracture 0.5 1 MPa.m1/ 0.455023 0.910047 ksi.in1/2

2
Toughness
Hardness 3000 6000 MPa 435.113 870.227 ksi

Loss 1e-005 0.0001 null 1e-005 0.0001 NULL

Coefficient

Modulus of 3300 3450 MPa 478.625 500.38 ksi

Rupture

Poisson's Ratio 0.21 0.23 null 0.21 0.23 NULL

Shear Modulus 30 36 GPa 4.35113 5.22136 106 psi

Tensile 1950 2050 MPa 282.824 297.327 ksi

Strength

Young's 72 85 GPa 10.4427 12.3282 106 psi

Modulus

Glass 820 850 K 1016.33 1070.33 °F

Temperature

Maximum 620 630 K 656.33 674.33 °F

Service
Temperature

Specific Heat 800 805 J/kg.K 0.619087 0.622956 BTU/lb.F

Thermal 1.2 1.35 W/m.K 2.24644 2.52725 BTU.ft/h.ft2.

Conductivity F

Thermal 4.9 5.1 10-6/K 8.82 9.18 10-6/°F

Expansion
1.3.2 CORE MATERIALS:

Both Open- and Closed-cell Structured foams and metal foams are used as
Core materials.

• Polyethersulfone foam
• Polyethylene foam
• Polyvinylchloride foam
• Polyurethane foam
• Polystyrene foam
• Syntactic foam
• Balsa wood
• Honeycombs etc.

1.3.2.1 H-130 PVC FOAM CORE:

PVC foams came into use as core materials in the 70’s. It is a rigid, light weight
and moisture resistant foam with a closed cell structure. Technically, it is an
Interpenetrating Polymer Network (IPN) of PVC and polyurea. The interaction
of these polymers gives the foam its unique characteristics.

Major Properties of PVC Foams:

• It is resistant to many solvents including styrene and most fuels.

• It is self-extinguishing and will not rot.
• Excellent fatigue life and good bond strength with common adhesives and
resins.

PVC foams are available in a variety of densities from 45 kg/m 3 to 400 kg/m3.
Among them, the foam used for this study is H-130 PVC Foam, having a density
of 130 kg/m3.
 Table 3: Properties of PVC Foams

1.3.3 ADHESIVES USED:

Adhesives used may be either Structural /Engineering Adhesive or

Synthetic Adhesive.

Following are a few examples:

• Epoxy resin
• Polyurethane resin
• Acrylic adhesive
• Contact Cement
• Resorcinol
• Polyvinyl Acetate (PVA)
1.4 NON-NEWTONIAN FLUID - DILATANT

A dilatant is a non-Newtonian fluid where the shear viscosity increases

with applied shear stress. This behaviour is only one type of deviation from
Newton’s Law, and it is controlled by such factors as particle size, shape, and
distribution. When they are reinforced with PVC foams, their property is
enhanced.

Figure 3: Graph between Shear Stress and Shear Strain of fluids

The most common everyday example of a non-Newtonian fluid is corn

starch dissolved in water. Behavior of Newtonian fluids like water can be
described exclusively by temperature and pressure. However, the physical
behavior of non-Newtonian fluid depends on the forces acting on it from second
to second. Non-Newtonian Fluids may be either shear thickening or shear
thinning. A fluid is shear thickening or dilatant if the viscosity of the fluid
increases as the shear rate increases. A common example of shear thickening
fluids is a mixture of corn starch and water. Fluids are shear thinning if the
viscosity decreases as the shear rate increases. Shear thinning fluids are also
known as pseudo-plastics. Common examples include ketchup, paints and blood.

Table 4: Major Physical Properties of Corn Starch Dilatant

PROPERTY VALUE

Poisson Ratio 0.5

Yield Stress 0.5 Pa

Density 1200 kg m-3

1.5 PROBLEMS IDENTIFIED

• Aircrafts are always subjected to Bird Strike during take-off and landing,
which is one the potential problem faced by the aviation industry.

• In US alone, it has been reported that more than 1,56,114 Bird Strikes has
caused 1,72,151 hours of downtime and $208 million losses.

• Due to this, the composite structures currently used (those made from
Carbon, Glass and Kevlar fibres) are more prone to BVID (Barely Visible
Impact Damage)

1.6 IMPACT OF THE PROBLEM

• Lifespan of the aircraft is reduced.

• They are more prone to structural failure.

• May even lead to fatal accidents, if not checked regularly.

1.7 OBJECTIVES OF THE STUDY

The objectives of the given study are:

• To fabricate sandwich composites of the following composition:

Table 5: Composition of the Sandwich Composites

SKIN CORE ADHESIVE

Basalt Fibre Mat H-130 PVC Foam Epoxy Resin

Basalt Fibre Mat H-130 PVC Foam Epoxy Resin

with a reinforcement
of Shear Thickening
“Non-Newtonian
Fluid” (Corn Starch
+Water)

E-Glass Fibre Mat H-130 PVC Foam Epoxy Resin

E-Glass Fibre Mat H-130 PVC Foam Epoxy Resin

with a reinforcement
of Shear Thickening
“Non-Newtonian
Fluid” (Corn Starch
+Water)

• To analyse the impact behaviour of the fabricated sandwich composites.

• To compare the impact behaviour of the different fabricated sandwich

composites.
 CHAPTER 2
LITERATURE SURVEY

• “Advanced body armour utilizing shear thickening fluids” by Y.

S. Lee, E. D. Wetzel, R.G. Egres Jr and N.J. Wagner. (2002)
[US7498276B2]

✓ It explains about the ballistic penetration performance of a

composite material composed of woven Kevlar fabric
impregnated with a colloidal shear thickening fluid.
✓ This material provides greater ballistic and puncture resistance
as compared to the conventional ballistic fabric.

• “In situ mechanical characterization during deformation of PVC

polymeric foams using ultrasonics and digital image correlation”
by T.H.Kidd, S.Zhuang and G.Ravichandran (December 2012)

✓ In this paper, the mechanical behavior of polymeric foams are

characterized using in-situ methods.
✓ PVC Foam shows a substantial increase in Impact resistance
and most suited for applications involving Heavy Impact.

• “Aircraft Sandwich Structures with Folded Core under Impact

Load” by S. Heimbs, P. Middendorf, C. Hampf, F. Hähnel and K.
Wolf (2018)

✓ In this paper, the mechanical behaviour of a sandwich structure

with a folded core made of carbon fibre-reinforced plastic under
low velocity impact loads is investigated experimentally and
numerically.
✓ It was inferred that Numerical simulations can be used for an
enhancement of the sandwich structure’s impact behaviour with
respect to core geometry or material.
• “Flexural behaviour of composite sandwich beams made up of
glass fibre-reinforced polymer skins and modified phenolic core
material in flatwise and edgewise positions” by A.C. Manalo et.al

✓ The Paper observed that the beams in the edgewise position

failed due to progressive failure of the skin.
✓ The Paper inferred while the beam in the flatwise position failed
due to brittle fracture, followed by the debonding of skin and
core.

• “Sandwich columns under edgewise compression loadings and

analysed their failure mechanisms” by N.A. Fleck and I. Sridhar

✓ The Paper inferred that estimated failure loads for different

modes of failure were found to be in accordance with the
observed strength.

• “Hygroscopic ageing behaviour of nonstandard size sandwich

composites made of thick ECR glass fibre reinforced vinylester
composite faces bonded to closed cell PVC foam core” by Anxin
Ding et.al

✓ The Paper observed that moisture absorption has negligible

effect on the properties of the PVC Foam core
✓ The Paper also inferred that it greatly affects the interfacial
properties between the face and core of the composite specimen.

• “Ageing of sandwich composites having vinyl ester-based

composite faces and PVC foam core in various extreme
environments” by Anxin Ding et.al

✓ The Paper inferred that PVC Foam core was less affected by the
adverse environments
✓ It was also found that there was a significant decrease in the
strength of interfacial layers between the core and the skin.
• “Effect of graphene nano-pellets on the mechanical properties of
Basalt/epoxy composites” by Mehmet Bulut et.al

✓ This Paper showed that the inclusions of graphene nano-pellets

in the Basalt/epoxy composite laminates showed a substantial
increase in its mechanical properties.

• “The Effect of flatwise compression and flexural loading on foam

core sandwich” by B.Ebdi et.al

✓ This Paper inferred that Polymer pin-reinforced foam core

sandwich composites showed a dramatic increase in the flexural
and flatwise compression properties.
✓ The improvement was greater in flatwise compression.

• “Mechanical behavior of basalt fibers in a basalt-UP composite”

by B. Soares, R. Preto, L.Sousaa, L. Reis

✓ This paper studies the mechanical properties of a Basalt-fibre

composite in an Unsaturated Polyester matrix produced by
RTM, with the composites subjected to tensile, compressive,
shear and flexural tests.
✓ The experimental results place Basalt fibres between the E-
Glass fibre composites and Carbon fibre composites.

• “Experimental and Numerical analysis of bird strike on an

Aircraft Panel” by Vasudevan.A, Saifuddin.K.P and Senthil
Kumaran.S

✓ In this paper, a Square panel model which withstands the impact

energy sufficient to the level of bird-strike requirement, using
Finite Element Analysis.
✓ It was inferred that Kevlar – epoxy laminated composites could
be a potential material for the aircraft structures in the future.
 CHAPTER 3
EXPERIMENTAL PROCEDURE
3.1 MATERIALS:

The following materials were procured for

this study:
• Basalt fibre mat (1*1 sq.m.)
• E-Glass fibre mat (1*1 sq.m.)
• H-130 PVC Foam (1*1 sq.m.)
• Epoxy Resin – LY556
• Hardener – HY951
• Corn Starch and Distilled Water
• Vacuum bag molding requirements Figure 4: Materials Procured

3.2 FOAM CUTTING AND DRILLING:

Figure 5: Foam Cutting

• The H-130 PVC Foam was cut using a mechanical cutter.

 Figure 6: Foam Drilling

• Holes of 10 mm diameter was drilled in the foam using Universal Drilling

Machine.

3.3 INTRODUCTION OF NON-NEWTONIAN FLUID:

3.3.1 METHOD OF PREPARATION:

The Dilatant was prepared by mixing Corn Flour with Distilled Water at a ratio
of 3:1. The mixture was subjected to continuous stirring and should be maintained
at room temperature. After some time, the required consistency of Dilatant was
achieved and they were transferred to the holes drilled in the Foam. When left
undisturbed for a long time, it gets hardened.

Figure 7: Non-Newtonian Fluid

3.3.2 METHOD OF REINFORCING THE FLUID:

The prepared non-Newtonian Fluid was then reinforced into the drilled holes
manually by sealing one end of the hole, using a sealant tape. After the dilatant
hardens, the tape is removed. The foam is then used for fabrication of the desired
sandwich composite.

3.4 FABRICATION PROCESSES:

3.4.1 HAND LAY-UP

Hand lay-up is the most common and least expensive open-molding method
because it requires the least amount of equipment. Fibre reinforcements are
placed by hand in a mold and resin is applied with a brush or roller.
This process is used to make both large and small items, including boats, storage
tanks, tubs and showers.

Figure 8: Hand Lay-up Process

Process:
Gel coat is first applied to the mold using a spray gun for a high quality surface.
When the gel coat has cured sufficiently, roll stock fiberglass reinforcement is
manually placed on the mold. The laminating resin is applied by pouring,
brushing, spraying, or using a paint roller. FRP rollers, paint rollers, or squeegees
are used to consolidate the laminate, thoroughly wetting the reinforcement and
removing entrapped air. Subsequent layers of fiberglass reinforcement are added
to build laminate thickness. Low density core materials such as end-grain balsa,
foam and honeycomb, are commonly used to stiffen the laminate. This is known
as Sandwich Construction.

3.4.2 ISSUES WITH THE COMPOSITE FABRICATED USING HAND

LAY-UP PROCESS:

• Partial Curing
• Low Adhesiveness of Epoxy
Resin
• Distortedness of Fibres in the
composite
• Overflow of Resin in the Setup
• Porosity in the Structure
Figure 8: Sandwich
• Low Impact Resistance Composite Fabricated using
Hand Lay-up process

3.4.3 VACUUM BAG MOLDING METHOD:

Vacuum bag moulding is a modification of hand lay-up, in which the lay-up

(necessarily smaller) is completed and placed inside a bag made of flexible film
and all edges are sealed. The bag is then evacuated, so that the pressure eliminates
voids in the laminate, forcing excess air and resin from the mould.
 Figure 9: Vacuum Bag Molding Process
Process:
In the simplest form of vacuum bagging, a flexible film (PVA, nylon, mylar, or
polyethylene) is placed over the wet lay-up, the edges are sealed, and a vacuum
is drawn. A more advanced form of vacuum bagging places a release film over
the laminate, followed by a bleeder ply of fiberglass cloth, non-woven nylon,
polyester cloth, or other material that absorbs excess resin from the laminate. A
breather ply of a non-woven fabric is placed over the bleeder ply, and the
vacuum bag is mounted over the entire assembly. Pulling a vacuum from within
the bag uses atmospheric pressure to eliminate voids and force excess resin
from the laminate. The addition of pressure further results in high fiber
concentration and provides better adhesion between layers of sandwich
construction. When laying non-contoured sheets of PVC foam of balsa into a
female mold, vacuum bagging is the technique of choice to ensure proper
secondary bonding of the core to the outer laminate.
 Figure 10: Vacuum Bag Molding Fabrication

Figure 11: Sandwich Composites fabricated using

Vacuum Bag Molding
 CHAPTER 4
IMPACT TESTING

3.1 BALL DOT IMPACT TESTER

Figure 12: Ball Dot Impact Testing Equipment

The ball-dot impact test is used for determining the impact resistance of
composites and various other materials (e. g. susceptibility to breaking and
cracking), using a chrome plated steel ball. The ball is made to fall on the mounted
specimen at different heights. The impact behaviour of the specimen is then
analysed using the test results.
TEST CONDITIONS:

• TEMPERATURE: Room Temperature (28+2)˚C

• STANDARD USED: ASTM D2794 – 93

Table 6: Specifications of the Testing Equipment

Test requirements Values

Ball diameter 12.7 mm

Ball weight 1000 g
Drop Heights 500, 1000 and 1500 mm
 CHAPTER 5
EXPERIMENTAL RESULTS AND ANALYSIS

5.1 SAMPLE 1:
SAMPLE DETAILS:

Designation: EG 1
Core Material: H130 PVC Foam
Skin: E-Glass (Bidirectional) x 3
P.E: Range of 5J to 15J

Table 7: Test Observations for Sample 1

MASS OF THE IMPACT HEIGHT OF OBSERVATION

TEST BALL DROP
1000 g 500 mm NO SLIGHT
CRACKS
1000 g 1000 mm SLIGHT BULGING

1000 g 1500 mm CRACKS WITH

BULGING

Figure 13: Photograph of Sample 1

5.2 SAMPLE 2:
SAMPLE DETAILS:

Designation: EG 2
Core Material: H130 PVC Foam
Skin: E-Glass (Bidirectional) x 3
Reinforcement: Non-Newtonian Fluid
P.E: Range of 5J to 15J

Table 8: Test Observations for Sample 2

MASS OF THE HEIGHT OF OBSERVATION

IMPACT TEST BALL DROP
1000 g 500 mm NO CRACKS
1000 g 1000 mm NO CRACKS
1000 g 1500 mm CRACKS WITH
BULGING

Figure 14: Photograph of Sample 2

5.3 SAMPLE 3:
SAMPLE DETAILS:

Designation: BS 1
Core Material: H130 PVC Foam
Skin: Basalt (Bidirectional) x 3
P.E: Range of 5J to 15J

Table 9: Test Observations for Sample 3

MASS OF THE IMPACT HEIGHT OBSERVATION

TEST BALL OF DROP
1000 g 500 mm NO CRACKS
1000 g 1000 mm SLIGHT BULGING
AND SLIGHT CRACKS
1000 g 1500 mm CRACKS WITH
BULGING

Figure 15: Photograph of Sample 3

5.4 SAMPLE 4:
SAMPLE DETAILS:

Designation: BS 2
Core Material: H130 PVC Foam
Skin: Basalt (Bidirectional) x 3
Reinforcement: Non-Newtonian Fluid
P.E: Range of 5J to 15J

Table 10: Test Observations for Sample 4

MASS OF THE HEIGHT OF OBSERVATION

IMPACT TEST BALL DROP
1000 g 500 mm NO CRACKS
1000 g 1000 mm NO SLIGHT
BULGING AND NO
CRACKS
1000 g 1500 mm NO CRACKS WITH
NO BULGING

Figure 16: Photograph of Sample 4

5.5 RESULTS AND INTERPRETATION:
From the results of the Ball Dot Impact Test performed on the four different
combinations of Sandwich Composites, the following results have been inferred:

➢ The E-Glass fibre-PVC foam based sandwich composite (EG-1) easily

showed some cracking when the ball was dropped from a height of
1000 mm and showed the least resistance to impact among the 4 types.

➢ In the E-Glass fibre – PVC foam based sandwich composite with a

reinforcement of non-Newtonian fluid (EG-2), there was no crack
formation or bulging initially. Crack formation occurred only when the
drop height was 1500 mm.

➢ For the sample BS-1 (Basalt fibre – PVC foam based sandwich composite),
bulging and crack initiation started at the drop height of 1000 mm itself.

➢ The impact resistance was maximum for the Basalt fibre – PVC foam based
sandwich composite with a reinforcement of non-Newtonian fluid (BS-2).

➢ Thus, it can be inferred that the reinforcement of non-Newtonian fluid

improves the impact behaviour of both the sandwich composites, with
skins of Basalt fibres as well as E-Glass fibres.

➢ But the effect is maximum for the Basalt fibre based composites.

CONCLUSION:
• The H-130 PVC Foam-Basalt Fibre with non-Newtonian Fluid
reinforcement based sandwich composites so fabricated showed a greater
resistance to the impact loads than the other Basalt and E-Glass based
composites.
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https://en.wikipedia.org/wiki/Basalt_fiber
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https://www.azom.com/properties.aspx?ArticleID=764
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https://docsemea.rsonline.com/webdocs/0dc3/0900766b80dc30fc.pdf