Fatigue crack growth and life prediction of foam core sandwich composites under flexural loading

Fatigue crack growth of foam core sandwich beams loaded in flexure has been investigated. Sandwich panels were manufactured using an innovative co-injection resin transfer molding process. S2-glass fiber with epoxy resins was used as face sheets over a PVC foam core. Testing was performed in a three-point flexure mode utilizing a newly designed fixture such that the localized indentation damage was minimal. Extensive fatigue data were generated for the S–N diagram and crack growth was monitored to develop a model for life prediction. The first visible sign of damage initiation was a core–skin debond parallel to the beam axis. This debond propagated slowly along the top interface and eventually kinked into the core as shear crack and then grew in an unstable manner resulting in total specimen collapse. A fatigue model based on this crack growth has been developed and validated with experiments.