Formability and Failure Behavior of a Thin Sandwich Panel with Stainless Steel Wire Mesh

Metallic sandwich panels featuring cellular metal cores are widely utilized across various sectors due to their exceptional load‐bearing efficiency and design versatility. However, their application is often limited by the challenge of shaping complex geometries. This study introduces a novel thin sandwich panel incorporating stainless steel wire mesh (SSWM) core, designed to offer both lightweight properties and enhanced flexibility. Mechanical properties and forming limit diagrams of the sandwich sheet are assessed through tensile tests and Nakajima forming tests. The study investigates how the SSWM stacking angle and strain paths influence the panel's failure behavior and formability. Comparative analyses with monolithic stainless steel sheets of identical dimensions are also conducted. The findings reveal that the sandwich sheet exhibits comparable formability to the monolithic sheet in the tension‐compression stain zone, with about 32% higher average specific tensile strength compared to the monolithic counterpart. Importantly, the formability and failure characteristics of the sandwich panel are significantly influenced by in‐plane shear deformation of the SSWM core, which is primarily dictated by the SSWM stacking angle and strain paths. Notably, the sandwich sheet with 45° stacking angle demonstrates superior plasticity and formability.