Experimental and numerical analysis of damage resistance in multi‐functional hybrid sandwich composites against low‐velocity impacts

Abstract This study introduces a novel hybrid‐sandwich composite structure tailored for nose radome applications, featuring a foam core and opposing face sheets crafted from Kevlar and S‐Glass materials. Building upon our previous research addressing mechanical performance, in‐phase electromagnetic properties, UV protection, and experimental low‐velocity impact responses, this paper delves into numerical investigation of the damage resistance of the proposed structures through finite element (FE) modeling. During LVIs, the impacts on S‐glass face sheets side demonstrated different energy dispersion and absorption mechanisms, leading to variations in indent damage depths and widths across all impact energy levels, unlike the impact damages observed from the Kevlar side. These effects are due to the unique damage absorption and dispersion properties of Kevlar and S‐Glass. To validate the impact response observed in the experimental tests, numerical simulations were performed using Abaqus. The model replicated key behaviors from the experimental results, such as force versus displacement behavior, indentation depth, damage width, and damage propagation. The simulations confirmed the experimental observations, demonstrating shallower and distributed damage on the S‐Glass side, and deeper, localized damage on the Kevlar side. This comprehensive validation highlights the reliability of the experimental findings and the robustness of the material configuration under different impact conditions. This study, unprecedented in existing literature, proposes hybrid sandwich structures with superior specific impact strength compared to various composite sandwich structures documented in the published literature. Highlights Innovative composites with superior low velocity impact response, tested for damage resistance performance. Designed for nose radomes found suitable for other impact prone applications. Experimental and numerical modeling showed comparable results. Major differences observed in damage mechanics, resistance, and tolerances.