Stainless steel wire mesh hybridization for improved bending fatigue performance in fiber reinforced <scp>polymer</scp> sandwich structures

Abstract Sandwich structures are preferred in many engineering applications where they are subjected to not only static but also variable loads. In this study, stainless‐steel wire mesh sheet hybridization was applied to very low‐density polymeric sandwich structures, and their fatigue performance under variable loading was investigated. Plain woven carbon fiber and stainless‐steel wire mesh sheet hybrid structure, epoxy resin, and closed cell polyvinyl chloride (PVC) foam (48 kg/m 3 ) were used for the face sheets, binding matrix, and core, respectively. Specimens were subjected to three‐point bending tests, both quasi‐static and fatigue. It was found that the thickness of the stainless‐steel wire mesh sheet and the hybridization position significantly influenced fatigue life. It was also observed that the hybridization effect became more pronounced as core thickness increased. S–N curves of four configurations were obtained for a detailed fatigue analysis. In 10 mm core sandwiches, hybridization was effective at high loading levels but not at low levels, whereas in 30 mm core sandwiches, it improved performance at all load levels. Highlights Stainless‐steel wire mesh hybridization enhances sandwich fatigue performance. Quasi‐static and fatigue tests confirm improved bending performance. S–N curves provide detailed insights into fatigue life. Face sheet hybridization effects increase with greater core thickness. Fatigue‐induced cavity formation occurs in thicker cores.