FEA and Experimental Investigation of Sandwich Composite Material Made by Aluminium Composite with Nylon

Abstract

Aluminium and nylon composite panels are advanced materials combining the lightweight and corrosion-resistant properties of aluminium with the high strength and flexibility of nylon. These composites are increasingly used in aerospace, automotive, and construction industries due to their excellent mechanical properties, durability, and cost-effectiveness. This report explores the fabrication methodology, mechanical performance, and potential applications of aluminium-nylon composite panels. The study highlights the bonding techniques, material characterization, and comparative advantages over traditional materials. The findings suggest that aluminium-nylon composites offer superior strength-to-weight ratios and enhanced fatigue resistance, making them suitable for high-performance applications. FEA results are analyzed for deformation and equivalent stress, static stress test conducted, and experimental test also conducted.

Introduction

Composite materials combine two or more distinct materials visibly on a macroscopic scale to form a new material with enhanced properties. Sandwich panels, a type of composite, are valued for their high strength-to-weight ratio and stiffness, making them ideal for aerospace, marine, and automotive uses.

The study’s objectives include evaluating mechanical properties, comparing numerical simulations (FEA) with experiments, analyzing stress and deformation, identifying failure modes, and assessing the aluminum–nylon composite sandwich’s suitability for lightweight structural applications.

The fabrication process involves aluminum surface treatment, chemical etching, anodization, and plasma treatment.

For analysis, software like SOLIDWORKS (for design) and ANSYS (for finite element analysis) are used. Tensile and compression tests are simulated and experimentally performed to study deformation, strain distribution, and mechanical behavior. Boundary conditions mimic real-world tensile testing by fixing one end and applying displacement on the other.

Results show:

• Tensile strength: 145.3 MPa with ductile nylon failure and epoxy delamination.

• Compression strength: 210.7 MPa with epoxy shear cracking and aluminum microbuckling.

• Nylon dominates tensile behavior (high strain capacity), while aluminum governs compression stiffness.

• Epoxy layers are the weakest link, prone to delamination or shear failure.

This comparative mechanical evaluation confirms the composite’s potential for structural applications requiring lightweight and durable materials.

Conclusion

The aluminium-nylon composite panel demonstrated superior mechanical properties, including high tensile strength, excellent impact resistance, and improved fatigue life compared to pure aluminium or nylon alone. The thermal lamination method provided better interfacial bonding than adhesive bonding, ensuring long-term durability. Key advantages of this composite include: 1) Lightweight yet strong, making it ideal for aerospace and automotive applications. 2) Corrosion-resistant, suitable for harsh environments. 3) Cost-effective compared to carbon fiber composites.

References

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Copyright

Copyright © 2025 Mr. V. Praveen Kumar, S. Karthi, G. Yuvaneshwaran. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.