• aluminium
• ansys
• bay
• catia
• equipment
• foam
• honeycomb
• launcher
• sandwich
• vehicle

This work aims to explore and compare two types of sandwich structures: Honeycomb and Aluminum Foam, analyzing their state of the art, fundamental characteristics and practical applications. The thesis is structured into six chapters, each focused on a specific aspect of the research.

The document starts with an in-depth analysis of sandwich structures. It delves into a variety of sheet materials and core types, including manufacturing processes. Moreover, significant emphasis is placed on elucidating the primary applications within the aeronautic and space sectors.

After the general introduction about sandwich structures, the focus shifts to aluminum foam, a material known for its porous cellular structure that offers exceptional lightweight properties, strength and energy absorption capabilities. The work explores various production methodologies for this material, which can be grouped into two categories: foam made from metallic melt and foam made from metal powder. It also details the mechanical characteristics, advantages and disadvantages of the two methods, underscoring the demanding applications in the automotive and aerospace fields.
The core of the work consists in a comparative analysis between two different material configurations when applied to a specific part of Ariane 5 launcher (Vehicle Equipment Bay - VEB): Epoxy Carbon Fiber sheets with Aluminum Honeycomb Core and Epoxy S-Glass Fiber with Aluminum Foam core.
VEB’s CAD is performed using CATIA 3DExperience software by Dassault Systemes and imported into Ansys software.
The mechanical properties of these two configurations (such as Young's Modulus, Poisson's ratio, and Shear Modulus) are derived using a theoretical approach and implemented into Ansys. This allows for two different simulations using the Ansys Composite PrePost module, which provides the capability to set the different layers accurately.
Reporting accurately the steps followed to set up the model (Element Orientation, Implementation of Composite Materials, Stackup generated), static analysis, buckling analysis, and modal analysis are conducted to evaluate the different responses of the two material variants under specific load conditions and constraints. Results in terms of deformation, equivalent stresses, instabilities, and natural frequencies, as well as a comparative analysis including costs, are discussed, emphasizing future work that needs to be carried out to enhance the study.