Design optimization of high interface strength metal–polymer–metal sandwich panels

High interface strength metal–polymer–metal sandwich panels with wire-mesh interlayers are fabricated using resistance welding and vacuum hot pressing. Finite element analyses of V-bending of fabricated sandwich panels is carried out to analyze skin-core interface weld failure and spring-back of sandwich panels. Spot and line welds are considered for joining wire-mesh with outer skin. Debonding at interface between skin and core layers is modeled using cohesive zone model. Design parameters including weld size, weld gap, core thickness, and die opening angle are optimized using multi-objective optimization algorithms to reduce weld failures and spring back. Response surfaces are used to identify the effect of design parameters on weld damage and spring-back angle in V-bending of fabricated sandwich panels. Higher weld size (spot diameter or line width) and die opening angle are found to reduce spring-back and weld damage of sandwich panels. Increase in core thickness reduces the spring-back and increases weld damage. [Display omitted] •Finite element analyses for spot and line welded sandwich panels is done.•Designs for avoiding delamination in V-bending of sandwich panels are identified.•Optimal designs are validated with FE analysis and V-bending experiments.