Nano‐enhanced epoxy sandwich composites: Investigating mechanical properties for future aircraft construction

The aviation sector is continually seeking ways to reduce the weight of aircraft structures without compromising their mechanical integrity. Lightweight materials, such as advanced epoxy sandwich composites with hybrid nanostructures, have the potential to significantly contribute to fuel efficiency, thereby addressing environmental concerns and operational costs. This research investigates the mechanical properties of hybrid sandwich polymer composites filled with silica nanoparticles (SNiPs). Epoxy isocyanate (PU) foam sandwich composites were fabricated with kevlar fiber, carbon fiber, and glass fiber, constructed by alternating inclined interply bidirectional fiber and foam layers. SNiPs were introduced into the composite system at varying percentages, such as 0, 2, 4, and 6 wt%. The study employs a systematic approach, incorporating experimental testing, to assess key mechanical parameters, including tensile strength, flexural strength, and shear strength. The test results indicate that the incorporation of SNiPs improved the mechanical properties of the composites, leading to enhanced strength, toughness, and modulus of elasticity. Incorporation of composite laminates with 4 wt% SiNPs resulted in improved three‐point bending, tensile, shear, and torsional strengths, with maximum values of ca. 64, ca. 5, ca. 2 MPa, and ca. 22 Nm, respectively. The findings contribute to the ongoing pursuit of materials that can meet the stringent demands of modern aviation, ultimately paving the way for advancements in aircraft construction and design.