A Dovetail Core Design for Joints in Composite Sandwich Structures

The increase in the size of composite sandwich structures requires the introduction of core splices to join various segments. In this study, a novel core splice joint configuration is studied and proposed for composite sandwich structures of thick aluminum-based honeycomb core and facesheets made from carbon fibers and epoxy matrix. Experimental and numerical efforts investigate the impact of dovetail joints with different tenon angles on the auxiliary behavior of composite sandwich structures. The results are compared to conventional or straight-core splices without dovetail features. The core-splice interaction with the complete mechanical behavior of the system was assessed by subjecting the fabricated specimens to combinations of bending and shear forces. Additionally, 3D-finite element models compared normal and shear stresses in the splice material and the core/splice interface among the dovetail configurations considered. The study shows that depending on the dovetail joint detail, an ultimate strength increase between 13 to 51% is achieved compared to the strength from currently used straight joints. In terms of toughness, the dovetail specimens show a 2% to 35% higher toughness compared to the standard straight joints.