Physical and Mechanical Properties of Sandwich Panels with Castor Oil-Based Polyurethane Biofoam Core.
Composite materials, Castor-oil polyurethane, Sandwich panels, Mechanical properties, Three-point bending.
This work investigated three bonding strategies, simple cure, co-cure with an adhesive layer, and direct bonding, applied to the adhesion between a castor-oil-based polyurethane biofoam core and aluminium faces. The strategies were evaluated through single-lap joint tests (ASTM D1002) to identify the most suitable condition for manufacturing sandwich panels. The results showed that the co-cure strategy yielded the highest apparent shear strength (1.07 MPa), whereas the simple cure exhibited the highest joint toughness (0.622 J), indicating a more ductile behaviour and greater energy absorption capacity. Based on these findings, the simple-cure strategy is used for the fabrication of sandwich panels with castor-oil polyurethane biofoam cores and aluminium or sisal composite faces were fabricated and mechanically characterized. Core shear strength, transverse shear stiffness, shear modulus, and flexural rigidity were determined through three-point bending tests in accordance with ASTM C393 and D7250 standards. Statistical analysis demonstrated that metallic faces provided higher stiffness and strength, while composite faces showed lower performance and increased flexibility. Additionally, sanding the composite faces, although not improving the elastic properties of the sandwich panels, eliminated the delamination failure observed in the majority of the unsanded composite samples. The properties of the fabricated sandwich panels were finally compared to those of other panels available in the literature, indicating that the modulus of elasticity of the fabricated panels is comparable or superior to the reported values.