Characterisation of Innovative Thermoplastic Sandwich Panels for Road and Rail Containers

This thesis explores the mechanical characterization of innovative thermoplastic sand-wich panels used in road and rail containers. Conducted in collaboration with AGESIA at Ghent University (Belgium), the research addresses significant performance issues identified during true-scale testing, where failures of the sandwich panels raised concerns about their structural integrity and reliability. A thorough literature review emphasizes the benefits of thermoplastic composites, including weight reduction, enhanced load capacity, and recyclability, all contributing to improved sustainability in transportation applications. The study includes mechanical testing of the sandwich panel components, specifically GFR PA6 and PET foam core, under various loading conditions at both ambient and elevated temperatures. Key static tests - including tensile, compression, and flexural tests - were conducted to assess the mechanical properties of the materials. The results indicate that the initial composite exhibited unsatisfactory mechanical properties due to manufacturing quality issues. Subsequent testing of a composite from an alternative supplier showed significantly improved performance, providing important insights into the influence of material selection on structural behavior. This research investigate the in-service behaviour of thermoplastic sandwich panels for road and rail containers. Furthermore, it offers recommendations for optimizing the manufacturing process and material choices for sandwich panels, ultimately aiming to enhance their performance and reliability in the transportation sector.