Honeycomb sandwich composites are suitable for making structural materials that are mainly characterized by their lightweight and high stiffness strength.The honeycomb structures filled with foam materials or granular materials concerning to the applications enhance the strength and the damping properties. In this paper, an emphasis has been provided for the comprehensive review of response of honeycomb sandwich structures in different conditions, namely, static, dynamic, and damping behaviors with and without filler material from an experimental and finite element simulation perspective. Various applications of honeycomb sandwich composites in different fields are also reviewed in this paper. Potential new directions in honeycomb sandwich composites are also identified in this paper in addition to the current practices. Conclusions and recommendations from different technical papers are reviewed by considering the honeycomb sandwich composites with filler materials. The given area of research seeks more scientific analysis, modeling, and experiments in future structural applications.

A detailed step‐by‐step fabrication procedural document of thin‐walled aluminum honeycomb sandwich composite structures, panels, and specimens using vacuum assisted resin infusion process was delivered in this paper. By and large, honeycomb sandwich structures are made by keeping the honeycomb core in between two face sheets, which are glued with the help of adhesives. In the present fabrication process, aluminum honeycomb core was glued in between the carbon fabric reinforced epoxy composite face sheets through vacuum assisted resin infusion technique. The present paper is aimed at fabricating two configurations of honeycomb sandwich composite panels namely, without considering any filler material inside the honeycomb cell, with considering the filler material inside the honeycomb cell. Plastic pellets made up of poly carbonate were considered as filler material for stiffening the aluminum honeycomb sandwich composite panels.

In the present work, a generic experimental investigation procedure was developed on mechanical characterization and testing of carbon fabric/epoxy material under uniaxial tensile loading condition. In this study, using IR Thermographic NDT, the defects are identified by measuring changes in temperature online during testing and by taking temperature contour images on the surface of the composite samples. The unidirectional elastic properties such as tensile modulus, in-plane shear modulus, Poisson's ratio, and strength parameter like ultimate tensile strength, shear strength are reported. The estimated mechanical properties of carbon fabric/ epoxy composite were statistically analysed in this work using the Weibull distribution. In addition, emphasis on the microstructural investigation using Scanning Electron Microscope (SEM) is given, in order to study the fracture mechanism of the carbon fabric/epoxy composite under uniaxial tensile loading. The failure surfaces of the tensile tested carbon fabric/epoxy specimens were examined by SEM and the detailed fracture process such as matrix cracking, fiber pull outs and delamination are observed and discussed.