The sandwich laminate is an extremely efficient structural design. Consisting of a lightweight core sandwiched between two stiff facesheets, very few constructions can match its stiffness-density ratio. Although many companies use sandwich laminates in their products, finding reliable design information can be difficult.

Unless you have The Handbook of Sandwich Construction, that is. This reference, edited by Dan Zenkert, is without a doubt the one book anyone who works with sandwiches should own. There is not a single important topic this book doesn't cover, and it covers them well.

Just getting started on a sandwich design can be a daunting task. The first two chapters give guidance in first deciding whether a sandwich is appropriate, and then in narrowing down the material options from the literally millions of combinations available. Metallic and composite facesheets, honeycomb, foam and wood cores, and the full range of adhesives are all discussed.

Beam and panel analysis is of course covered, with attention given to the details specific to sandwich construction such as global and local failure, and thermal loads. Analytical plate solutions can be quite complex, so graphs and numerical examples are used to show general trends. A general design procedure helps to organize the many analyses that must be performed on all structures. Finite element analysis is covered, too. The emphasis here is on practical development of models, not on the theory behind the elements.

Engineers making the transition from <monocoque to sandwich structures should pay close attention to the chapters on curved beams and panels, localized loads, inserts and joints. Sandwich structures are designed to carry only shear loads through the core. A curved structure, however, has normal stresses through the core. These stress components, as well as those near localized point or line loads, are often ignored but can lead to premature failure. Similar localized loads arise near joints and inserts. If these features cannot be avoided, The Handbook gives detailed information on how to design and analyze for them.

The extensive chapter on testing would be of interest to anyone working with composites or plastics, not just sandwich laminates. It covers everything from coupon testing of the facesheet and core materials to testing of actual sandwich constructions. Each section references the appropriate international standards, including ASTM, ISO and CRAG. The following chapter on non-destructive testing (NDT) is also of general interest, though rapid development in this field may mean some of the practical information is outdated.

Although some chapters are a bit short and perhaps lacking in detail, ample references are given at the end of each section. The grammar is sloppy in many places, but doesn't detract from the excellent readability of this book.

Details: The Handbook of Sandwich Construction, edited by Dan Zenkert, published by Engineering Materials Advisory Services Ltd. (EMAS), 1997, ISBN 0-947817-96-4.
1. Introduction; 2. Materials and Material Properties; 3. Beam Analysis; 4. Panel Analysis; 5. Design Procedures; 6. Analysis and Design using Finite Elements; 7. Design of Curved Beams and Panels; 8. Localised Loads; 9. Inserts in Sandwich Panels; 10. Joints between Sandwich Panels; 11. Testing of Sandwich Materials, Components and Structures; 12. Thermal Insulation; 13. Non-Destructive Testing of Structures; 14. Damage Assessment of Structures; 15. Manufacturing

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