Fabrication of one-piece high-strength glass cenospheres/aluminum core sandwich by pressure infiltration

In this study, one-piece glass cenospheres/aluminum core sandwich is prepared using a pressure infiltration method. In comparison to adhesive bonding, the layers combined by metallurgical bonding are straight and smooth, and the sandwich shows high shear stress of 80.4 MPa. The failure mode is analyzed through a combination of mises stress distribution simulated using the finite element analysis and in-situ strain distribution obtained from a digital image correlation system. After cracks initiated at interfaces, they propagate to nearby layers in the sandwich structure, which can delay the shear failure by avoiding significant damage of core layer.