Development of the hybrid insert for composite sandwich satellite structures

Composite sandwich structures which are widely employed in satellite structures require many inserts for assembly. In this study, a new lightweight insert for sandwich structures was developed by reinforcing the web of insert with high strength carbon composite to increase the loading capability with reduced mass. Finite element analysis was performed to numerically predict the load capability of the new insert as well as to investigate the effects of the new insert on the structural reliability. The load capability and the failure modes of the composite sandwich structures assembled with the inserts were measured by the pull-out and shear tests and compared with the calculated results.