In this study, sandwich panels were fabricated with neat and nanophased foam cores and three-layered plain weave carbon fabric/SC-15 epoxy-nanoclay composite face sheets. Neat and nanophased foam cores with Nanocor® I-28E nanoclay at a loading of 0.5% and 1% by weight were prepared. Sandwich panels were then fabricated using the co-injection resin transfer molding (CIRTM) process. The face sheets were made by infusing SC-15 epoxy containing 1 and 2% by weight of nanoclay into three layers of plain weave carbon fabric. Samples of size 100 × 100 mm were then cut from the panels and subjected to impact loading using an instrumented impact test setup. Impact response of the samples was recorded and compared. The tested samples were then sectioned into two halves and scanned using a scanner, and optical and scanning electron microscopes to understand the failure patterns. Samples with nanophased foam sustained higher loads and had lower damage areas as compared with neat counterparts. Nanophased foam cores exhibited brittle fracture.
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