Mode I Debonding Characterisation in Polymer-Based Sandwich Structures: A Review of Experimental Methods

Polymer-based sandwich structures are widely used for their lightweight and tailorable properties, but interfacial failure phenomena often govern their performance. Among these, Mode I skin/core debonding is a critical mechanism that limits structural reliability. This review provides a unified and critical assessment of experimental methodologies for Mode I fracture characterisation, focusing on the ASTM D8637/D8637M standard and alternative setups, including Double Cantilever Beam (DCB), Single Cantilever Beam (SCB), and Climbing Drum Peel (CDP) tests. Alongside the influence of geometrical factors, processing conditions and intrinsic polymer properties on Mode I characterisation are detailed. Conventional DCB setups are shown to introduce mixed-mode effects due to asymmetric loading. In contrast, the modified DCB-UBM setup achieves near-pure Mode I conditions at the expense of increased complexity. Comparative analysis indicates that the SCB configuration with a roller base outperforms the standardised flexible-rod setup, particularly for specimens with non-linear responses. The review also indicates that Mode I debonding behaviour is strongly influenced by several factors, including interfacial adhesion quality, constituent material properties, manufacturing-induced defects, specimen configurations, and environmental factors. Therefore, the interpretation of debonding performance requires a comprehensive structure–property–processing framework. Moreover, geometric constraints imposed by ASTM D8637/D8637M are also revisited, demonstrating that reduced-dimension specimens can yield comparable fracture toughness, thereby enabling greater design flexibility. Additionally, while the standard prescribes Modified Beam Theory (MBT) and Area Method (AM) for initiation and propagation, both methods provide comparable propagation toughness under linear conditions. For non-linear systems, alternative data reductions based on CDP concepts, with the SCB–roller base setup, are effective. Based on this assessment, key challenges and potential improvements are identified, guiding the development of more accurate and reliable testing methodologies for polymer sandwich structures.