Sandwich Composites: Components, Materials, and Fabrication
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SANDWICH COMPOSITES
COMPONENTS OF SANDWICH
COMPOSITES
face sheets, facings, skins
core material
adhesive
FACE SHEETS
traditional composite materials
CORE MATERIALS
honeycomb (
honeycomb (
Hexcel
Hexcel
,
,
Plascore
Plascore
)
)
–
method of manufacture
method of manufacture
expansion process or corrugation process (
expansion process or corrugation process (
see mfg processes
see mfg processes
)
)
determines difference in L/W performance (
determines difference in L/W performance (
see data sheet
see data sheet
)
)
–
materials (
materials (
see property comparison
see property comparison
)
)
aluminum (CR-PAA/CRIII 5052 and 5056, ACG)
aluminum (CR-PAA/CRIII 5052 and 5056, ACG)
aramid fiber reinforced phenolic (HRH-10 (Nomex), KOREX)
aramid fiber reinforced phenolic (HRH-10 (Nomex), KOREX)
glass reinforced phenolic (HRP, HFT)
glass reinforced phenolic (HRP, HFT)
glass reinforced polyimide (HRH-327)
glass reinforced polyimide (HRH-327)
thermoplastic
thermoplastic
closed cell rigid foam
closed cell rigid foam
–
Rohacell
Rohacell
(polymethacrylimide)
(polymethacrylimide)
–
Divinycell
Divinycell
,
,
CoreLite
CoreLite
(polyvinyl chloride)
(polyvinyl chloride)
cast (two-part expanding) foam
cast (two-part expanding) foam
balsa (
balsa (
Baltek
Baltek
,
,
CoreLite
CoreLite
)
)
ADHESIVE BONDING
rely on resin used in face sheet (particularly in wet
lay-up)
film adhesive
select adhesive according to application
FABRICATION PROCESS
forming
–
machining
–
for foams
curing/annealing to achieve desired density and strength
thermoforming
cleaning
–
vacuuming
–
for aluminum - vapor degreasing
–
for Nomex - ethyl alcohol
drying (elevated temperature in air-circulating oven)
face sheets cocured or post-bonded
must check compaction pressure will not crush core materials
or cause intercell buckling of face sheets
ADDITIONAL CONSIDERATIONS
hardpoints for fasteners
hardpoints for fasteners
edge closures
edge closures
Explore the world of sandwich composites, delving into the components such as face sheets, facings, and core materials like honeycomb. Learn about adhesive bonding, fabrication processes, and additional considerations for these versatile materials used in various industries.
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Presentation Transcript
COMPONENTS OF SANDWICH COMPOSITES face sheets, facings, skins core material adhesive
FACE SHEETS traditional composite materials
CORE MATERIALS honeycomb (Hexcel, Plascore) method of manufacture expansion process or corrugation process (see mfg processes) determines difference in L/W performance (see data sheet) materials (see property comparison) aluminum (CR-PAA/CRIII 5052 and 5056, ACG) aramid fiber reinforced phenolic (HRH-10 (Nomex), KOREX) glass reinforced phenolic (HRP, HFT) glass reinforced polyimide (HRH-327) thermoplastic closed cell rigid foam Rohacell (polymethacrylimide) Divinycell, CoreLite (polyvinyl chloride) cast (two-part expanding) foam balsa (Baltek, CoreLite)
ADHESIVE BONDING rely on resin used in face sheet (particularly in wet lay-up) film adhesive select adhesive according to application
FABRICATION PROCESS forming machining for foams curing/annealing to achieve desired density and strength thermoforming cleaning vacuuming for aluminum - vapor degreasing for Nomex - ethyl alcohol drying (elevated temperature in air-circulating oven) face sheets cocured or post-bonded must check compaction pressure will not crush core materials or cause intercell buckling of face sheets
ADDITIONAL CONSIDERATIONS hardpoints for fasteners edge closures
