Understanding Sandwich Composites: Components, Materials, and Fabrication

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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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SANDWICH COMPOSITES

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