Professional Documents
Culture Documents
Andrew C. Marshall
Fig. 12.2 A striking example of how conversion to sandwich stiffens a structure without materially increas-
ing its weight. This example uses 1.6 mm (0.063 in) thick aluminum facings and 1/4-5052 37 kg/m7 (2.3
lb/fPj aluminum core.
vehicle industry, snow skis, display cases, resi- amounts of ’B’ staged resins; high strength
dential construction materials, interior resins; tough, high peel adhesives requiring
partitions, doors, cabinets and a great many lower cure temperatures and pressures; as
other everyday items. well as the discovery of the resistance of sand-
Although the employment of sandwich wich to sonic fatigue.
design to produce lightweight or special pur-
pose load-carrying members is thought to
12.2 FACING MATERIAL
have originated as early as 1820, routine com-
mercial use of the idea did not occur until The primary function of the face sheets in a
about 110 years later. What started this sudden sandwich structure is to provide the required
acceptance was the successful commercial pro- bending and in-plane shear stiffness and to
duction of structural adhesives, starting in carry the edgewise and bending loads, as well
both UK and USA in the 1920s and 1930s. as the in-plane shear loading. In the aerospace
This early production began with the use of field, facings most commonly chosen are resin
casein glue and later urea-formaldehyde and impregnated fiberglass cloth or a laminate of
phenolics, with wood facings and cores. The unidirectional fibers (commonly called
search for better adhesives subsequently ’prepreg’), graphite prepreg, 2024 or 7075 alu-
resulted in the development of the rubber- minum alloy, titanium alloy, or any of several
phenolics and the vinyl-phenolics, which were stainless steel or refractory metal alloys. Even
suitable for use with metals. Commercial the most economical of these products repre-
adhesives such as ’Cycleweld,’ (from Chrysler sents a substantial cost and customary practice
Motors), ’Plycosite,’ (from US Plywood) and is to choose among them very carefully on a
’Redux’ (from Bonded Structures, in Duxford, value engineering, or lowest lifetime cost,
UK) adhered well to both wood and metals basis.
and possessed rather high and predictable
strength.
12.2.1 SUITABILITY OF MATERIALS
The result was the beginning of a revolution
in bonding technology. Many further develop- When choosing facing materials (as well as the
ments followed in only a few years. They core, adhesive, or other materials) for an appli-
included improved cleaning methods for cation, it is wise to examine the less obvious
metal skins; low weight, high strength/stiff- properties of the material, such as toughness
ness honeycomb core materials; ‘B’ staged or brittleness, mode of fracture, durability and
tape adhesives which could be stored for long weatherability, compatibility with rivets and
times; glass fabrics and collimated tapes bolts and other such attributes which may
preimpregnated with accurately measured directly affect the usability or success of the
256 Sandwich construction
end product, even though not directly applications such as boat hulls, large tanks and
involved in stress analysis or weight savings. airborne pallets and containers. This broaden-
An understanding of these requirements has ing usage is also prompted by its excellent
resulted in a switch from aluminum to fiber- compressive strength and modulus properties
glass skins and from fiberglass to aramid when compared to all but the aramid paper
(Nomex, from DuPont) cores for most aircraft honeycombs, which are much more expensive.
cabin interior panels. Complete information can be obtained from
the leading producer of these materials,
BaltekI3,or Balsa Ecuador Lumber Company.
12.3 CORE MATERIALS
exception to this statement lies in the extensive foams, even though this value is needed for
use of polystyrene foams as cores in several sandwich panel design. This property, even
thousand amateur-built composite aircraft. where listed, cannot be considered to be a reli-
This application was pioneered by Burt Rutan, able value. The actual value for an application
in his ’moldless construction’, used in his at hand must be determined for the actual
series of high performance small aircraft and materials and conditions of use in order to be
the many similar designs offered by others in considered reliable. When a value for shear
subsequent years. strength is not available, it may be roughly
The polyvinyl chloride (PVC) foams, which estimated to be about 0.7 times the compres-
made an impact on the transport aircraft sive strength shown. Even the compressive
industry as flooring cores, have been largely strength cannot be considered to be reliable,
replaced by the more efficient high density however, as many differing methods of mea-
aramid honeycombs. suring this value are commonly used and each
The foam-in-place system of producing results in a substantially different value
sandwich structures has been used for more reported.
than 35 years, because of its simple concept.
However, users of this system have always
12.3.2 HONEYCOMB
had difficulty with the continuing problem of
producing uniform properties from one mix to Honeycomb types in common usage include
the next and in achieving uniformly high core products made from uncoated and resin-
and bond strengths to the metal or pre-cured impregnated kraft paper, various aluminum
glass fiber skins. The use of systematic incom- alloys, aramid paper and glass or carbon fiber
ing inspection, automatic mixing and reinforced plastic in a number of cloth weaves
dispensing equipment and, in the case of criti- and resin systems. Honeycombs based on tita-
cal airframe parts, test coupons, produced nium, stainless steel and many others are used
integrally with the basic part, have all helped in lesser quantities. Most honeycomb cores are
to keep the problems under control. constructed by adhesively bonding strips of
It will be noted that Table 12.1 does not list thin material together, as shown in Fig. 12.3.
the shear strength of many of the various In the case of aramid paper honeycomb, the
Roll c T r
TYP Compressive
Tensile strength Maximum
strength at 10% deflection service
Density (ASTM 01623) (ASTM 01621) temperature
lb/ft3 kg/m3 psi MPa psi MPa "F "C
ABS
(acrylonitrile
bu tadiene-styrene)
Injection molding
type pellets 40-56 641-897 20004000 13.8-27.6 2300-3700 15.8-25.5 176-180 80-82
Cellulois acetate
Boards and rods
(rigid, closed
cell foam) 6.0-8.0 96-128 170 1.2 125 0.86 350 177
Epoxies
Rigid closed cell, 5.0 80 51 0.35 90 0.62 350 177
precast blocks, 10.0 160 180 1.2 260 1.8 350 177
slabs, sheet 20.0 320 650 4.5 1080 7.4 350 177
Phenolics
Foam-in-phase 'X-1% 5-24 3-17 0.021-0.12 2-15 0.014-0.10
liquid resin 2-5 32-80 20-54 0.1384.372 22-85 0.15-0.58 Continuous
7-10 112-160 80-130 0.552-0.896 158-300 1.09-2.07 service at 145
300
Polypropylene
Pellets 50 801 5500 37.9 7500 51.7 270 132
Polypropylene" 35.0 561 1600 11.03 2100 14.4
Polyurethaneb 1.3-3.0 2148 15-96 0.104.65 15-60 0.10-0.41 180-250 82-121
4-8 64-128 90-290 0.62-1.99 70-275 0.48-1.90 200-250 93-131
9-12 144192 230450 1.58-3.10 290-550 1.99-3.79 250-275 121-135
13-18 208-288 475-700 3.284.83 650-1100 4.48-7.58 250-300 121-149
19-25 30p400 775-1300 5.34-8.96 1200-2000 8.27-13.8 250-300 121-149
Skinned molded
(rigid)
Skin 25-65 400-1041 100-2700 0.68-18.6 40-3000 0.28-20.7 150-250 66-121
Core 3-30 48481 15-1500 15-1500 150-250 66-121
Polyvinyl chloride
Rigid closed cell 3 48 1000 6.90 95 0.65
andup andup
boards and billets 6 96 200 1.38
* Where shear strength and modulus properties are not shown, use a figure of 0.7 times the compressive strength shown
as a first approximation for design feasibility consideration. Always test actual material used for true value of shear
strength and modulus.
a High density, foam, molded, parts and shapes, with solid, integral skin.
Rigid (closed cell) molded parts; boards, blocks, slabs; pipe covering; one-shot, two- and three-package systems for
foam-in-place;for spray, pour, or froth-pour techniques.
Core materials 259
Type Thermal
conductivity Shear Shear
strength modulus
BTU in
h-'Pf2 Wm-' K-I psi MPa psi MPa
~ _ _
ABS
(acrylonitrile
butadiene-styrene)
Injection molding
type pellets 0.58-2.1 0.08-0.30
Cellulose acetate
Boards and rods
(rigid, closed
cell foam) 0.31 0.04
Epoxies
Rigid closed cell, 0.26 0.04
precast blocks, 0.28 0.04
slabs, sheet 0.32 0.05
Phenolics
Foam-in-phase 0.2 1-0.28 0.03-0.04
liquid resin 0.20-0.22 0.03-0.04
0.24-0.28 0.03-0.04
Polypropylene
Pellets 1.05 0.15
Polypropylene" 4.2 0.61
Polyurethaneb 0.11-0.21 0.2-0.4 20 0.14 226 1.56
0.15-0.29 0.02-0.04 90 0.62 1500 10.3
0.19-0.35 0.03-0.05 180 1.24 4500 31.0
0.26-0.40 0.04-0.06
0.34-0.52 0.05-0.07 450 3.1 15000 103.5
Skinned molded
(rigid)
Skin 0.12-0.80 0.02-0.12
Core 0.21-0.55 20-500 225-15 000
Polyvinyl chloride
Rigid closed cell 2.0 at 70 65 0.45 1200 8.3
boards and billets 120 0.83 2200 15.2
* Where shear strength and modulus properties are not shown, use a figure of 0.7 times the compressive strength shown
as a first approximation for design feasibility consideration. Always test actual material used for true value of shear
strength and modulus.
a High density, foam, molded, parts and shapes, with solid, integral skin.
Rigid (closed cell) molded parts; boards, blocks, slabs; pipe covering; one-shot, two- and three-package systems for
foam-in-place; for spray, pour, or froth-pour techniques.
260 Sandwich construction
inherent toughness and abuse resistance of the enced by the properties of the materials from
material makes cores of 1 6 4 8 k g / m 3 (1-3 which they are manufactured. Some of these
lb/ft3) an excellent choice for aircraft cabin differences are obvious in the thermal conduc-
interior walls and ceilings, even with glass fab- tivity information shown in Fig. 12.4 and Fig.
ric-reinforced skins as low as 0.254 mm (0.010 12.5. However, several significant properties
in) in thickness. of honeycomb cores are peculiar to the materi-
Physical and mechanical properties of the als and should be separately noted.
honeycomb core materials are strongly influ-
E13021
W
P-=x
&j.014
w
0)
U
007
(4 0
25(1 0) 5 0 (20) 76(30 lO(40)
Core Thickness- cm (in )
1.2 , I I I I I I I I
1.1
1.o
Y
a .9
8
4:
Y
.e
.7
5
F .6
8 .5
0
0 .4
I 1 I I I
I
I I
2
I
HEXAGON' C E L L S
3
I I
4
used to confirm actual values obtained, as the CORE THICKNESS (INCHES J
Density
All mechanical properties increase with higher the loads anticipated. Figure 12.7shows typical
density, as shown in Fig. 12.6. differences in shear strength for the L and W
directions. In addition, some cell shapes allow
easy forming or curving at a small loss in
Cell shape
strength/weight ratio. This attribute can be of
All honeycombs are anisotropic and the result- great importance in manufacturing curved
ing directional properties should be adapted to parts of appreciable thickness.
1 PCF
I L Fig. 12.6(b) Typical 'L' shear
0 20 40 60 80 100 120 140 160kglm'
Density strengths.
C D
E F
Cell size
Although cell size tends to be a secondary
variable for most mechanical properties of
core materials, it is primary in fixing the
strength level of the core-to-face attachment
(or, more accurately, in fixing the required
lower limit on core-to-panel adhesive weight)
and in determining stress levels at which
intracell buckling or face dimpling of facings
occurs.
Thickness v :
The shear and compressive properties noted
Fig. 12.9 Plate shear test for honeycomb shear
for a 'pecific 'Ore type can Only be strength and modulus 1.27 cm (0.50 in) thick steel
when test methods are 'Pecified and plates are oven-cleaned and may be reused many
controlled and the correct thickness of core is times.
tested. Failure to allow for the effect of thick-
ness can affect observed values by a factor of 4
or more, as noted in Fig. 12.5. It should be
emphasized that the correction factor shown
may be considerably different, depending on
skin material and thickness, as well as the
exact test method used.
employed as decoration - and are still fre- Some of the above alloys are also available as
quently seen today as seasonal decorations in corrugated, corrugated and reinforced, over-
department stores in the form of expanded expanded and flexible cell configurations.
bells, spheres and so forth. Some have also been produced in a specially
Current materials used as sandwich cores tailored geometry to make all the cell axes lie
are different, in that much stronger kraft paper on a true radius of a cylinder, a sphere, or
is employed and 11-35% phenolic resin is fre- other unique configurations. These same alloy
quently used to improve mechanical foils can also be wound as a corrugated spiral
properties, as well as moisture and fungus to form a cylinder or tube for very light energy
resistance. Many variations are available in absorption applications.
cell sizes of 10,13 and 19 mm (%, X and % in) or The aluminum honeycomb cores remain
even larger sizes. The higher strength versions the most used, as well as the most versatile of
are only produced in the smaller cell size, with the various core materials obtainable and are
the 10mm (% in) cell available as a water- often found to possess the most favorable per-
migration resistant grade meeting military formance/cost ratio available. Expanded
specification MIL-H-2104Q. aluminum cores commercially available
Most applications are found in non-aircraft ranges from a low of about 32 kg/m3 (2 lb/ft3)
uses, where cost saving is the one primary to a high of 192kg/m3 (12.0Ib/ft").
objective. Usage is growing rapidly in recre- Corrugated aluminum cores, however, start at
ational vehicles; for doors, walls and under 128kg/m3 (81b/ft3) and can be pur-
partitions; for factory produced kitchen cabi- chased up to 880 kg/m3 (55 lb/ft3). At
nets; in packaged patio room additions for densities below 128 kg/m3 (8 lb/ft3) corru-
homes; in curtain wall panels; and in bearing gated core suffers a serious penalty in shear
walls for commercial building. properties when compared to expanded core.
This family of materials has been in produc- This family of materials is most commonly
tion and growing since about 1947.Aluminum used in electrically sensitive parts, such as
honeycomb now includes four alloys, at least radomes and antennae, or where a heat resis-
five cell shapes and many foil gauges to pro- tant resin and low thermal conductivity make
vide a range of densities. The alloys generally it a natural choice. It has also seen distin-
available are: guished service as a matrix for retaining
non-structural ablative materials, such as soft
0 3003-H19, the lowest strength of the group, silicone rubbers or syntactic rigid epoxy
usually used for non-aircraft applications; foams, which otherwise could not have been
0 5052-H39, the most often used aircraft used effectively as ablative heat shields on the
grade, available with a corrosion resistant Gemini and Apollo re-entry vehicles.
surface treatment. Mechanical properties Only high temperature phenolic and poly-
are listed in Table 12.2; imide cores are generally produced. They are
0 5056-H39, the strongest of the regular air- commonly available in cell sizes of 5, 6.3 and
craft grades, available with a corrosion 10 mm (K, X and X in) with a 3 mm (% in) cell
resistant surface treatment; available in a bias weave glass reinforcement.
0 2024-T3 or T81, the most heat-resistant alloy Densities range from 32 to 192 kg/m" (2 to 12
and slightly stronger in some properties lb/ft3). Mechanical properties of several com-
than 5056-H39. Available with a corrosion mercially available glass fiber-reinforced cores
resistant surface treatment. are shown in Tables 12.3-12.6.
Core materials 269
__
designation Strength, Strength, Modulus, Strength, Modulus, Strength, Modulus,
material - cell - density__ psi psi ksi psi ksi psi ksi
typical typical typical typical typical typical typical
HFT - 1/8 - 3.0 300p 350p 22p 185p 17P 95P 7P
HFT - 1 / 8 - 4.0 390p 575p 45p 300p 32P 150p 12p
HFT - 1 / 8 - 5.5 52533 960p 67p 425p 42P 225p 17p
HFT - 1/8 - 8.0 1450p 1625p 1OOp 575p 48P 340p 25p
HFT - 3/16 - 1.8 75P 120p 14p 105p 13P 5% 4P
HFT - 3/16 - 2.0 loop 170p 17p 115p 15P 6OP 5P
HFT - 3/16 - 3.0 27513 375p 32p 200p 24P loop 9P
HFT - 3/16 - 4.0 435p 550p 45p 275p 3% 140p 12p
HFT/OX - 3/16 - 6.0 lOOOp 11OOp 67p 290p 13P 335p 30p
* Test data obtained at 0.500 in thickness. Honeycomb is normally not tested for bare compressive strength.
in typical panels result in low volumes of space vehicles. In addition to this small usage,
smoke and gases given off in fire tests. Typical however, carbon fiber honeycomb is now used
applications make use of these properties very as the structural core for nacelle assemblies in
effectively.As a consequence, they have grown the Boeing Model 777 transport aircraft. The
to a commercial volume nearly as large as that constant pressure for lighter structures in such
of aluminum, for use in aircraft structures. designs has led to the use of carbon fiber fac-
Uses outside the aerospace industry are lim- ings, which have a potential corrosion
ited due to the high cost of the material, but problem when used with aluminum cores.
despite this it has seen some application in This concern for corrosion problems has sub-
boat hulls up to 10.2 m (40 ft) in length, as well sequently led to the adoption of a new class of
as in skis, racing shells and several other prod- carbon fiber honeycomb materials for this air-
ucts. craft and will possibly lead to further use in
Aramid core is normally produced in cell other future designs.
sizes of 3, 5, 6.5 and 10 mm (%, 36,X and % in), Two types of carbon fiber cores are now
in densities of 24-192 kg/m3 (1.5-12 lb/ft"). being produced. One is for purely structural
Densities higher than 64 kg/m3 (4 lb/ft3) are applications, while the other has a require-
almost entirely used for aircraft flooring. ment for heat transfer through the thickness of
Mechanical properties of some of these core the panel. The former type uses only the usual
materials are shown in Table 12.6. pan based carbon fibers, while the latter
employs pitch based carbon fibers, which
duplicate the heat transfer properties of the
Carbon fiber honeycomb
aluminum core which it replaces. Although
Reinforced plastic honeycomb has for many neither of these materials is as yet in large vol-
years employed glass fabric reinforcement,b u t ume production, the economic impact is
only rarely employed other fibers. In the past substantial, since these honeycombs are
few years, however, both Kevlar and carbon markedly higher in price than the aluminum
fiber have become much more common as or Nomex cores they replace.
reinforcing fibers for honeycomb. Carbon Little data is yet available on these new
fibers only now are beginning to be used in cores, but it is likely they will see substantial
Adhesive materials 271
use and public scrutiny in the next several be understood by the designer and fabricator
years. in order for the otherwise inevitable problems
to be avoided. Some factors which merit atten-
tion are discussed below.
Kevlar honeycomb
This honeycomb has been in use for a number
of years as a core for space vehicle antenna 12.4.1 PRODUCTS GIVEN OFF DURING CURE
reflectors. The purpose of the Kevlar honey- Some adhesive types, such as phenolic, give
comb is to allow transmission of radio signals off a vapor as a product of the curing reaction
through the panel, while at the same time the and the presence of these secondary materials
Kevlar facing acts as a partial reflecting antenna can lead to several problems:
for a different wavelength of a different signal.
Kevlar honeycomb, based on one of several 0 internal pressure, resulting in little or no
fabrics woven from Kevlar yarn, is usually bond in some areas, or 'blisters';
produced in cell sizes of 6.3-9.5 mm (%-% in) . 0 core splitting, as the gas forces its way
Usual densities available range from 16 to through the core to a lower pressure area;
64 kg/m3 (14 Ib/ft3). 0 core movement, sometimes several inches,
resulting in an unusable cured part;
0 subsequent corrosion of core or skins by the
Kevlar paper honeycomb chemical action of the vapor or its residual
In addition to Kevlar honeycomb made from condensate.
woven fabric, DuPont has recently introduced
a new honeycomb, based on a Nomex-like 12.4.2 BONDING PRESSURE
paper, which is entirely composed of fibers
derived from Kevlar. This material has rather Adhesives such as the phenolics and some
surprising mechanical and physical proper- others actually require more than atmospheric
ties, with strengths well above both glass and pressure in order to prevent excessive poros-
Nomex honeycombs and dielectric properties ity. Certain forms may be suitable for solid
somewhat superior to Nomex. This material is cores like balsa, but cannot be used at all in
trade named 'Kortex' and is available in the open cores such as honeycomb or large cell
usual range of cell sizes and densities. foams. Also, most core materials will not alone
Because the material is somewhat more withstand compressive bonding loads exceed-
expensive than Nomex, no large scale replace- ing a few atmospheres and consequently
ment of Nomex honeycomb appears likely, cannot be used with any adhesive system
although many special purpose applications requiring higher pressures.
have been developed in both air and space
craft.
12.4.3 FILLET FORMING
In order to achieve a good attachment to an
12.4 ADHESIVE MATERIALS
open cell core, such as honeycomb, the adhe-
Adhesives, as they apply to sandwich struc- sive must have a unique combination of
tures, constitute a somewhat different family surface tension, surface wetting and controlled
of materials than those required to bond an flow during early stages of cure. Controlled
open cellular core to a stiff and continuous fac- flow prevents the adhesive from flowing
ing. Although these differences are less down the cell wall and leaving a low strength
important with some of the newer modified top skin attachment and an overweight bot-
epoxy materials, they remain basic and must tom skin attachment.
272 Sandwich construction
Loloo
m m m
OOLo
m a m
+ e m
Adhesive matevials 273
m o o
d N N
o m 0
d m N
m a -
s;
2.N
-..
6
u
u
m
274 Sandwich construction
12.4.4 ADAPTABILITY
The requirements noted above must all be met
while also meeting all the requirements of a
skin-to-skin to skin-to-doubler attachment. In
the case of contoured parts, the adhesive must
also be a good 'gap-filler ' without appreciable
strength penalty, since tolerance control of
details is much more difficult to achieve on
contoured than on flat panels and a greater
degree of latitude for misfit must usually be
allowed.
The peel test is used to control quality 12.4.9 NITRILE RUBBER MODIFIED EPOXIES
throughout the sandwich industry. Values
These make up a broad group of more recent
obtained, provided the adhesive weight and
materials which provide much of the flow and
core material are in balance, will give indica-
toughness shown by the nylon-epoxies, along
tions of tooling or cure problems and of
with the durability and weather resistance of
adherend surface preparation problems. It is
the vinyl-phenolics. They are the most com-
particularly useful for this when an environ-
mon of the 'toughened' thermosetting
mental exposure involving both elevated
adhesives and are usually limited to about
temperature and high humidity is interposed
149°C (300°F) service temperature. Some of
between manufacture and test. It is also adapt-
these materials routinely achieve shear
able to use with nearly any skin material,
strengths of 34500 kPa (5000psi) and most
except that it becomes impractical with very
can be cured over a wide range of tempera-
thick or very stiff skins.
tures and pressures.
It can be readily seen that a number of points
of difference separate the sandwich adhesives
from other structural adhesives. Fortunately for 12.4.10 URETHANES
the sandwich user, many adhesives are avail-
able which satisfactorily meet both sets of Urethane based adhesives are used in
requirements. me types available, along with commercial structures. Both moisture-cured
some salient features, are as follows. and two-part systems are available.
216°C (420°F) for some of the materials All the above forms of adhesive are in cur-
intended for service at elevated temperatures. rent use at substantial volume and most are
available from many sources.
Supported films
12.5 DESIGNING A SANDWICH
Films or tapes having a carrier of light glass
fiber, cotton, nylon, or polyester fabric, or The usual objective of a sandwich design is to
spunbonded synthetic fiber are provided save weight or to increase stiffness or to use
either dry or with slight to moderate ’tack’ or less of an expensive skin material, or perhaps
stickiness, so that the parts of the assembly all three. Sometimes other objectives, such as
stay in place as they are being assembled. reducing tooling or manufacturing costs,
achieving aerodynamic smoothness, reducing
reflected noise, or increasing durability under
Unsupported films, containing only the
exposure to acoustic energy, are also involved.
adhesive
The designer’s problems sift down to rela-
The very low weight films are nearly always tively few, such as getting the loads in, getting
furnished without a carrier, as the weight of the loads out and attaching small or large
the carrier itself becomes quite appreciable in load-carrying members, under constraints of
very light sandwich structures. They are often deflection, contour, weight and cost.
hard to handle and sometimes have bond line
Understand the fabrication sequence and meth-
control problems.
ods. The cost of a sandwich structure is
fundamentally fixed at the design stage and
Reticulating films a considerable difference in cost can result
from alternate solutions to the design prob-
These are intended for use at very low
lem. Both of the edge close-out details
weights, with the adhesive being melted by
shown in Fig. 12.12 perform essentially the
hot air after placing on the core, so that it
same job at the same weight. Placing the
draws back to the cell edge and provides
legs of the channel facing outward instead
material to form the largest possible fillet
of inward saves the cost of two relief cuts
without wasting any on the inside facing sur-
into the core and the very difficult step of
face in the middle of the cell.
sliding the edge of the core and adhesive
into the channel. Another alternative at
Cell-edge adhesive even lower cost for either fixed or simply
supported edges is shown in Figs.
This is a material pre-placed on the cell edge
12.13-12.16.
by the honeycomb manufacturer to provide
Use the right core. Several densities of core
the same results as those produced with retic-
can be used in a single panel, each appro-
ulating films.
priate to the load carried in the area and
adhesively bonded to its neighbor, as
Self-adhesive skins shown in Fig. 12.17. In many cases, how-
ever, the weight saved in lower density
These skins are usually structural fabrics of
areas of core is added back in the form of
glass, graphite, quartz, or aluminum coated
core splice adhesive weight. Core splices,
glass fibers, pre-impregnated with a resin,
such as those shown in Fig. 12.18(b)or (c),
which is then cured so that the fiber-filled
have been used to produce ablative matrix
resin becomes both the face structure and the
structures for large re-entry heat shields,
attaching material.
Designing a sandwich 277
1 (
GOOD
POOR
~ .. .
Fig. 12.12 The square edge close-out shown here using a channel may result in a neat, clean edge, but
requires machining both the top and bottom of the core and squeezing adhesive and core into the channel
during assembly. The alternative shown on the left would be much better.
Densified Core 2
''2
METAL
F O RMEO RING ---.
Fig. 12.14 Several common edge treatments.
278 Sandwich construction
Fig. 12.15 Several suggestions for corner designs, edge close-outs and splices.
Ex trurion,
f Weldd
b
\
Locking Bar
C
Fig. 12.18 Joint A may be formed by simply crushing one piece of glass fabric honeycomb into the adjoin-
ing section. This method will work to some extent with some aluminum honeycombs, but not with most
other core materials. Joints B and C require a perfect match of cell shape and cell pitch and are very diffi-
cult to produce on any realistic and cost-effective basis.
but become prohibitively expensive to pro- 5. Use doublers where needed, instead of a heavier
duce for splices more than a few inches facing over the entire part. The use of doublers,
long. although adding labor cost in assembly,
Do not hesitate to use several joining methods often improves the part quality. Where
in the same part. Fittings to be included in a skins are formed of glass or graphite
bonded sandwich may be produced from prepreg, the problem is even simpler, since
weldments, forgings or riveted assemblies, extra plies can be added to carry extra loads
or may themselves be bonded assemblies. exactly where and as needed.
Available adhesives permit secondary 6. Use external doublers rather than infernal dou-
bonding to be performed at temperatures blers wherever possible. The use of internal
from 16°C (60°F) up to 177°C (350°F) with- doublers usually means that a relief cut
out degrading the integrity of the must be made in the thickness dimension of
previously bonded sub-assemblies. the core to prevent bridging and a conse-
Use bolts and rivets for carrying loads (not for quent unbonded area where the doubler
soothing fears). Where space is not available ends. Figure 12.19 shows a panel where the
for progressive doublers or wide-area loads which can be carried are the same at
bonded overlaps to carry high loads, the each end of the panel. The design detail on
addition of rivets or bolts is sometimes the the left end can cost substantially more to
only solution. Their use, however, often manufacture than that on the right end.
results in lower (sometimes dramatically Figure 12.20 shows the same panel with
lower) fatigue life of the structure, in addi- both ends produced at low cost, while still
tion t o increased weight. The use of achieving an unbroken outer skin line on
'chicken rivets', added for the sole purpose one side. In the case of some skin materials,
of appearance, is to be particularly avoided, such as 0.25mm (0.010in) aluminum, or
since they often defeat much of the advan- most weights of pre-impregnated glass or
tage which would otherwise result from use graphite cloth, it is feasible to use thin dou-
of the bonded structure. blers without a relief cut in the core, since
280 Sandwich construction
I
1
Fig. 12.20 Low cost doubler treatment.
the gap caused by bridging is small enough 12.6 STRUCTURAL ANALYSIS FOR SPECIFIC
to be within the capacity of the adhesive to CASES
fill. Sometimes an extra layer of adhesive The following notations are used in sandwich
film is added to help. An example of a dou- design formulas.* This chapter’s formulas are
ble skin splice using this method is shown only for honeycomb beams and columns
in Fig. 12.21. which have the same facings on each side of
the core.
Structural analysis for specific cases 281
Facing failure
Initial failure may occur in either
compression or tension face. caused Of =
M
t, hb
~
General buckling
Caused by insufficient panel
thickness or insufficient core rigidity.
Shear crimping
Sometimes occurs following, and
as a consequence of, general buckling.
Caused by low core shear modulus, PCr= tcGc
or low adhesive shear strength.
Fig. 12.22 Modes of failure in sandwich structures. Sandwich structures must be designed to resist these
modes of failure. Failures may occur which combine more than one of the modes shown.
Structural analysis for specific cases 283
Maximum Shear
shear deflection
Beam type
force constant
V
I Simple s t m
. .o r t Uniform load 1
1- I f E
8
5
__
384
1
-
8
I I
I
Simple support
A
IP
Center load
P
-
2
E
4
“ I +
192
I I I
Cantilever Uniform load
P = ql
lrrrrrrr
I I I
Fig. 12.23 Loaded beam chart, where P = total load (per unit width), L = span, 0,= facing stress, t, = skin
= core stress, compressive,A = (1 -/,L)~facing prop-
thickness, h = centroid distance, zcs= core stress, shear, tcc
erty, E , = modulus of elasticity of facings, Gc = modulus of elasticity of core in shear, Ism,= moment of inertia,
sandwich, s = cell size, Ec = modulus of elasticity of core in compressions, F S = factor of safety, T = total
sandwich thickness (note that P must be determined for a beam unit width). If deflections are critical,
actual deflections should be verified by tests.
284 Sandwich construction
-[I
2E, t,
ufcnt. = 1 ,
Skin, t,: Try t = 0.090 in
E,tc
A = 0.98, E , = 1.85 x lo6.
Calculate h:
Factor of safety:
K,P'L~~P
Allowable or typical stress A=
FS = tPE,
calculated stress
-
-
0.013 x 0.833 x 964x 2 x O.98ll2
12.6.5 SAMPLE PROBLEM: ANALYSIS OF FLAT
0.090 x 96/270 x 1.85 x lo6
RECTANGULAR SANDWICH BEAMS h = 5.518 (round out to 5.5 = panel total thick-
ness, h = 5.41)
Design a flat roof panel for a bus stop. Use a
Try thicker skin t, = 0.150
snow load of 120 lb/ft2. Use a simple panel
with a simply supported span of 0.203 m (8 ft).
h = 0.013 x 0.833 x 96*x 2 x O.98ll2
Deflection is to be limited to L/270 and the fac- 0.150 x 96/270 x 1.85 x lo6
tor of safety is to be greater than 2.0. Skin
= 4.274
Use 4.00 overall thickness, h = 3.850. Since
either construction is practical check out the
skin and core stresses:
P'L2 - 0.833 ~ 9 6 = ~ 1971 psi
Uf = ~
Uf =
0.833 962 = 1662 psi
0.150 x 3.85 x 8
te that the skin stresses are quite close;
therefore, the factors of safety would be simi-
lar.
38 000
Fig. 12.24 Schematic diagram of a flat sandwich FS = = 19;FS = 38000 = 23
panel. 1971 1662
~ ~
286 Sandwich construcfion
Table 12.7
Subject MIL-HDBK-23 *
CHAPTER
~~
_ _ ~ ~~~ ~~~
1. Make sure the core is properly sized to fit much more slowly, resulting in warpage
the space it is intended to occupy. If it has problems upon cool-down. Warpage on
been stretched a little, to make the distance very light parts can also be caused by one
from one edge member to the opposite one, side cooling down too fast as a result of
it will probably shrink back as the cure having one side removed from the still-hot
cycles starts, leaving mysterious voids next tooling, while the other side continues to
to an edge member. If it is undersize in stay at the temperature of the tool. Also one
thickness at an edge, the adjoining edge side, next to the bag may be heating faster
member or fitting will hold the facing away or to a higher temperature than the oppo-
from the core and result in an unbonded site face, which is in contact with a massive
area. and still cold tool. Slower heat-up rates or
2. If a honeycomb core is being used, remem- better heat distribution in the tool design
ber that the adhesive between the core and will help prevent these problems.
the faces will end up much thinner than the 6. Be sure to provide a route for the escape of
same adhesive between the edges or solid trapped air and gases from a totally enclosed
inserts and the facings. For this reason, it is part while it is being cured. This is particu-
common to require the core to be as much larly important in parts which are vacuum
as 0.25 mm ( 0.010 in) thicker than adjoining bagged to a female tool and cured in an auto-
solid parts in the same assembly. clave. A coarse cloth 'breather' should be
3. The elevated temperatures which most enclosed inside the bag to prevent the bag
core-to-facing adhesives require for curing from sealing off portions of the assembly as
are often inaccurately measured. A good pressure is being applied. Critical or expen-
point to remember is that only the adhesive sive assemblies should have several vacuum
being cured can give you the cure tempera- lines attached at different points of the bag,
ture you are trying to measure. Some shops with each monitored separately by a pres-
insert thermocouples directly into the bond sure recorder.
line to determine temperature and then 7. Caul plates should be carefully matched to
leave the thermocouple permanently in the the job they are expected to perform. These
part after cure is completed. tooling aids are often used to cover the top
4. Most adhesives flow at an early point in the of an assembly containing several different
cure cycle. At this time, the bond lines will pieces of core, inserts, edges, etc., so that a
change in thickness by substantial amounts. thin skin will not push each detail to the
The tooling employed to establish the shape minimum bond line thickness and result in
of the part and hold details in place must an uneven outer surface. When the caul
also allow the details to move into their plate is moderately stiffer than the top skin,
final cured position. Simple examples are a the bonding pressure is transmitted more to
hot platen press, in which the platens close the thicker inserts and less to the under-
on the sandwich as the bond lines grow sized inserts, allowing all of the details to
thinner, or an autoclave, in which a flexible 'float' in the adhesive before cure, resulting
bag follows the details as the adhesive in optimum relative placement of all the
flows, continuously transmitting the auto- internal details in the sandwich. If the caul
clave pressure to the shrinking assembly. plate is extremely stiff or thick, this effect is
Keep in mind that most adhesives are very changed to one of simply bridging over the
weak and crack-prone as they go through most oversized details and the danger of
the gel point. producing voids or unbonded areas over
5. Inserts or heavy members being cured as a the thinner details is substantially
part of a very light assembly will heat up increased. Generally, the caul plate should
Manufact uring sandwich structures 289
REFERENCES
1. MIL-HDBK-23, US Government Printing Office,
Washington, DC*.
2. MIL-HDBK-17, US Government Printing Office,
Washington, DC.
3. MIL-HDBK-5, US Government Printing Office,
Washington, DC.
4. MIL-A-132, US Government Printing Office,
Washington, DC.
5. MIL-A-25463, US Government Printing Office,
Washington, DC.
6. MIL-STD-401, US Government Printing Office,
Washington, DC.
7. Adhesive Bonded Aerosvace Structures Standard
Repair Handbook, US’ Government Printing
Fig. 12.27 Nose radome core assembly, assembled Office, Washington, DC,
by edge-bonding together several post-formed sec- 8, Hexcel Corporation, TSB-120.
tions of glass fabric-phenolic honeycomb. Nomex 9. Hexcel Corporation, TSB-123.
core may also be formed in this manner. 10. Hexcel Corporation, TSB-124.
11. Alcore, TR-il2.
12. American Cyanamid, Handbook of Adhesives.
13. Baltek Corporation, Baltek Catalog.
14. Plantema, Frederic J., Sandwich Construction,
John Wiley & Sons, New York. 1966.
15. American Plywood Association, Plywood Design
Specifica tion.
16. Roark, R.J., Formulas for Stress and Strain,
McGraw-Hill, New York, NY., 5th edn, 1975.
17. Timoshenko, S., Woinowsky-Krieger, S., Theoy
ofPlates and Shells, McGraw-Hill, New York, NY.
I
2nd edn, 1959.
*Publicationsof the US Government may be updated
and revised from time to time. Be sure you have the
most recent edition. This can be checked by con-
tacting the Plastics Technical Evaluation Center, US
Army Armament Research and Development
Fig. 12.28 Effect of roll-forming on aluminum hon- Command, Dover, New Jersey. The publication
eycomb. The core on the left has been roll-formed in MIL-HDBK-23 was abandoned some years ago.
sheet metal forming rolls, while the piece on the However, because the information it contained con-
right has not been pre-formed at all. Note the anti- tinues to be needed by designers of spacecraft
clastic, or ‘saddle shape’, which the unformed piece structures, the entire publication will in future be
assumes when forced to a cylindrical form. included within MIL-HDBK-17.