Application of perforated over expanded Aluminum honeycomb core


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Tim Ane
Tim Ane
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Hi everyone,
my question is about use of perforated aluminum honeycomb core. in my case, i am working with sandwich structure of honeycomb and carbon fiber prepreg bonded with epoxy adhesive film. will epoxy generate volatile during cure that will be trapped in honeycomb without perforation? or working with epoxy resin will not generate volatiles so non perforated honeycomb cores can be used?

Confusion is in between perforated and non perforated aluminum honeycomb cores used with epoxy in sandwich structure.

Thank You.
Lester Populaire
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Tim Ane - 10/23/2020 5:34:28 AM
Hi everyone,
my question is about use of perforated aluminum honeycomb core. in my case, i am working with sandwich structure of honeycomb and carbon fiber prepreg bonded with epoxy adhesive film. will epoxy generate volatile during cure that will be trapped in honeycomb without perforation? or working with epoxy resin will not generate volatiles so non perforated honeycomb cores can be used?

Confusion is in between perforated and non perforated aluminum honeycomb cores used with epoxy in sandwich structure.

Thank You.

Depends on the final application too. perforations are there too so the cells can vent to ambient pressure. But i don't think you are working on an high altitude reconnaissance airplane or a satellite structure? BigGrin

So for most applications with epoxy you are fine with non perforated ones

Warren (Staff)
Warren (Staff)
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As lester says, at ambient pressure use the perforations make very little difference. Its only really specific high end applications that might need perforated honeycomb. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
Tim Ane
Tim Ane
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Lester Populaire - 10/23/2020 6:36:38 AM
Tim Ane - 10/23/2020 5:34:28 AM
Hi everyone,
my question is about use of perforated aluminum honeycomb core. in my case, i am working with sandwich structure of honeycomb and carbon fiber prepreg bonded with epoxy adhesive film. will epoxy generate volatile during cure that will be trapped in honeycomb without perforation? or working with epoxy resin will not generate volatiles so non perforated honeycomb cores can be used?

Confusion is in between perforated and non perforated aluminum honeycomb cores used with epoxy in sandwich structure.

Thank You.

Depends on the final application too. perforations are there too so the cells can vent to ambient pressure. But i don't think you are working on an high altitude reconnaissance airplane or a satellite structure? BigGrin

So for most applications with epoxy you are fine with non perforated ones

what can be perforation size? (hole diameter)

Tim Ane
Tim Ane
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Warren (Staff) - 10/23/2020 8:13:12 AM
As lester says, at ambient pressure use the perforations make very little difference. Its only really specific high end applications that might need perforated honeycomb. 

over expanded aluminum honeycomb comes in percentage of expansion. example, 10%,20% or 30% expansion. what will be the effect of percentage expansion on process. in my case, i am working with cylinder of composite sandwich structure so what will be percentage expansion suited for this application?

Rosta Spicl
Rosta Spicl
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For most earthly applications a nonperforated honeycombs are OK.
Be carefull for high temperature or high altitude applications is highly recommended to use vented honeycombs because the air volume expansion closed in cells depends on temperature and could causes the internal delamination if the ambiente pressure is lower.

Warren (Staff)
Warren (Staff)
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Over expansion is going to distort the cells thus change the balance of strength so it is biased in one direction. How far you can over expand before you damage it considerably is not something we have data for. 

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
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