Cork Core


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Has anyone got any experience with using cork as a core?  Several kayak manufacturers have started using it recently and was wondering if anyone has any experience with it as a material for both vac bag and infusion?

How does it compare with foam core for impact resistance?

How stiff do the finished laminate end up compared with other traditional core materials?

Will any cork sheet do or is there a specific grade needed for use in composites?

Hanaldo
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Yes, I love it. Best way to describe it is as a direct replacement for Soric, but it's better in every way. 1/5th of the resin consumption, stiffer, lighter, higher impact resistance, higher shear strength, lower delimitation, lower print through etc. Can still be used as an internal flow media, although it flows slower than Soric. I see no reason to go back to using Soric. 

Dravis
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I have just infused a test sheet using ordinary thin (3 mm) floor "anti-sound" cork sheet... not very uniform in thickness, and a bit porous, but very cheap.

I will test it in a few days, when fully cured.

1 layer of 375 gsm Satin weave CF + 1 layer 200 gsm twill  on both sides.

I did three strips:  1 floor-cork, 1 Soric and 1 3D-core   All 3 mm. 

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Thanks Guys,

Would love to hear how your tests get on Dravis, keep us updated.

Where abouts can I go about getting cork specifically for composites in the uk?

Dravis
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http://www.matrix-composites.co.uk/

Smile

In my test I infused three parallel strips in the same go, on a small glass plate.  I did not notice a significant difference in infusion speed, but since the cork strip was in the middle and inlet and vacuum was at the ends of the cork, it may have compensated for a slower infusion rate for the cork.

I'm away from my workshop until early next week, so results will follow some time next week.
Smile



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Edited 10 Years Ago by Dravis
Dravis
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OK, my test infusion of three different core materials went very well..!

Preliminary results  (Pictures and precise measurements will follow Smile )


I did a completely parallel infusion by putting three strips of core material side by side in the same stack with the reinforcement.

The infusion setup was with infusion mesh only at the wacuum and infusion ends, only CF fabric, core and peel-ply in the center.

The previous info was not quite correct however..  The 3D-core I have is 3 mm, and the floor-cork and Soric is 2 mm..

I tinted the IN2 infusion resin with translucent blue, to be able to see the resin in the core when cutting up the samples.

After 24 hours and  a 2 x 2 hour double post-cure at around 80 deg., I demoulded the laminate

I cut the single laminate into three strips with exactly the same dimensions, one of each core material, and tested from there.

Weights for the three identical sized samples were. (The three samples were set up in my milling machine and milled to the exact same size, i can not measure any difference with my calipers  BigGrin )

3-D core: 37,66 grams

Soric:  35,75 grams

Floor Cork:  31,45 grams

The Cork-core laminate  is definetely lighter, and seems to take up less Resin, but since I infused all three in the same go, I have no direct measurement of the resin uptake, however the cheap floor cork also did not infuse as well, leaving a slightly resin starved front side with distinct pinholing.

the 2 mm Soric did the absolutely best job, when it comes to cosmetic appearance, virtually no pinholing, close to perfect infusion.

The 3 mm 3D core did not do as well as the Soric, but better than the Cork, but bear in mind that this was 3 mm core, as opposed to the 2 mm of Soric or Cork.

All three core materials left absolutely no print-through on the front side (but the mould being plate glass, probably prevents this.)
On the back, the 3D-core left a very visible hexagonal print, very easily felt by hand even when the peel ply was removed.
The Soric left a much less deep and much smaller hex-pattern.
The cork left only a slightly uneven random "distortion" that can only just be felt by touch.


I did a stiffness test using a weight and a 1/1000"  indicator dial setup from my lathe .. This showed no real diffierence in stiffness between the Soric and the Cork, while the 3D core was almost a third stiffer.. Looking at that from a purely mechanical point, most of that can be explained merely by the 1 mm thicker laminated core.

I have not yet tested the crush resistance of the 3 laminates, but I will do that later this week.

My conclusion is that the cheap floor-dampening cork is perfectly usable for infusing non-critical panel parts.
Car panel parts, mud guards e.t.c. can be made with this material.   The cost is considerably less than Soric, and only about  1/10 of that of 3D-core.

If you want to make "green" cored panels, a combination of Jute/flax reinforcement and cork core would be very CO2 -friendly I think....BigGrin

I do not know the prices of the Cork-core specifically made for composite work, but it may well be cheaper than Soric.


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Hanaldo
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For the sake of science, I'll do an exact copy of your test, except using the composite-specific Corecork. It's unfortunate I don't have access to the same resin you do, can't really be a straight comparison. I don't have any issues with pinholes or resin starvation using this stuff. It costs me about AUD$14 per meter off a 1.25m wide roll, so about half the price of Soric. Considering it uses a 5th of the resin as well, it ends up substantially cheaper to boot. 
Dravis
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Right!Smile

I infused a square about 28 cm x 28 cm..  (roughly 1 square foot)

After cutting and separating, I have 3 "strips" 6 cm wide by 25 cm long.

We can compare results, when you have done your infusion.

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Warren (Staff)
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Dravis, I note that you do not use a flow media on the cores itself? 

I would expect the use of a flow media over the entire core would remove the pinholing issue you found with the 3D core.  Logic dictates that less open structure = less flow and that was bourn out in your test, so the additional flow media in the bagging stack may help rectify that.

With the cork core, preparing it like you would a PVC foam, eg holes and fine scoring, would probably help eliminate the pinholing there too.

I am surprised at the higher weight of the 3D core panel compared to the soric panel. Maybe a direct comparison 3mm to 3mm would be better as again, logic would dictate soric should have a higher resin uptake due to more open space in the core material.

But still, some very useful results from your testing and it does seem that the cork core does make a good light core material at this stage.

Although you say you cannot work out resin uptake directly, you can indirectly.

You know the weight of each fabric and core material used in each sample - well you can easily calculate it from the manufacturers GSM figures.

Therefore simply the remaining quantity is the resin.

In broad brush terms, with all 3 samples being infused under the same conditions, in fact the same bag, you should be able to make the fair assumption that the resin uptake of the fabrics are almost identical (save for pinholes) and hence the difference between resin weights of each sample should indicate the resin uptake.   For completeness a non-cored test panel should have been done so that you can check uptake of the cork, but I suspect the cork has a negligible uptake from other experience with the material.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
Dravis
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Regarding the flow media:  I think I will do another test, this time only with cork and Soric, and use standard infusion mesh on the whole square.

I've so far found good use for smaller pieces of the cored panels, so the work is not just "test & scrap" Smile

I just did a set of measurements on the thickness and "precision" or evenness of the thickness of the cored panels, and both the Soric and cork have a very even thickness.

The 3D-core is very uniform in thickness as well.

More to follow!  Smooooth

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103% of all people do not understand statistics...

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