Bonding Aluminium Honeycomb (19.1mm cell size ) to sheet Aluminium.


Bonding Aluminium Honeycomb (19.1mm cell size ) to sheet Aluminium.
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NigelGroom
NigelGroom
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I am working on the design of an impact attenuator for a Formula Student car. 

I am interested in using aluminium honeycomb, specifically the 19.1mm cell size as it is the most cost effective, and I am in the process of testing a design using this in solidworks. 

One concern I have is how the sheets and honeycomb layers will be bonded together. 

I have attatched an image of the current attenuator design because it is a little bit difficult to explain. 

I would like to know, along with what the best resin/adhesive to use is, what material exactly should be selected and used during the cad process. 

I can see that it is of the 3003 series, however I am unsure what material out of this series specifically as they are given properties in solid form rather than treated as a honeycomb section.

All help and feedback is greatly appreciated!

I am also open to using a different material providing it is not ridiculously expensive. The budget for this project is around £500 so it is limited.









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Dravis
Dravis
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You can use Permabond ET538 .. this is specifically formulated for bonding Alu honeycomb, both to composites and to aluminium .

I would recommend keying the alu sheet surfaces before bonding the honeycomb to it.

You could also use a purely composite structure, by using kevlar/Carbon sheets, and nomex honeycomb.

This will have the added advantage of being able to cope with repeated impacts.

I'm not sure of the sizes involved, so I find it a bit difficult to assess the costs of building of the structure, so determining if the alternative solution will be too expensive depends on the size of the structure and demands om its performance.

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Edited 10 Years Ago by Dravis
NigelGroom
NigelGroom
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Thank you for your reply and feedback. I feel those materials are a little out of the price range.

I am also curious as to what you meant by keying? I have not heard of this process done with regards to these materials before.

Repeated impacts are not a concern. The attenuator is designed to be used only once, as per the regulations of IMechE. 
GO

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