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NASA NTRS1980

Some considerations of the performance of two honeycomb gas path seal material systems

A standard Hastelloy-X honeycomb material and a pack aluminide coated honeycomb material were evaluated as to their performance as labyrinth seal materials for aircraft gas turbine engines. Consideration from published literature was given to the fluid sealing characteristics of two honeycomb materials in labyrinth seal applications, and their rub characteristics, erosion resistance, and oxidation resistance were evaluated. The increased temperature potential of the coated honeycomb material compared to the uncoated standard could be achieved without compromising the honeycomb material's rub tolerance, although there was some penalty in terms of reduced erosion resistance.

Bill, R. C.↗

NASA NTRS1981

Considerations for the installation of honeycomb and screens to reduce wind-tunnel turbulence

Tests were conducted on a half-scale model representing a 0.914-m (3.0-ft) square stream tube of the flow through the fourth corner and settling chamber of the Langley 8-Foot Transonic Pressure Tunnel. The model included the tube cooler 45 degree turning vanes, and the turbulence reduction screens and honeycomb, which were the subject of the tests. Hot-wire measurements of the turbulence reduction for various combinations of screens and honeycomb were made at various duct speeds. Of the four sizes of honeycomb cells tested, none were found to have a superior performance advantage. The effectiveness of screens and honeycomb in reducing turbulence is greatly affected by relatively minor physical damage; therefore, extreme care must be exercised in installing and maintaining honeycomb or screens if the turbulence reduction performance is to be maintained.

Scheiman, J.↗

NASA NTRS1980

Design optimization of sinusoidal glass honeycomb for flat plate solar collectors

The design of honeycomb made of sinusoidally corrugated glass strips was optimized for use in water-cooled, single-glazed flat plate solar collectors with non-selective black absorbers. Cell diameter (d), cell height (L), and pitch/diameter ratio (P/d) maximizing solar collector performance and cost effectiveness for given cell wall thickness (t sub w) and optical properties of glass were determined from radiative and convective honeycomb characteristics and collector performance all calculated with experimentally validated algorithms. Relative lifetime values were estimated from present materials costs and postulated production methods for corrugated glass honeycomb cover assemblies. A honeycomb with P/d = 1.05, d = 17.4 mm, L = 146 mm and t sub w = 0.15 mm would provide near-optimal performance over the range delta T sub C greater than or equal to 0 C and less than or equal to 80 C and be superior in performance and cost effectiveness to a non-honeycomb collector with a 0.92/0.12 selective black absorber.

Mcmurrin, J. C.↗

NASA NTRS1989

Annular honeycomb seals: Test results for leakage and rotordynamic coefficients; comparisons to labyrinth and smooth configurations

Test results are presented for leakage and rotordynamic coefficients for seven honeycomb seals. All seals have the same radius, length, and clearance; however, the cell depths and diameters are varied. Rotordynamic data, which are presented, consist of the direct and cross-coupled stiffness coefficients and the direct damping coefficients. The rotordynamic-coefficient data show a considerable sensitivity to changes in cell dimensions; however, no clear trends are identifiable. Comparisons of test data for the honeycomb seals with labyrinth and smooth annular seals show the honeycomb seal had the best sealing (minimum leakage) performance, followed in order by the labyrinth and smooth seals. For prerotated fluid entering the seal, in the direction of shaft rotation, the honeycomb seal has the best rotordynamic stability followed in order by the labyrinth and smooth. For no prerotation, or fluid prerotation against shaft rotation, the labyrinth seal has the best rotordynamic stability followed in order by the smooth and honeycomb seals.

Childs, Dara W.↗

NASA NTRS1989

Annular honeycomb seals: Test results for leakage and rotordynamic coefficients - Comparisons to labyrinth and smooth configurations

Test results are presented for leakage and rotordynamic coefficients for seven honeycomb seals. All seals have the same radius, length, and clearance; however, the cell depths and diameters are varied. Rotordynamic data, which are presented, consist of the direct and cross-coupled stiffness coefficients and the direct damping coefficients. The rotordynamic-coefficient data show a considerable sensitivity to changes in cell dimensions; however, no clear trends are identifiable. Comparisons of test data for the honeycomb seals with labyrinth and smooth annular seals shows the honeycomb seal had the best sealing (minimum leakage) performance, followed in order by the labyrinth and smooth seals. For prerotated fluids entering the seal, in the direction of shaft rotation, the honeycomb seal has the best rotordynamic stability followed in order by the labyrinth and smooth. For no prerotation, or fluid prerotation against shaft rotation, the labyrinth seal has the best rotordynamic stability followed in order by the smooth and honeycomb seals.

Childs, D.↗

NASA NTRS1990

A comparison of mechanical properties of some foams and honeycombs

A comparative study is conducted of the mechanical properties of foam-core and honeycomb-core sandwich panels, using a normalizing procedure based on common properties of cellular solids and related properties of dense solids. Seven different honeycombs and closed-foam cells are discussed; of these, three are commercial Al alloy honeycombs, one is an Al-alloy foam, and two are polymeric foams. It is concluded that ideal, closed-cell foams may furnish compressive strengths which while isotropic can be fully comparable to the compressive strengths of honeycombs in the thickness direction. The shear strength of ideal closed-cell foams may be superior to the shear strength of honeycombs.

Bhat, Balakrishna T.↗

NASA NTRS1997

Porous and Microporous Honeycomb Composites as Potential Boundary-Layer Bleed Materials

Results of an experimental investigation are presented in which the use of porous and microporous honeycomb composite materials is evaluated as an alternate to perforated solid plates for boundary-layer bleed in supersonic aircraft inlets. The terms "porous" and "microporous," respectively, refer to bleed orifice diameters roughly equal to and much less than the displacement thickness of the approach boundary-layer. A Baseline porous solid plate, two porous honeycomb, and three microporous honeycomb configurations are evaluated. The performance of the plates is characterized by the flow coefficient and relative change in boundary-layer profile parameters across the bleed region. The tests were conducted at Mach numbers of 1.27 and 1.98. The results show the porous honeycomb is not as efficient at removing mass compared to the baseline. The microporous plates were about equal to the baseline with one plate demonstrating a significantly higher efficiency. The microporous plates produced significantly fuller boundary-layer profiles downstream of the bleed region for a given mass flow removal rate than either the baseline or the porous honeycomb plates.

Davis, D. O.↗

NASA NTRSDate not supplied

Finite Element Modeling for Compression Strength Prediction of Honeycomb Cores with Geometric Imperfections Measured using X-ray CT Imaging

Aluminum honeycomb cores have been used extensively in composite sandwich panels due to having high bending rigidity while maintaining low density. During manufacturing of the aluminum honeycomb, the thin metal walls are susceptible to imperfections that deviate from an ideal honeycomb shape. Computational tools to quantify imperfections and investigate their effects on quasi-static compression and impact response can inform design criteria to construct safer and lighter launch vehicle structures. This paper presents the results of a study on finite element modeling of metallic honeycomb cores (HCC) with geometric imperfections measured using X-ray Computer Tomography (CT), to predict the compression response. Finite element (FE) models are constructed with measured imperfections with appropriate boundary conditions. It is shown that the average behavior of larger 10x11 cell models can be predicted by sampling single cell models from the larger domain. Amplification of imperfections for cells at the center of sampled specimens are mode switched from the larger out-of-plane imperfection to the mode shape of the adjacent cells resulting in strengthening of the center specimens.

aluminum honeycomb↗

NASA NTRS1973

The use of paper honeycomb for prototype blade construction for small to medium-sized wind driven generators

Paper honeycomb is used for the construction of conventional, propeller-type, windmill blades. Using fairly simple techniques and conventional power tools, it is possible to shape both simple foils and more complex foils with or without tapered plan forms and with or without varying profiles. A block of honeycomb, in its compressed form, is mounted on a wedge and run through a bandsaw with the table at an appropriate tilt angle. It is the combination of the wedge angle and the table angle that gives the tapered planform and profile shape. Next the honeycomb is expanded on the shaft and jigged to give the desired angles of attack. With the honeycomb fixed in position, the blade is covered with a fine weave fiberglass cloth. Any surface quality can then be achieved with filling and sanding.

Meyer, H.↗

NASA NTRS1974

Titanium honeycomb acoustic lining structural and thermal test report

The results are presented of static, fatigue and thermal testing of titanium honeycomb acoustic panels representing the acoustic tailpipe for the Pratt and Whitney Aircraft JT8D Refan engine which is being studied for use on the Boeing 727-200 airplane. Test specimens represented the engine and tailpipe flange joints, the rail to which the thrust reverser is attached and shear specimens of the tailpipe honeycomb. Specimens were made in four different batches with variations in configuration, materials and processes in each. Static strength of all test specimens exceeded the design ultimate load requirements. Fatigue test results confirmed that aluminum brazed titanium, as used in the Refan tailpipe design, meets the fatigue durability objectives. Quality of welding was found to be critical to life, with substandard welding failing prematurely, whereas welding within the process specification exceeded the panel skin life. Initial fatigue testing used short grip length bolts which failed prematurely. These were replaced with longer bolts and subsequent testing demonstrated the required life. Thermal tests indicate that perforated skin acoustic honeycomb has approximately twice the heat transfer of solid skin honeycomb.

Joynes, D.↗

NASA NTRS1977

Ambient temperature fatigue tests of elements of an actively cooled honeycomb sandwich structural panel

Elements of an actively cooled structural panel for a hypersonic aircraft have been investigated for fatigue characteristics. The study involved a bonded honeycomb sandwich panel with d-shaped coolant tubes. The curved portion of these tubes was embedded in the honeycomb, and the flat portion was bonded or soldered to the inner surface of the outer skin. The elements examined were two plain skin specimens (aluminum alloy); two specimens with skins attached to manifolds and tubes (one specimen was bonded, the other soldered); and a specimen representative of a corner section of the complete cooled sandwich. Sinusoidal loads were applied to all specimens. The honeycomb sandwich specimen was loaded in both tension and compression; the other specimens were loaded in tension only. The cooling tubes were pressurized with oil throughout the fatigue tests. The most significant results of these tests follow: All specimens exceeded their design life of 20,000 cycles without damage. Crack growth rates obtained in the plain skin specimens were used to determine the crack growth characteristics of aluminum alloy. Cracks in skins either bonded or soldered to cooling tubes propagated past the tubes without penetration. The coolant tubes served as crack arresters and temporarily stopped crack growth when a crack reached a tube-skin interface. The honeycomb core demonstrated that it could contain leakage from a tube.

Sharpe, E. L.↗

NASA NTRS1977

Honeycomb-laminate composite structure

A honeycomb-laminate composite structure was comprised of: (1) a cellular core of a polyquinoxaline foam in a honeycomb structure, and (2) a layer of a noncombustible fibrous material impregnated with a polyimide resin laminated on the cellular core. A process for producing the honeycomb-laminate composite structure and articles containing the honeycomb-laminate composite structure is described.

Gilwee, W. J., Jr.↗

NASA NTRS1977

Aerodynamic performance of conventional and advanced design labyrinth seals with solid-smooth abradable, and honeycomb lands

Labyrinth air seal static and dynamic performance was evaluated using solid, abradable, and honeycomb lands with standard and advanced seal designs. The effects on leakage of land surface roughness, abradable land porosity, rub grooves in abradable lands, and honeycomb land cell size and depth were studied using a standard labyrinth seal. The effects of rotation on the optimum seal knife pitch were also investigated. Selected geometric and aerodynamic parameters for an advanced seal design were evaluated to derive an optimized performance configuration. The rotational energy requirements were also measured to determine the inherent friction and pumping energy absorbed by the various seal knife and land configurations tested in order to properly assess the net seal system performance level. Results indicate that: (1) seal leakage can be significantly affected with honeycomb or abradable lands; (2) rotational energy absorption does not vary significantly with the use of a solid-smooth, an abradable, or a honeycomb land; and (3) optimization of an advanced lab seal design produced a configuration that had leakage 25% below a conventional stepped seal.

Stocker, H. L.↗

NASA NTRS1985

Advanced radiator concepts utilizing honeycomb panel heat pipes (stainless steel)

The feasibility of fabricating and processing moderate temperature range heat pipes in a low mass honeycomb sandwich panel configuration for highly efficient radiator fins for the NASA space station was investigated. A variety of honeycomb panel facesheet and core-ribbon wick concepts were evaluated within constraints dictated by existing manufacturing technology and equipment. Concepts evaluated include: type of material, material and panel thicknesses, wick type and manufacturability, liquid and vapor communication among honeycomb cells, and liquid flow return from condenser to evaporator facesheet areas. In addition, the overall performance of the honeycomb panel heat pipe was evaluated analytically.

Fleischman, G. L.↗

NASA NTRS1995

The Honeycomb supernova remnant

At 2.5 min southeast of SN 1987A, the Honeycomb Nebula Supernova remnant (SNR) is named after its interesting morphology, which consists of over ten loops with sizes of 2-3 pc. High-dispersion spectra of these loops show hemispheres expanding toward the observer at 100-300 km/s. Using archival data X-ray data and a combination of new and archival radio data, we find bright X-ray and nonthermal radio emisssion associated with the Honeycomb Nebula. New CCD images further show enhanced (S II) H-alpha ratios. These results confirm a model in which the Honeycomb Nebula is due to a supernova shock front, traveling toward the observer, encountering an intervening sheet of dense, but porous, interstellar gas. The bulk of the supernova remnant resides in a low-density cavity, and is not otherwise visible. The situation is similar to the hidden supernova remnants postulated for the X-ray bright superbubbles. The Honeycomb Nebula has an unusually steep radio spectral index (S(sub nu) is proportional to nu(exp -1.2)), normally associated with young SNRs.

Chu, You-Hua↗

NASA NTRS1995

Wax Reinforces Honeycomb During Machining

Method of machining on conventional metal lathe devised for precise cutting of axisymmetric contours on honeycomb cores made of composite (matrix/fiber) materials. Wax filling reinforces honeycomb walls against bending and tearing while honeycomb being contoured on lathe. Innovative method of machining on lathe involves preparation in which honeycomb is placed in appropriate fixture and the fixture is then filled with molten water-soluble wax. Number of different commercial waxes have been tried.

Towell, Timothy W.↗

NASA NTRS2006

Assessment of Bulk Absorber Properties for Multi-Layer Perforates in Porous Honeycomb Liners

CONTINUING progress in materials technology provides potential for improved acoustic liners for attenuating broadband fan noise emissions from aircraft engine nacelles. Conventional liners (local-reacting perforate-over-honeycomb structures) provide significant narrow-band attenuation, but limited attenuation over wide bandwidths. Two approaches for increasing attenuation bandwidth are to (1) replace the honeycomb structure with bulk material, or (2) cascade multiple layers of perforate/honeycomb structures. Usage of the first approach is limited because of mechanical and maintenance reasons, while multi-layer liners are limited to about three layers because of their additional mechanical complexity, depth and weight. The current research concerns a novel approach reported by the University of Cincinnati, in which a single-layer conventional liner is converted into an extended-reaction, broadband absorber by making the honeycomb core structure porous. This modified single-layer liner requires no increase in depth and weight, and minimal increase in mechanical complexity. Langley has initiated research to identify potential benefits of liner structures with porous cell walls. This research has two complementary goals: (1) develop and validate experimental techniques for treating multi-layer perforates (representative of the internal cells of a liner with porous cell walls) as 1-D bulk materials, and (2) develop analytical approaches to validate this bulk material assumption. If successful, the resultant model can then be used to design optimized porous honeycomb liners. The feasibility of treating an N-layer perforate system (N porous plates separated by uniform air gaps) as a one-dimensional bulk absorber is assessed using the Two-Thickness Method (TTM), which is commonly used to educe bulk material intrinsic acoustic parameters. Tests are conducted with discrete tone and random noise sources, over an SPL range sufficient to determine the nonlinearity of the test specimens, for test specimens consisting of 5, 10 and 15% porous plates. Measured impedances for two liner thicknesses (e.g., 12 and 24 layers) are used as input to the TTM to determine the characteristic impedance and propagation constant that characterize these liners as bulk absorbers. These parameters are then used to calculate the predicted impedance of liners with different thicknesses (e.g., 36 layers), and a comparison of predicted and measured impedances for these other thicknesses is used to determine the efficacy of this approach. Finally, an independent method is used to educe the propagation constant for a single representative sample, and excellent comparison between the results for this method and those for the TTM provides increased confidence in the results achieved with the TTM. In general, the results demonstrate these multi-layer perforates can be acceptably treated as bulk absorbers.

Jones, Michael G.↗

NASA NTRS2009

Development of Quiet Honeycomb Panels

Sandwich honeycomb composite panels are lightweight and strong, and, therefore, provide a reasonable alternative to the aluminum ring framelstringer architecture currently used for most aircraft airframes. The drawback to honeycomb panels is that they radiate noise into the aircraft cabin very efficiently provoking the need for additional sound treatment which adds weight and reduces the material's cost advantage. A series of honeycomb panels were made which incorporated different design strategies aimed at reducing the honeycomb panels' radiation efficiency while at the same time maintaining its strength. The majority of the desi gns were centered around the concept of creatin g areas of reduced stiffness in the panel by adding voids and recesses to the core. The effort culminated with a reinforced./recessed panel which had 6 dB higher transmission loss than the baseline solid core panel while maintaining comparable strength.

Palumbo, Daniel L.↗