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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.↗

NASA NTRS2010

Quiet Honeycomb Panels

Sandwich honeycomb composite panels are lightweight and strong, and, therefore, provide a reasonable alternative to the aluminum ring frame/stringer architecture currently used for most aircraft airframes. The drawback to honeycomb panels is that they radiate noise into the aircraft cabin veil- efficiently provoking the need for additional sound treatment which adds weight and reduces the material's cost advantage. A series of honeycomb panels was made -hick incorporated different design strategies aimed at reducing the honeycomb panels' radiation efficiency while at the same time maintaining their strength. The majority of the designs were centered around the concept of creating 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.↗

NASA NTRS2012

Compression After Impact on Honeycomb Core Sandwich Panels With Thin Facesheets: Experiments - Part 1

McQuigg, Thomas D.↗

NASA NTRS2012

Compression After Impact on Honeycomb Core Sandwich Panels with Thin Facesheets, Part 2: Analysis

A two part research study has been completed on the topic of compression after impact (CAI) of thin facesheet honeycomb core sandwich panels. The research has focused on both experiments and analysis in an effort to establish and validate a new understanding of the damage tolerance of these materials. Part 2, the subject of the current paper, is focused on the analysis, which corresponds to the CAI testings described in Part 1. Of interest, are sandwich panels, with aerospace applications, which consist of very thin, woven S2-fiberglass (with MTM45-1 epoxy) facesheets adhered to a Nomex honeycomb core. Two sets of materials, which were identical with the exception of the density of the honeycomb core, were tested in Part 1. The results highlighted the need for analysis methods which taken into account multiple failure modes. A finite element model (FEM) is developed here, in Part 2. A commercial implementation of the Multicontinuum Failure Theory (MCT) for progressive failure analysis (PFA) in composite laminates, Helius:MCT, is included in this model. The inclusion of PFA in the present model provided a new, unique ability to account for multiple failure modes. In addition, significant impact damage detail is included in the model. A sensitivity study, used to assess the effect of each damage parameter on overall analysis results, is included in an appendix. Analysis results are compared to the experimental results for each of the 32 CAI sandwich panel specimens tested to failure. The failure of each specimen is predicted using the high-fidelity, physicsbased analysis model developed here, and the results highlight key improvements in the understanding of honeycomb core sandwich panel CAI failure. Finally, a parametric study highlights the strength benefits compared to mass penalty for various core densities.

Mcquigg, Thomas D.↗

NASA NTRSDate not supplied

Sensitivity Analysis of Geometric Imperfection Sources in Honeycomb Cores on Flatwise Compression Behavior

Manufacturing aluminum honeycomb core material using the expansion process can lead to geometric imperfections in the cellular core structures. These imperfections arise due to irregularities introduced in the initial foil bonding, variations in foil thickness, and residual stresses from manufacturing processes. Such geometric imperfections include cell shape distortions, cell wall waviness, non-uniform cell wall thickness, and variability in the shape and height of the adhesive fillet. Imperfections in the cell walls negatively affect the transverse compression and shear strength, while also reducing the resistance to damage under impact loads. Previous work presented the identification and quantification of these manufactured imperfections using high resolution X-ray computed tomography (CT) scans of honeycomb cores in co-cured composite sandwich panels. The present paper presents a sensitivity analysis of individual components of the sources of geometric imperfections on the flatwise compression of aluminum honeycomb cores. The initial geometric imperfections in honeycomb cells are decomposed into three components, namely cell shape (cell edge length and cell internal angles) in-plane cell wall waviness, and out-of-plane waviness along the core thickness. A sensitivity analysis is conducted using finite element (FE) models of the decomposed imperfections to understand how each component affects compression failure.

aluminum honycomb↗

DOE OSTI2026

Crystal structure, magnetism, and specific heat of lightly depleted layered honeycomb oxides, Na$_2$(Ni$_{2-x}$D$_x$)TeO$_6$ ($D$ = Mg, Ga, Co; 0.10 ≤ $x$ ≤ 0.25)

Layered oxides, in which transition metal atoms form a honeycomb lattice, are known for complex magnetic phase diagrams. In this work we study the doped compounds, Na$_2$(Ni$_{2-x}$D$_x$)TeO$_6$, $D$ = Mg, Ga, and Co (0.10 ≤ $x$ ≤ 0.25), to understand how chemical dilution at the nickel site influences the stability of magnetic exchanges within the honeycomb layer of the parent, Na$_2$ Ni$_2$ TeO$_6$. Here, the studied compounds were found to crystallize in $P6_3/mcm$ space group common to P2 type layered oxides. In general, the lattice parameters and the unit cell volume expanded with increased doping. The oxidation states determined from X-ray photoelectron spectroscopy were consistent with bond valence sum estimates, that confirmed the presence of Ni$^{2+}$, Mg$^{2+}$, Ga$^{3+}$, Co$^{2+}$ in our samples. Irrespective of magnetic or non-magnetic doping, the magnetic phase transition temperature ($T_N$) of the doped compounds were reduced from that of Na$_2$ Ni$_2$ TeO$_6$ or Na$_2$ Co$_2$ TeO$_6$, and lay between 21.7 K and 26.8 K. The effective paramagnetic moments extracted from Curie–Weiss analysis were in the range 3.17 μ B to 3.84 μ B and the Weiss temperatures were between $-15$ K and $-25$ K, suggesting antiferromagnetism. Mg- and Ga-doped compounds showed free spin formation, indicated by Curie–Weiss tails in their magnetic susceptibility. Our results suggest emergence of short-range magnetic correlations in Na$_2$(Ni$_{2-x}$D$_x$)TeO$_6$, enhanced due to the depletion of the Ni honeycomb lattice.

75 - CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY A↗

DOE OSTI2025

Synthesis and Characterization of Metastable Cobalt Honeycomb KCoAsO 4

The Kitaev model has served as a long-sought-after target in the realization of a quantum spin liquid that could host Majorana Fermions. Such non-Abelian anyons could revolutionize quantum computing if properly implemented to overcome decoherence. A 3d 7 electronic configuration, like Co 2+ , has been explored by theory and experimental work to design Kitaev materials. Here, in this study, we report the synthesis of a new cobaltate honeycomb material KCoAsO 4 . The compound is synthesized through a low-temperature solution route and crystallized in space group R¯3 with lattice parameters a = 5.0394(1) and c = 28.6790(1) as determined by neutron powder diffraction. The crystal structure follows motifs similar to those of the honeycomb compound BaCo2(AsO 4 ) 2 but presents differing magnetic behavior. Magnetization/heat capacity measurements on the powder show antiferromagnetic transition T N = 14 K. Two lower-temperature transitions are present in susceptibility at low field that resemble spin reorientations. Magnetization data as a function of field have curvature indicative of metamagnetic behavior below the magnetic ordering temperature, with the magnetic ordering suppressed upon application of a higher magnetic field. Computational studies suggest the presence of a weak nearest-neighbor Kitaev term, K 1 , consistent with related honeycomb cobaltates. Together, the data suggest that this material should present a new platform for developing Kitaev quantum spin liquids.

cobaltate↗

DOE OSTI2025

Magnetic properties of metastable honeycomb KCoAsO 4

We present comprehensive neutron scattering data on polycrystalline samples of a new metastable honeycomb material KCoAsO 4 . Below 𝑇 𝑁 = 14 K, the system orders into a zigzag antiferromagnetic state, with spins ordered into alternating ferromagnetic chains similar to the isostructural sister compound KNiAsO 4 . In the case of KCoAsO 4 , we find the moments are robustly canted out of plane closer to the crystallographic 𝑐 axis. A combination of weak interlayer coupling, lattice strain, and inhomogeneities lead to the coexistence of two magnetic ordering wave vectors 𝑘 1 = (1.5 0 0) and 𝑘 2 = (0.5 0 0.5), where the two structures differ only in their layer stacking. Inelastic data show the presence of a spin orbital mode at 24 meV, supporting a pseudospin $\tilde{𝑆}$ = 1/2 Kramer's doublet ground state of the Co 2+ ions. We model the low energy excitations using both a conventional XXZ Hamiltonian and generalized Kitaev Heisenberg Hamiltonian within a linear spin wave limit. While either model can qualitatively reproduce the observed spectra, the lack of fine features and observation of disorder prevent a clear-cut determination of the low energy Hamiltonian. In the case of an XXZ-type model, a large easy-axis anisotropy is necessary to reproduce the gapped spectra and canting of the magnetic moments. For the generalized Kitaev model, despite the large canting of the moments away from the honeycomb layers, we find a noticeable if nondominant Kitaev term persists. In conclusion, the contrast of the magnetic properties of KCoAsO 4 to other cobalt honeycombs highlights the sensitivity of the low energy magnetic properties of Co 2+ to fine details of its crystalline environment.

Honeycomb lattice↗

DOE OSTI2025

Magnetic excitations from the hexagonal spin clusters in the 𝑆 = $\frac{1}{2}$ distorted honeycomb lattice antiferromagnet Cu 2 ⁢(pymca)⁢ 3 ⁢(ClO 4 )

Cu 2 ⁢(pymca) ⁢3 (ClO 4 ) (pymca: pyrimidine-2-carboxylate) consists of a slightly distorted honeycomb lattice of Cu 2+ spins, which shows no long-range magnetic order down to 0.6 K. A magnetization study revealed 1/3 and 2/3 plateau phases [A. Okutani et al., J. Phys. Soc. Jpn. 88, 013703 (2019)], which is not expected for regular honeycomb antiferromagnets. Inelastic neutron scattering experiments were performed using a powder sample to investigate the exchange interactions of this material. The spin excitations from the singlet ground state to the first three triplet states, predicted from the antiferromagnetic hexagonal spin cluster interacting with 3.9 meV, were observed. Using the exact diagonalization methods, the intercluster coupling was estimated from the excitation peak width to be about 20% of the intracluster interaction, which is consistent with the previously reported value. Finally, our exchange path model explains the anisotropic exchange interactions in the distorted honeycomb plane.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS2014

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel: Comparison of In- and Out-of-Autoclave Facesheet Configurations

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10-m diameter barrel section of the Heavy Lift Launch Vehicle, were manufactured and tested under the NASA Composites for Exploration and the NASA Constellation Ares V programs. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.0 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: in-autoclave IM7/977-3 and out-of-autoclave T40-800b/5320-1. Smaller 3 ft. by 5 ft. panels were cut from the 1/16th barrel sections and tested under compressive loading. Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of each 3 ft. by 5 ft. panel. To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear models yielded good qualitative and quantitative predictions. Additionally, it was correctly predicted that the panel would fail in buckling prior to failing in strength. Furthermore, several imperfection studies were performed to investigate the influence of geometric imperfections, fiber angle misalignments, and three-dimensional effects on the compressive response of the panel.

epoxy matrix composites↗

NASA NTRS2014

Buckling Testing and Analysis of Honeycomb Sandwich Panel Arc Segments of a Full-Scale Fairing Barrel: 8-ply Out-of-Autoclave Facesheets - Part 3

Four honeycomb sandwich panels, representing 1/16th arc segments of a 10 m diameter barrel section of the heavy lift launch vehicle, were manufactured under the NASA Composites for Exploration program and the NASA Constellation Ares V program. Two configurations were chosen for the panels: 6-ply facesheets with 1.125 in. honeycomb core and 8-ply facesheets with 1.000 in. honeycomb core. Additionally, two separate carbon fiber/epoxy material systems were chosen for the facesheets: inautoclave IM7/977-3 and out-of-autoclave T40-800B/5320-1. Smaller 3- by 5-ft panels were cut from the 1/16th barrel sections. These panels were tested under compressive loading at the NASA Langley Research Center. Furthermore, linear eigenvalue and geometrically nonlinear finite element analyses were performed to predict the compressive response of the 3- by 5-ft panels. This manuscript summarizes the experimental and analytical modeling efforts pertaining to the panel composed of 8-ply, T40-800B/5320-1 facesheets (referred to as Panel C). To improve the robustness of the geometrically nonlinear finite element model, measured surface imperfections were included in the geometry of the model. Both the linear and nonlinear, two-dimensional (2-D) and three-dimensional (3-D), models yield good qualitative and quantitative predictions. Additionally, it was predicted correctly that the panel would fail in buckling prior to failing in strength.

heavy lift launch vehicles↗

NASA NTRS2015

A Numerical Study on the Effect of Facesheet-Core Disbonds on the Buckling Load of Curved Honeycomb Sandwich Panels

A numerical study on the effect of facesheet-core disbonds on the post-buckling response of curved honeycomb sandwich panels is presented herein. This work was conducted as part of the development of a damage tolerance approach for the next-generation Space Launch System heavy lift vehicle payload fairing. As such, the study utilized full-scale fairing barrel segments as the structure of interest. The panels were composed of carbon fiber reinforced polymer facesheets and aluminum honeycomb core. The panels were analyzed numerically using the finite element method. Facesheet and core nodes in a predetermined circular region were detached to simulate a disbond induced via low-speed impact between the outer mold line facesheet and honeycomb core. Surface-to-surface contact in the disbonded region was invoked to prevent interpenetration of the facesheet and core elements. The diameter of this disbonded region was varied and the effect of the size of the disbond on the post-buckling response was observed. A significant change in the slope of the edge load-deflection response was used to determine the onset of global buckling and corresponding buckling load.

structural failure↗

NASA NTRS2016

Post-Buckling Analysis of Curved Honeycomb Sandwich Panels Containing Interfacial Disbonds

A numerical study on the effect of facesheet-core disbonds on the post-buckling response of curved honeycomb sandwich panels is presented herein. This work was conducted as part of the development of a damage tolerance plan for the next-generation Space Launch System heavy lift launch vehicle payload fairing. As such, the study utilized full-scale fairing barrel segments as the structure of interest. The panels were composed of carbon fiber reinforced polymer facesheets and aluminum honeycomb core. The panels were analyzed numerically using the finite element method incorporating geometric nonlinearity. In a predetermined circular region, facesheet and core nodes were detached to simulate a disbond, between the outer mold line facesheet and honeycomb core, induced via low-speed impact. Surface-to-surface contact in the disbonded region was invoked to prevent interpenetration of the facesheet and core elements and obtain realistic stresses in the core. The diameter of this disbonded region was varied and the effect of the size of the disbond on the post-buckling response was observed. Significant changes in the slope of the edge load-deflection response were used to determine the onset of global buckling and corresponding buckling load. Finally, several studies were conducted to determine the sensitivity of the numerical predictions to refinement in the finite element mesh.

elastic buckling↗

NASA NTRSDate not supplied

Characterization and Modeling of Cell Wall Imperfections in Aluminum Honeycomb Cores using X-ray CT Imaging

Honeycomb cell imperfections may significantly affect the failure of sandwich composites in core crushing and shear modes. Identification and quantification of the different types of imperfections and evaluation of their effects on the mechanical response of honeycomb cores in flatwise compression is presented. X-Ray computed tomography (CT) scans of honeycomb cores in co-cured composite sandwich panels were performed. Image analysis methods are applied to characterize and quantify core cell geometry and cell wall waviness. An approach is developed for extracting cell wall mid surface planes and waviness for constructing finite element models using shell elements. Analysis results from models with the as-manufactured imperfections are compared to results from models with idealized geometries to evaluate the effect of the as-manufactured imperfections on the initiation of cell wall buckling and subsequent core crushing.

aluminum honeycomb↗

NASA NTRS2021

Compression After Impact Strength Comparison of Rohacell Foam and Aluminum Honeycomb Core Sandwich Structure

This Technical Memorandum is a follow-on study to a previous one1 that examined the compression after impact (CAI) strength of carbon fiber sandwich structure with aluminum honeycomb core and Rohacell foam core with barely visible impact damage (BVID). In this current study a wider range of impact energies were utilized and the CAI strength assessed with these different damage severity levels. This was done to provide a more complete database for the two types of sandwich structure tested in these studies. In addition, the honeycomb sandwich specimens were tested with both the ‘L’ and ‘W’ directions aligned with the axis of compression loading. As in the study examining CAI strength with BVID1, the results were normalized by the mass of the sandwich structure. The results showed that the CAI strength did differ depending on the orientation of the core during testing and that when tested in the W-direction, the honeycomb core sandwich structure had about the same CAI strength as the foam core sandwich structure when normalized by the mass of the sandwich structures.

Sandwich Structure↗

NASA NTRS1972

Development of beryllium honeycomb sandwich composite for structural and other related applications

The feasibility of fabricating large beryllium honeycomb panels was demonstrated. Both flat and curved sandwich structures were manufactured using practical, braze bonding techniques. The processes developed prove that metallurgically assembled beryllium honeycomb panels show decided potential where rigid, lightweight structures are required. Three panels, each 10 square feet in surface area, were fabricated, and radiographically inspected to determine integrity. This examination revealed a 97 percent braze in the final panel. It is believed that ceramic dies for forming and brazing would facilitate the fabrication techniques for higher production rates. Ceramic dies would yield a lower thermal gradient in the panel during the braze cycle. This would eliminate the small amount of face sheet wrinkling present in the panels. Hot forming the various panel components demonstrated efficient manufacturing techniques for scaling up and producing large numbers of hot formed beryllium components and panels. The beryllium honeycomb panel demonstrated very good vibrational loading characteristics under test with desirable damping characteristics.

Vogan, J. W.↗