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At least 19 records

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NASA NTRS2016

Vibroacoustic Characterization of Corrugated-Core and Honeycomb-Core Sandwich Panels

The vibroacoustic characteristics of two candidate launch vehicle fairing structures, corrugated- core and honeycomb-core sandwich designs, were studied. The study of these structures has been motivated by recent risk reduction efforts focused on mitigating high noise levels within the payload bays of large launch vehicles during launch. The corrugated-core sandwich concept is of particular interest as a dual purpose structure due to its ability to harbor resonant noise control systems without appreciably adding mass or taking up additional volume. Specifically, modal information, wavelength dispersion, and damping were determined from a series of vibrometer measurements and subsequent analysis procedures carried out on two test panels. Numerical and analytical modeling techniques were also used to assess assumed material properties and to further illuminate underlying structural dynamic aspects. Results from the tests and analyses described herein may serve as a reference for additional vibroacoustic studies involving these or similar structures.

Allen, Albert↗

NASA NTRS1990

An examination of impact damage in glass-phenolic and aluminum honeycomb core composite panels

An examination of low velocity impact damage to glass-phenolic and aluminum core honeycomb sandwich panels with carbon-epoxy facesheets is presented. An instrumented drop weight impact test apparatus was utilized to inflict damage at energy ranges between 0.7 and 4.2 joules. Specimens were checked for extent of damage by cross sectional examination. The effect of core damage was assessed by subjecting impact-damaged beams to four-point bend tests. Skin-only specimens (facings not bonded to honeycomb) were also tested for comparison purposes. Results show that core buckling is the first damage mode, followed by delaminations in the facings, matrix cracking, and finally fiber breakage. The aluminum honeycomb panels exhibited a larger core damage zone and more facing delaminations than the glass-phenolic core, but could withstand more shear stress when damaged than the glass-phenolic core specimens.

Nettles, A. T.↗

NASA NTRS1978

Development of graphite/polyimide honeycomb core materials

Honeycomb panel constructions consisting entirely of graphite/polyimide composites were developed and evaluated. Graphite/polyimide composites, were used in the honeycomb core webs and in pre-cured sandwich skins. Polyimide adhesives were also developed and evaluated for use in skin-core bonding. The purpose of this program was to develop light weight sandwich constructions for high temperature applications which could provide comparable shear strength and stiffness to metallic honeycomb constructions.

Stone, R. H.↗

NASA NTRS1987

Method for stabilizing thick honeycomb core composite articles

A method of stabilizing thick honeycomb core composites is disclosed. The method comprises bonding a layer of resin impregnated woven graphite fibers to one surface of the honeycomb core, then curing the resin impregnates forming a stabilized honeycomb core. This stabilized core is then cut to net shape and the composite structure is formed by laying one or more resin impregnated fiber layers onto the stabilized core surf aces and curing the lay-up under heat and pressure forming the composite article. Also disclosed is a stabilized honeycomb subassembly formed by bonding a graphite fiber, resin impregnated layer onto one of the honeycomb core surfaces and curing the resins, then shaping the stabilized honeycomb core to the desired form.

Gary J Jacaruso↗

NASA NTRS1998

Evaluation of the Transient Liquid Phase (TLP) Bonding Process for Ti3Al-Based Honeycomb Core Sandwich Structure

The suitability of using transient liquid phase (TLP) bonding to fabricate honeycomb core sandwich panels with Ti-14Al-21Nb (wt%) titanium aluminide (T3Al) face sheets for high-temperature hypersonic vehicle applications was evaluated. Three titanium alloy honeycomb cores and one Ti3Al alloy honeycomb core were investigated. Edgewise compression (EWC) and flatwise tension (FWT) tests on honeycomb core sandwich specimens and tensile tests of the face sheet material were conducted at temperatures ranging from room temperature to 1500 F. EWC tests indicated that the honeycomb cores and diffusion bonded joints were able to stabilize the face sheets up to and beyond the face sheet compressive yield strength for all temperatures investigated. The specimens with the T3Al honeycomb core produced the highest FWT strengths at temperatures above 1000 F. Tensile tests indicated that TLP processing conditions resulted in decreases in ductility of the Ti-14Al-21Nb face sheets. Microstructural examination showed that the side of the face sheets to which the filler metals had been applied was transformed from equiaxed alpha2 grains to coarse plates of alpha2 with intergranular Beta. Fractographic examination of the tensile specimens showed that this transformed region was dominated by brittle fracture.

Bird, R. Keith↗

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↗

NASA NTRS1959

Elevated-Temperature Tests Under Static and Aerodynamic Conditions on Honeycomb-Core Sandwich Panels

Stainless-steel honeycomb-core sandwich panels which differed primarily in skin thicknesses were tested at elevated temperatures under static and aerodynamic conditions. The results of these tests were evaluated to determine the insulating effectiveness and structural integrity of the panels. The static radiant-heating tests were performed in front of a quartz-tube radiant heater at panel skin temperatures up to 1,5000 F. The aerodynamic tests were made in a Mach 1.4 heated blowdown wind tunnel. The tunnel temperature was augmented by additional heat supplied by a radiant heater which raised the panel surface temperature above 8000 F during air flow. Static radiant-heating tests of 2 minutes duration showed that all the panels protected the load-carrying structure about equally well. Thin-skin panels showed an advantage for this short-time test over thick-skin panels from a standpoint of weight against insulation. Permanent inelastic strains in the form of local buckles over each cell of the honeycomb core caused an increase in surface roughness. During the aero- dynamic tests all of the panels survived with little or no damage, and panel flutter did not occur.

Groen, Joseph M.↗

NASA NTRS2018

Relevence of 3D Simulations and Sandwich Core Topology for the Modeling of Honeycomb Core Sandwich Panels Undergoing Mode I Delamination

A recently developed cohesive zone traction-separation law, which includes the effects of fiber bridging in a novel way, is extended from 2D to 3D. The proposed cohesive model is applied to low fidelity (i.e. homogenized core representation) and high fidelity (i.e. directly accounting for the core topology) finite element models of a composite panel comprised of carbon fiber reinforced plastic facesheets and a honeycomb sandwich core. This enables the investigation of 2D to 3D parameter transferability, width-dependent effects such as thumbnail-shaped crack growth, and the verification of plane strain / plane stress assumptions. A pronounced curvature of the initial interface-related crack front is observed, while the bridging-related crack front is straight. Furthermore, it is found that the cohesive parameters can easily be transferred from 2D to 3D under plane stress assumptions, but not under plane strain assumptions. The numerical predictions are compared to experimental load-displacement and R-curves.

Composites↗

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 NTRS2013

Characterizing Facesheet/Core Disbonding in Honeycomb Core Sandwich Structure

Results are presented from an experimental investigation into facesheet core disbonding in carbon fiber reinforced plastic/Nomex honeycomb sandwich structures using a Single Cantilever Beam test. Specimens with three, six and twelve-ply facesheets were tested. Specimens with different honeycomb cores consisting of four different cell sizes were also tested, in addition to specimens with three different widths. Three different data reduction methods were employed for computing apparent fracture toughness values from the test data, namely an area method, a compliance calibration technique and a modified beam theory method. The compliance calibration and modified beam theory approaches yielded comparable apparent fracture toughness values, which were generally lower than those computed using the area method. Disbonding in the three-ply facesheet specimens took place at the facesheet/core interface and yielded the lowest apparent fracture toughness values. Disbonding in the six and twelve-ply facesheet specimens took place within the core, near to the facesheet/core interface. Specimen width was not found to have a significant effect on apparent fracture toughness. The amount of scatter in the apparent fracture toughness data was found to increase with honeycomb core cell size.

Rinker, Martin↗

NASA NTRS2021

Bioinspired Honeycomb Core Design: An Experimental Study of the Role of Corner Radius, Coping, and Interface

The honeybee’s nest has inspired the design of engineering honeycomb core that primarily abstract the hexagonal cell shape and exploit its mass minimizing properties to construct lightweight panels. This work explored three additional design features that are part of the natural honeybee comb but have not been traditionally considered as design features of interest in honeycomb design: the radius at the corner of each cell, the coping at the top of the cell walls, and the interface between cell arrays. These features were first characterized in natural honeycomb using optical and X-ray techniques, and then incorporated into honeycomb core design, and fabricated using an additive manufacturing process. The honeycomb cores were then tested in out-of-plane compression and bending, and since all three design features added mass to the overall structure, all metrics were examined per unit mass to assess performance gains. The study concluded that the addition of an interface increases specific flexural modulus but has little benefit in out-of-plane compression; coping radius positively impacts specific flexural strength; but that the corner radius has no significant effect in bending, and actually is slightly detrimental for out-of-plane compression testing.

honeycomb↗

NASA NTRS2001

Heat Transfer in Adhesively Bonded Honeycomb Core Panels

The Swann and Pittman semi-empirical relationship has been used as a standard in aerospace industry to predict the effective thermal conductivity of honeycomb core panels. Recent measurements of the effective thermal conductivity of an adhesively bonded titanium honeycomb core panel using three different techniques, two steady-state and one transient radiant step heating method, at four laboratories varied significantly from each other and from the Swann and Pittman predictions. Average differences between the measurements and the predictions varied between 17 and 61% in the temperature range of 300 to 500 K. In order to determine the correct values of the effective thermal conductivity and determine which set of the measurements or predictions were most accurate, the combined radiation and conduction heat transfer in the honeycomb core panel was modeled using a finite volume numerical formulation. The transient radiant step heating measurements provided the best agreement with the numerical results. It was found that a modification of the Swann and Pittman semi-empirical relationship which incorporated the facesheets and adhesive layers in the thermal model provided satisfactory results. Finally, a parametric study was conducted to investigate the influence of adhesive thickness and thermal conductivity on the overall heat transfer through the panel.

Daryabeigi, Kamran↗

NASA NTRS1965

Experimental verification of an analytical determination of overall thermal conductivity of honeycomb-core panels

Analytical determination of thermoconductivity of honeycomb-core panels fabricated from cobalt-base alloy

COBALT ALLOY↗

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 NTRS1992

Preelectroplating Treatment Of Titanium Honeycomb Core

New technique used to treat titanium honeycomb core electrochemically by applying conversion coat to keep honeycomb active and receptive to electroplating with solution of sodium bichromate and hydrofluoric acid. Maskant permits electroplating of controlled amount of filler metal on edge of honeycomb. Eliminates excess copper filler.

Kelly, Michael L.↗

NASA NTRS1989

Fabrication and evaluation of enhanced diffusion bonded titanium honeycomb core sandwich panels with titanium aluminide face sheets

A joining process was developed for fabricating lightweight, high temperature sandwich panels for aerospace applications using Ti-14Al-21Nb face sheets and Ti-3Al-2.5V honeycomb core. The process, termed Enhanced Diffusion Bonding (EDB), relies on the formation of a eutectic liquid through solid-state diffusion at elevated temperatures and isothermal solidification to produce joints in thin-gage titanium and titanium aluminide structural components. A technique employing a maskant on the honeycomb core was developed which permitted electroplating a controlled amount of EDB material only on the edges of the honeycomb core in order to minimize the structural weight and metallurgical interaction effects. Metallurgical analyses were conducted to determine the interaction effects between the EDB materials and the constituents of the sandwich structure following EDB processing. The initial mechanical evaluation was conducted with butt joint specimens tested at temperatures from 1400 - 1700 F. Further mechanical evaluation was conducted with EDB sandwich specimens using flatwise tension tests at temperatures from 70 - 1100 F and edgewise compression tests at ambient temperature.

Hoffmann, E. K.↗

NASA NTRS2013

Evaluation of Ceramic Honeycomb Core Compression Behavior at Room Temperature

Room temperature flatwise compression tests were conducted on two varieties of ceramic honeycomb core specimens that have potential for high-temperature structural applications. One set of specimens was fabricated using strips of a commercially-available thin-gage "ceramic paper" sheet molded into a hexagonal core configuration. The other set was fabricated by machining honeycomb core directly from a commercially available rigid insulation tile material. This paper summarizes the results from these tests.

Bird, Richard K.↗