Documente Academic
Documente Profesional
Documente Cultură
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Comparison and Benefits of Honeycomb Versus Alternative Core Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
How Honeycomb Is Manufactured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Honeycomb Cell Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Honeycomb Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fiberglass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Aramid Fiber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Nomex® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Kevlar® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Special Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Acousti-Cap® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Mechanical Properties and Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Density and Thickness Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Compressive Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crush Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
L and W Shear Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Additional Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Classification of Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Correlation of Shear Strength Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Effect of Core Thickness on Plate Shear Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Correlation of Flexural Shear Strength Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional Properties of Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Acoustical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Air/Fluid Directionalization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Pressure Drop Across Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Bending of Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Coefficient of Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Moisture Absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Dielectric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Energy Absorption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Radio Frequency Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Comparison of Typical Mechanical Properties and Other Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Specifying Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Guide to Determining Which Type of Honeycomb to Specify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Most Important Attributes of Each Honeycomb Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mechanical Property Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
HexWeb® CR III 5052 Hexagonal Aluminum Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HexWeb® CR III 5056 Hexagonal Aluminum Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HexWeb® CR-PAA Honeycomb Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
HexWeb® Aluminum Flex-Core Mechanical Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HexWeb® Rigicell™ Corrosion Resistant Aluminum Corrugated Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HexWeb® HRH-10® Aramid Fiber/Phenolic Resin Honeycomb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HexWeb® HRH-310 Aramid Fiber/Polyimide Resin Honeycomb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HexWeb® HRH-36 Para-Aramid/Phenolic Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HexWeb® HRH-49® Honeycomb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HexWeb® HRP Glass Flex-Core® Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HexWeb® HDC Heavy Density Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 32
HexWeb® Fibertruss® HFT® Fiberglass/Phenolic Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
HexWeb® HRH-327 Fiberglass Reinforced Polyimide Honeycomb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
HexWeb® HRP and HTP Fiberglass/Phenolic Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HexWeb® HRH-10 Nonmetallic Flex-Core® Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Hexcel Honeycomb Technical Literature Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2
Introduction
Honeycomb is a lightweight core material for structural Hexcel has produced more than 700 varieties of
stiffening applications. This versatile material is widely honeycomb over the past 60 years.Today, HexWeb®
used in the construction of aircraft components such honeycomb is available in a wide range of materials
as floors, interior paneling and helicopter rotor blade and cell configurations, and additional products are
aerofoils. Other applications include railway carriage continually developed in response to new uses for
doors and ceiling panels, marine bulkheads and honeycomb sandwich construction.
furniture. Honeycomb is also the ideal material for
energy absorption (bumpers/fenders, lift shaft bases), This brochure lists the materials, configurations,
for RF shielding and fluid and light directionalization. and mechanical properties of Hexcel’s standard
honeycomb as a guide to selecting honeycomb core
best suited for particular applications.
Applications
The major usage of honeycomb Other aerospace vehicles that use Marine
is for structural applications. honeycomb include: ¥¥Commercial vessel and naval
Honeycomb’s beneficial strength- ¥¥Helicopters
vessel bulkheads
to-weight and stiffness-to-weight ¥¥Satellites ¥¥America’s Cup sailing yachts
ratios (see diagram on bottom ¥¥Missiles ¥¥Wall, ceiling, and partition
of page 4) compared to other
¥¥Space Shuttle
materials and configurations are panels
¥¥Satellite Launch Vehicles
unmatched.
Other applications for honeycomb
Honeycomb’s long-standing After aircraft and other airborne that are not transportation related
traditional application is in aircraft. aerospace vehicles, the next most include:
Some of the aircraft parts that are prominent uses for honeycomb ¥¥Clean room panels
made from honeycomb include: occur in various land and water
¥¥Exterior architectural curtain wall
¥¥Ailerons transportation vehicles.The
different types of vehicles and most panels
¥¥Elevators
common applications are: ¥¥Air, water, fluid, and light direc-
¥¥Flaps
tionalization
¥¥Nacelles Automobiles ¥¥Heating, ventilation, air condi-
¥¥Slats ¥¥Energy absorption protective
tioning (HVAC) equipment and
¥¥Struts structures in Formula 1 race
devices
¥¥Trailing Edges cars ¥¥Skis and snowboards
¥¥Cowls ¥¥Air directionalization for engine
¥¥Energy absorption protective
¥¥Empennages fuel injection system
structures
¥¥Flooring ¥¥Energy absorption in pillars and
¥¥Electronic shielding enclosures
¥¥Radomes along roof line for passenger ¥¥Acoustic attenuation
¥¥Spoilers protection
¥¥Tabs ¥¥Crash testing barriers
¥¥Doors
¥¥Fairings Rail
¥¥Leading Edges ¥¥Doors
¥¥Rudders ¥¥Floors
¥¥Partitions
3
Comparison and Benefits of Honeycomb
Versus Alternative Core Materials
t 2t 4t
700 3700
Relative Stiffness 100 7 times more rigid 37 times more rigid!
350 925
Relative Strength 100 3.5 times as strong 9.25 times as strong!
103 106
Relative Weight 100 3% increase in weight 6% increase in weight
A striking example of how honeycomb stiffens a structure without materially increasing its weight.
Materials other than honeycomb are used as core materials. These are primarily foams and wood-based
products. The advantages of honeycomb compared to these alternative core materials are as follows.
4
How Honeycomb Is Manufactured
5
Honeycomb Cell Configurations
Hexagonal Core
The standard hexagonal
honeycomb is the basic and most
common cellular honeycomb
configuration, and is currently
available in metallic and
nonmetallic materials.
T
W
direction
L
direction
T
W
direction
L
direction
OX-Core™
The OX configuration is a
hexagonal honeycomb that
has been overexpanded in
the W direction, providing a
rectangular cell configuration that
facilitates curving or forming in
the L direction. The OX process
increases W shear properties and
decreases L shear properties
when compared to hexagonal
honeycomb.
T
W
direction
L
6 direction
Flex-Core®
The Flex-Core cell configuration
provides for exceptional formability in
compound curvatures with reduced
anticlastic curvature and without
buckling the cell walls. Curvatures
of very tight radii are easily formed.
When formed into tight radii, Flex-
Core provides higher shear strengths
than comparable hexagonal core
of equivalent density. Flex-Core
is manufactured from aluminum,
aramid papers and fiberglass
substrates.
L
direction
Double-Flex™
Double-Flex is a unique large cell
Flex-Core for excellent formability
and high specific compression
properties. Double-Flex™ formability
is similar to standard Flex-Core®.
W
direction
L
direction
Other Configurations
Hexcel can design and fabricate special cell geometries in response to specific needs.
Vented options are also available.
7
Honeycomb Materials
Alumninum Honeycomb
CR III
CR III corrosion-resistant coating consists of a
chromate- based protective layer and an organo-
metallic polymer. CR III corrosion-resistant coating has
been specified by the U.S. military for almost 50 years.
CR-PAA™
CR-PAA phosphoric acid anodized coating provides
superior performance in certain instances. CR-PAA is
superior with regards to:
¥¥bond strength to aluminum facings in sandwich
panel applications
¥¥salt spray environments
8
Fiberglass Reinforced Honeycomb
HFT®
HFT is a fiberglass fabric reinforced honeycomb that
incorporates a ±45° Fibertruss® bias weave dipped
in a heat-resistant phenolic resin to achieve the final
density.This material is recommended for use at
service temperatures up to 350°F but is well suited
for short exposures at higher temperatures. The
Fibertruss configuration greatly enhances the shear
properties. HFT has a much higher shear modulus
than HRP or HRH®-10.
9
Honeycomb Materials
HRH®-10
This product consists of Dupont® Nomex® aramid-
fiber paper dipped in a heat-resistant phenolic resin
to achieve the final density. It features high strength
and toughness in a small cell size, low density
nonmetallic core. It is available in hexagonal, OX-Core,
and Flex-Core configurations. It is fire-resistant and
recommended for service up to 350°F.
HRH®-310
HRH-310 is made from the same aramid-fiber paper
described above, except dipped in a polyimide resin to
achieve the final density.It is available in Hexagonal cell
configuration. Outstanding features are its relatively
Hexcel aramid-fiber reinforced honeycomb is low dielectric and loss tangent properties.
designated as follows: HRH®-49
Material – Cell Size – Density HRH-49 is made from Kevlar® 49 fabric impregnated
Example: HRH-10 – 3/16 – 3.0 with an epoxy resin. Significant advantages of HRH-
49 honeycomb are its excellent thermal stability and
Where: relatively low coefficient of thermal expansion.
HRH-10 – refers to the type of material
HRH®-36
3/16 – is the cell size in fractions of an inch HexWeb® HRH-36 is a very high performance
3.0 – is the nominal density in pounds per cubic foot honeycomb, constructed from DuPont’s Kevlar®
paper and reinforced with a high temperature resistant
Hexcel manufactures aramid-fiber reinforced
phenolic resin. Providing strength and retention at up
honeycomb from two types two types (Nomex® and
to 350°F/175°C, and with very high shear strength.
Kevlar®) of para-aramid substrates. These para-aramid
substrates are Nomex® (HRH-10, HRH-310),Kevlar®
(HRH-49), and HRH-36.
10
Special Honeycomb
Acousti-Cap®
Hexcel’s HexWeb® Acousti-Cap® noise reducing
honeycomb, has enabled aircraft engine designers to
achieve superior acoustical performance, including
dramatic noise reduction during takeoff and landing
without a structural weight penalty. This marks an
improvement on current technology which requires
tradeoffs between weight and noise reduction.
11
Mechanical Properties
and Test Methods
The test methods used for the honeycomb properties listed in this brochure are based on MIL-STD-401
and the applicable ASTM Standards.The properties and the test methods employed are outlined below.
Unless specifically stated, the test properties listed have been performed at room temperature.
Density and Thickness Measurements The bare compressive strength is the ultimate
The density of honeycomb is expressed in pounds compressive strength of the core in pounds per
per cubic foot. Hexcel certifies that aerospace grade square inch when loaded in the T direction without
core will not vary in density by more than ±10% stabilization of the cell edges. The value is normally
from list nominal values. The density tolerance for used for an acceptance criteria since this test is easier
commercial grade aluminum core is ±17%.The density and faster to perform.
of production honeycomb is normally measured on
full-size expanded sheets.
Test Methods
Physical dimensions and weight measurements are The standard specimen Compressive Test
taken to within 0.5%.The thickness is measured to the size for bare and stabilized
nearest 0.001 inch (0.0254mm) in accordance with compressive tests is 3” L x
ASTM C366, Method B. 3” W x 0.625”T (76.2mm x
76.2mm x 15.875mm) 3” L
Compressive Properties x 3” W x 0.500”T (76.2mm
The stabilized compressive strength (also called x 76.2mm x 12.7mm) for
flatwise compressive strength) represents the ultimate nonmetallic cores. For cell sizes
compressive strength of the honeycomb in pounds 1/2 inch or larger, a 4” L x 4”
per square inch when loaded in the T direction. W (101.6mm x 101.6mm) or
Normally for this test, facings are adhesively bonded to even a 6” L x 6” W (152.4mm
the honeycomb material (stabilized compressive). x 152.4mm) specimen size
is used to reduce the error
The stabilized compressive modulus, also expressed
developed by edge effect on
in pounds per square inch, is determined from the
small samples. Stabilized compressive specimens are
slope of the initial straight-line portion of the stress-
normally prepared by bonding 0.032” AL (0.8128mm)
strain curve. Some honeycomb materials exhibit
5052 thick facings to each side.
a linear initial stress-strain relationship, while other
honeycomb materials exhibit a nonlinear curved initial Both bare and stabilized compressive tests are
stress-strain relationship. conducted with self-aligning loading heads. Unless
otherwise specified, the loading rate used produces a
General Honeycomb Initioal Compressive Stress-Strain Curves failure in three to six minutes. Deflection recordings are
made with a displacement transducer that measures
the relative movement of the loading and bearing
Carbon Aluminum Compressive surfaces through the center of the specimen.
Strength
Stress
Nomex
Strain
12
Crush Strength L and W Shear Properties
After honeycomb has exceeded its ultimate The shear strength of honeycomb as presented in this
compressive strength, it will continue to deform brochure refers to the ultimate stress in pounds per
plastically and crush uniformly. The load-deflection square inch when a shear load is applied parallel to
curve shows such a typical response. The average the L–W plane.The shear modulus is the slope of the
crush load per unit cross-sectional area is defined initial straight-line portion of the stress-strain curve.The
as the crush strength,expressed in pounds per values so obtained are dependent upon the orientation
square inch. Honeycomb will crush at virtually of the applied loading with respect to the L and W
a constant stress level (dependent on the core dimensions, being highest in the L direction and
material and density), hence its absorption capacity lowest in the W direction for hexagonal honeycomb.
is predictable,making it ideal for energy absorption
applications. When used in this manner, the core is Test Methods
often precrushed slightly to remove the compressive Plate Shear Test Method
peak in the load-deflection curve. The crush strength The shear strength and modulus values presented in
of honeycomb decreases with increasing angle this brochure were obtained using the compressive
loading from the thickness. and/or tensile plate shear method. The specimen
Typical Load-Deflection Curve size for aluminum honeycomb is normally 7.5” x
2” x 0.625” T (190.5mm x 50.8mm x 15.875mm).
Nonmetallic honeycombs test sample size is 6” x 2”
Bare Compressive Strength 0.500”T (152.4mm x 50.8mm x 12.7mm).
Tensile Plate Shear
Thicknesses conform to MIL-C-7438
and MIL-C-8073, respectively. The
Load
Crush Strength
specimens are bonded to steel loading
plates and then tested as shown. The
loading rate used produces a failure in
three to six minutes. Shear deflections
are measured with a displacement
transducer that senses the relative
movement of the two plates. Since
Test Methods some nonmetallic materials will not
Fixed loading and bearing plates are used for crush always have a truly linear stress-
strength tests and a deflectometer is employed strain curve (particularly at elevated
to measure the travel of the crosshead of the test temperatures), the shear modulus is
machine. In order to obtain a meaningful crush load- normally calculated from the slope of
deflection curve, a minimum core thickness of 0.625 the initial straight-line portion of the
inches (15.875mm) should be used. load-deflection curve.
It should be noted that the crush strength values Honeycomb with densities of 8.0
presented in this brochure are typical static test pcf (128.1477kg3) and higher are
results. It has been found that under dynamic loading,
sometimes difficult to fail in shear by the
these values increase nonlinearly with impact velocity,
plate shear method because of the high
and numbers as much as 30% higher have been
shear loads introduced to the adhesive
reported.
bond between the core and the steel
plates. In some cases, shear data from
beam-flexure testing will be more applicable. This is
true for thicker and also heavier density cores.
13
Mechanical Properties
and Test Methods
Beam-Flexure Test Method Additional Mechanical Properties
Although the plate shear method is preferred for Numerous tests on both core materials and bonded
obtaining actual honeycomb shear strength and sandwich panels have been run by Hexcel laboratory
modulus results, the beam-flexure test is often used personnel for qualification to military specifications, or
to evaluate overall sandwich panel performance. for internal R&D purposes.
Experience indicates that since these values are very
much dependent on the facing thickness, facing Classification of
material, and loading conditions, the calculated Mechanical Properties
honeycomb properties may vary considerably from Hexcel classifies its mechanical
one test series to the next. Many types of beam- properties data into three
flexure tests have been used. The two most common categories dependent upon
techniques are shown schematically below. the extent of the testing being
reported. These classifications
The specimen size is 8” x 3” (203.2mm x 76.2mm). are as follows:
The span between supports is 6” (152.4mm) and
either one or two point loading can be used. The 1. Preliminary – Data
distance between the load pads for two point loading resulting from a very limited
is normally 1/3 the span. For additional details refer to amount of testing are
MIL-C-7438 and ASTM C393. indicative of the properties
expected, but do not
Again, it should be stressed that the resulting beam- necessarily represent the
flexure data should only be considered a test of the mean values of a normal
facings, adhesives, and core acting as a composite scatter of test data.
sandwich structure. Core shear values obtained by Generally, preliminary values
flexure tests are often higher than those obtained from are obtained from testing
plate shear tests (see page 14 for correlation factors one or two blocks of a Sample bonded to
honeycomb type. Numbers aluminum blocks
followed by the letter P
indicate preliminary data.
2. Typical – Data
representing extensive
testing of many blocks of
a particular honeycomb
material. A typical value
is the mean average of a
relatively large number of
test values.
14
Correlation of Shear Strength Data
Effect of Core Thickness on Plate Shear Strength a substantial fraction of the thickness and possibly the
Honeycomb shear strength will vary with core entire cell wall may be filleted. Such a phenomenon
thickness. would affect the “apparent” core shear strength
considerably. Also, since the filleting depth depends
Referring to the tensile plate shear shown on page 11, on the adhesive used, test results on thin cores vary
it can be shown that the shear load induces a minor from one adhesive to another.
component parallel to the cell axis that stretches the
honeycomb. The honeycomb, therefore, is not being For the above reasons and in view of typical core
subjected to pure shear but to a combination of shear thickness values in actual usage, as well as several
and tension. Thicker cores will have a lower usable aircraft company and military specifications, aluminum
shear strength than thinner ones. honeycomb is generally tested at 0.625” (15.875mm)
T while nonmetallic honeycomb is tested at 0.500”
In view of the above, one might conclude that a plot (12.7mm) T. However, Hexcel is often asked to qualify
of usable shear strength vs. core thickness would core materials to other thickness values. The graph
show the “true” core shear strength approached below, generated from actual Hexcel data, gives
asymptotically with vanishing core thickness. However, correction factors for both aluminum and nonmetallic
for very thin cores the filleting of the core-to-skin honeycomb for values other than 0.625” (15.875mm)
adhesives has a strengthening effect on the shear T and 0.500” (12.7mm) T respectively. The graph
data. Normally, the filleting depth is but a fraction of shows average correction factors.
the core thickness, but for very thin cores this depth is
Correction Factors
1.2
1.1
1.0
Correction Factor – K
No Alum
.9 nm
eta inum
llic
.8
.7
.6
.5
.4
.3
Core Thickness
15
Correlation of Flexural
Shear Strength Data
As previously indicated, the plate shear test method after the core has yielded. Several specifications,
is regarded as the most desirable way of obtaining such as MIL-C-7438, still call for beam-flexure tests
actual honeycomb shear properties. The results for heavy density cores. We have therefore provided
from the beam-flexure method have been found to the graph below, which shows the results of beam-
be influenced by several parameters, such as facing flexures on 5052 aluminum honeycomb when tested
thickness, facing material, core thickness, and loading per the military specifications, and compares the L and
conditions. The facing thickness alone will cause W curves to the plate shear data for the same core
large variations because the skins are able to carry type. It should be noted that the military specification
shear loads in addition to what the core carries and, calls for facing thicknesses that are different for L and
furthermore, are able to take on additional shear loads W tests at a given density.
1000
(1.0)
re
xu
le
-F
ar
m
e
ea
750 Sh
”B
Shear Strength – PSI (KSI)
(.75) e
at
“L
Pl
”
“L re
e xu
- Fl
a m
500 Be ar
(.50) ”
S he
“W te
la
”P
“W
250
(.25)
0
0 2 4 6 8 10
(32) (64) (95) (128) (192)
16
Additional Properties of Honeycomb
0.8
0.8
0.6
0.6
1/8"CELL
NRC
0.5
0.4 0.4
T
4"
0.3
0.2
T
2"
Static Pressure Drop – Inches of Water
0
0 1” 2” 3” 0.2
(25.4mm) (50.8mm) (76.2mm)
T
1"
0.10
Air/Fluid Directionalization
T
0.06
1"
0.01
1000 2000 3000 5000 7000 10000
17
Additional Properties of Honeycomb
Bending of Honeycomb
When hexagonal honeycomb is
bent, it exhibits a phenomenon
where the honeycomb is forcibly
curved around one axis and
the core reacts by bending in a
reversed curvature along an axis
oriented 90°.This phenomenon
is called anticlastic curvature.
This is a normal, unavoidable
phenomenon and is to be
expected
18
Dielectric Dielectric Constant at 0° Incidence Angle
Nonmetallic honeycomb is used 1.20
extensively in radomes, both Parallel Polarization
airborne and stationary, because Perpendicular Polarization
1.12
only negligible reflection and
10
absorption. The figure below HR
H-
P
HR -32
7
shows the dielectric constant as a 1.08 HRH
function of core density for several
honeycomb types. The values were
obtained for both polarizations
1.04
and with the electric field vector
E perpendicular and parallel to
the ribbon direction. Testing was 1.00
conducted at 9375 Megahertz. 0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
Honeycomb Density – PCF
In addition to the electric field
polarization, the dielectric constant
is a function of the incidence
angle and the thickness of the Aluminum Honeycomb Crush Curve
honeycomb.
Energy Absorption
As mentioned under the Crush
Peak load
Strength property description
(page 10), honeycomb loaded
axially beyond its ultimate
compressive peak will absorb
energy at constant stress. The
figure below shows the crush
curve of aluminum honeycomb.
Hexagonal honeycomb used in this
manner can be designed to crush
Load – lb
Displacement – in
19
Additional Properties of Honeycomb
0.7
typical facing materials may be Acousti-Core
Thermal Conductivity
1/8"
found in handbooks. Thermal 0.6
3/16"
resistance values for typical 0.5
1/4"
core-to-facing adhesives are 3/8"
3/4"
0.03 for film adhesives with a 0.4
–200 –150 –100 –50 0 50 100 150 200 250 300 350 400
Mean Temperature – °F
20
Comparison of Typical Mechanical
Properties and Other Design Considerations
The curves on the following pages compare the typical properties. Many other factors have to be
mechanical properties of several honeycomb types. considered.A few of these considerations and the
They are intended to show relative strength and shear relative ratings of several honey- comb materials are
moduli at ambient temperature. Included also are two presented in the table below. In overall economics
graphs showing the effect of elevated temperatures on or value analysis, one should also keep in mind such
honeycomb strength after 30 minutes and 100 hours factors as tooling requirements, shop losses, previous
of exposure. experience, and, of course, the optimization of
structural properties at minimum weight for the overall
The selection of a particular honeycomb type is, structure. Hexcel can assist with honeycomb material
of course, not only dependent on the mechanical selection and trade-off analysis.
5052 5052
Attributes 5056 5056 HRP HFT HRH-327 HRH-10 HRH-36
CR III
CR III CR-PAA
Relative Cost Mod Low Med Very Low Mod High High Very High Med High
Maximum Long-Term
350°F 350°F 350°F 350°F 350°F 500°F 350°F 350°F
Temperature
Flammability Resistance E E E E E E E E
Impact Resistance G G G F G F E E
Moisture Resistance E E E E E E G E
Fatigue Strength G G G G G G E E
Heat Transfer High High High Low Low Low Low Low
Corrosion Resistance G E G E E E E E
21
Comparison of Typical Mechanical
Properties and Other Design Considerations
Temperature Effects
HRH-327
80 80
HFT
HRH-327
5052, 5056
60 60
HRP
HRH-10
40 40
HRP
20 20
0 100 200 300 400 500 0 100 200 300 400 500
3000 3000
d
te
FT
ga
P
,H
Crush Strength – PSI
HR
ru
10
or
-
C
RH
52
,H 50
2000 56 2000
50
52
50
7
32
H-
HR
1000 1000
d
de
an
xp
56E ed
50 nd
pa
2 Ex
505
0 2 4 6 8 10 12 0 4 8 12 16 20
Density – PCF Density – PCF
22
Typical L Shear Strength Typical L Shear Modulus
1200 250
1000
P 200
5056 HR
800
HRH-327 150
5052, 5056
600
HFT
HRH-10
100
400
HFT, HRH-327
50
200
HRP
HRH-10
0 2 4 6 8 10 12 0 2 4 6 8 10 12
Density – PCF Density – PCF
80
P
600
56
50 HR
52
"W" Shear Strength – PSI
50
"W" Shear Modulus – KSI
60
HRH-327
5052, 5056 400
HFT
40
HRH-10
HFT 27 200
H-3
HR
20
HRP
HRH-10
0 2 4 6 8 10 12 0 2 4 6 8 10 12
23
Specifying Honeycomb
¥¥Greatest strength/weight
Cell sizes range from 1/8” to 1”,with 1/8”, 3/16”,
¥¥Thinnest cell walls
1/4”, and 3/8” being the most common. Honeycomb
densities range from 1.0 lb/ft3 to 55 lb/ft3. ¥¥Smooth cell walls
– Compressive Fiberglass
– Impact ¥¥Multidimensional strength of a woven structure
– Fatigue ¥¥Insulative
¥¥Moisture
¥¥Color
¥¥Environmental chemicals
¥¥Flammability/fire retardance
¥¥Electrical conductivity
¥¥Abrasion resistance
¥¥Cushioning
¥¥Machinability/Formability
¥¥Facings
– Material
– Bonding process, adhesive, conditions
– Thickness
24
Mechanical Property Tables
The most commonly measured honeycomb properties and the shear strength and moduli in the LT and
are bare compressive strength, stabilized compressive WT directions. The honeycomb properties in other
strength and modulus, crush strength, and L direction secondary directions are extremely low compared
and W direction plate shear strength and moduli. to the properties provided for the primary designed
orientation of honeycomb. The L and W direction
The following tables contain the mechanical properties compressive properties are typically less than 5% of
of the various honeycomb core types for which Hexcel the compressive properties in the T direction. The
has data. It should be noted that some of the core plate shear strength is substantially less in the LW
types listed are not always readily available. plane than in either the LT or WT plane, while the plate
shear modulus in the LW plane is typically less than
Hexcel has produced additional core types not
5% of the plate shear modulus in either the LT plane or
listed, and in some cases larger or smaller cell sizes,
WT plane.
intermediate or higher densities, and special materials
can be provided. In addition to compressive strength and plate shear
properties, sometimes other honeycomb properties
For detailed information on standard or special sheet
are important for particular applications. These include
sizes, refer to the appropriate data sheets. Crush
fatigue for repeated loads, creep from constant stress
strength values presented in this brochure are to be
over a long period of time (especially at elevated
used for preliminary designs. For core densities below
temperatures or when combined with other materials),
3 pcf, these values vary as much as ±20%. For all
and flatwise tensile strength.
other densities, crush strength values vary by ±15%.
Note: See page 12 for definitions of “preliminary,”
The honeycomb properties that follow are for the
“typical,” and “minimum.”
compressive strength and modulus in the T direction,
25
HexWeb® CR III 5052 Hexagonal Aluminum Honeycomb
Typical values (typ) are presented below, as well as minimum average (min) for a product type.
26
HexWeb® CR III 5056 Hexagonal Aluminum Honeycomb
Typical values (typ) are presented below, as well as minimum average (min) for a product type.
27
HexWeb® CR-PAA Honeycomb Mechanical Properties
Typical values (typ) are presented below, as well as minimum average (min) for a product type.
1/4 2.3 190 120 210 130 45 75 140 100 32.0 85 57 16.2
1/4 3.4 340 240 370 250 90 150 230 180 50.0 140 105 24.0
1/4 4.3 500 350 540 370 140 230 320 265 66.0 200 155 29.8
1/4 5.2 690 500 760 510 190 335 410 360 82.0 265 200 35.4
1/4 6.0 990 630 1100 660 235 430 530 445 96.0 340 265 40.5
1/4 7.9 1420 970 1490 1050 340 725 700 650 130.0 440 390 52.8
3/8 1.6 90 60 95 70 20 40 85 60 21.0 50 32 11.0
3/8 2.3 190 120 200 130 45 75 135 100 32.0 80 57 16.2
3/8 3.0 285 190 310 200 70 120 200 145 43.0 125 85 21.2
3/8 3.7 370 270 410 285 105 180 250 200 55.0 160 115 26.0
3/8 4.2 520 335 560 355 135 220 310 255 65.0 200 150 29.0
3/8 5.4 740 500 800 535 200 360 430 380 86.0 280 228 36.8
3/8 6.5 950 700 1000 750 265 505 545 500 105.0 350 300 43.5
1/8 4.5 630 475 690 500 185 320 440 350 70.0 255 205 28.0
1/8 6.1 1120 760 1200 825 295 535 690 525 102.0 400 305 38.0
1/8 8.1 1750 1200 1900 1300 435 810 945 740 143.0 560 440 51.0
5/32 3.8 450 360 500 375 140 235 335 272 57.0 195 155 24.0
5/32 5.3 820 615 865 650 240 420 550 435 85.0 325 250 33.0
5/32 6.9 1120 920 1340 1000 350 650 760 610 118.0 430 360 43.0
3/16 3.1 380 250 410 260 97 170 265 200 45.0 150 110 20.0
3/16 4.4 620 460 670 490 180 310 425 340 68.0 245 198 27.0
5056
3/16 5.7 920 685 1000 735 270 480 565 480 94.0 330 280 36.0
1/4 2.3 240 145 265 155 58 100 180 130 32.0 100 62 15.0
1/4 3.4 400 300 480 315 115 200 290 230 50.0 175 130 22.0
1/4 4.3 580 440 620 465 172 300 400 325 67.0 230 190 27.0
1/4 5.2 790 600 820 645 230 410 490 425 84.0 300 245 32.0
3/8 1.6 100 75 110 80 30 50 90 78 20.0 60 38 10.5
3/8 2.3 215 155 225 155 58 100 170 130 32.0 95 62 15.0
3/8 3.0 320 240 340 260 92 160 245 190 43.0 145 100 19.0
Test data obtained at 0.625 inch thickness. I = Beam shear for 12.0 pcf products.
28
HexWeb® Aluminum Flex-Core Mechanical Properties
Typical values (typ) are presented below, as well as minimum average (min) for a product type.
F40 – .0037 5.7 935 630 1050 700 290 380 400 280 68.0 230 170 23.0
F80 – .0013 4.3 524 402 542 455 195 – 300 196 45.0 190 120 20.0
F80 – .0019 6.5 1200 700 1300 735 310 – 540 308 72.0 310 180 24.0
F80 – .0025 8.0 1600 1100 1750 1120 400 – 650 434 98.0 455 260 31.0
F40 – .0014 2.1 240 150 260 182 65 – 105 74 18.0 55 42 10.0
F40 – .0020 3.1 460 284 465 329 125 – 200 150 32.0 120 90 13.0
F40 – .0025 4.1 680 440 740 483 185 – 310 217 45.0 200 132 17.0
5056
F80 – .0014 4.3 780 475 860 518 195 – 375 235 47.0 240 138 20.0
F80 – .0020 6.5 1400 805 1500 910 310 – 645 364 73.0 420 213 24.0
F80 – .0023 8.0 1800 1210 1950 1260 410 – 850 518 100.0 570 307 32.0
P = preliminary values that are obtained from testing of only one or two blocks of honeycomb types.
29
HexWeb® HRH-10® Aramid Fiber/Phenolic Resin Honeycomb
HRH-10 - 3/16 - 2.0 120 100 140 105 11 110 90 4.3 60 45 2.1
HRH-10 - 3/16 - 3.0 300 235 325 270 20 175 140 6.5 100 85 3.4
HRH-10 - 3/16 - 4.0 500 430 540 470 28 245 215 7.8 140 110 4.7
HRH-10 - 3/16 - 6.0 935 780 1020 865 60 420 370 13.0 225 200 6.5
HRH-10 - 1/4 - 1.5 80 65 90 75 6 70 55 3.0 35 25 1.3
HRH-10 - 1/4 - 2.0 140 115 155 125 11 105 85 4.0 50 40 2.0
HRH-10 - 1/4 - 3.1 285 240 310 265 21 185 160 6.5 90 75 3.0
HRH-10 - 1/4 - 4.0 440 360 480 390 28 250 205 8.0 125 100 3.5
HRH-10 - 3/8 - 1.5 95 75 105 80 6 70 55 3.0 35 25 1.5
HRH-10 - 3/8 - 2.0 140 115 155 125 11 90 72 3.7 55 36 2.4
HRH-10 - 3/8 - 3.0 290 240 320 270 17 185 160 5.6 95 80 3.5
HRH-10/OX - 3/16 - 1.8 110 85 120 95 7 65 45 2.0 70 50 3.0
OX-Core
HRH-10/OX - 3/16 - 3.0 320 260 350 285 17 115 95 3.0 135 110 6.0
HRH-10/OX - 3/16 - 4.0 600 500 650 550 26 130 105 4.6 150 130 8.4
HRH-10/OX - 1/4 - 3.0 350 280 385 310 17 110 90 3.0 135 110 6.0
30
HexWeb® HRH-36 Para-Aramid/Phenolic Core
HexWeb® HRH-36 Honeycomb is manufactured from DUPONT® KEVLAR® type N636 paper
Compressive Plate Shear
Material – Cell Size – Density Strength psi Strength psi Strength psi Modulus ksi Strength psi Modulus ksi
Notes: Test data obtained at 0.500” thickness. p = Preliminary (see page 12).
HRH-327 Fiberglass Reinforced Polyimide Honeycomb normally is not tested for bare compressive strength.
HexWeb® HRP® – Fiberglass cloth reinforced with a high temperature phenolic resin
32
HexWeb® HRP and HTP Fiberglass/Phenolic Honeycomb
HRP – 1/4 – 4.5 585 480 640 560 70 355 280 15.0 200 155 8.0
HRP – 1/4 – 5.0 680 530 820 660 84 400 305 20.0 230 180 10.0
HRP – 1/4 – 6.5 1025 800 1180 920 120 580 450 23.0 330 260 13.0
HRP – 3/8 – 3.2 315 260 390 300 38 205 160 11.0 110 85 5.0
HRP – 3/8 – 3.5 340 290 410 325 41 210 165 11.3 120 95 5.3
HRP – 3/8 – 4.5 550 450 690 530 65 325 260 14.0 190 150 8.0
HRP – 3/8 – 6.0 830 650 1000 800 100 470 400 23.0 280 210 11.8
OX-Core
HRP/OX – 1/4 – 4.5 560 480 675 540 43 250 200 7.0 260 210 15.0
The following mechanical properties apply to the various HRP core types when tested per AMS-STD 401 at 0.500 inch thickness and meet the
requirements of MIL-C-8073 Class II, AMS3715, and most airframe manufacturers’ specifications.
33
Hexcel Honeycomb
Technical Literature Index
Brochures ¥¥HRH®-10 - Aramid Fiber/Phenolic Honeycomb
¥¥Hexcel CR-PAA™ ¥¥HRH®-49 - Honeycomb of Kevlar® 49
Standards Honeycomb
¥¥Hexcel Special Process ¥¥HRH®-327 - Fiberglass Reinforced Polyimide
Corrugated Honeycomb
Data Sheets
¥¥A1 and A10 - High Strength Aramid Honeycomb Guide
[U.K. manufactured equivalent to ¥¥Aluminum and Nomex® Honeycombs Cross
Honeycomb
¥¥Aluminum Flex-Core® - Formable Aluminum
Honeycomb
¥¥CR III® - Corrosion Resistant Specification Grade
Aluminum Honeycomb
¥¥CR III® - Aluminum Honeycomb
Honeycomb
¥¥CROSS-CORE® - Bi-directional Aluminum
Corrugated Honeycomb
¥¥Fibertruss® HFT® - Fiberglass/Phenolic
Honeycomb
¥¥Nonmetallic Flex-Core® - Formable Nonmetallic/
Phenolic Honeycomb
34
Notes
35
Hexcel Product Family
HiTape®
Modipur® HexWeb®
Advanced
Polyurethane Engineered Core
Reinforcements
HiMax™
Multiaxial
Reinforcements
For US quotes, orders and product information call toll-free 1-866-611-4038. For other worldwide sales office
telephone numbers and a full address list, please go to:
http://www.hexcel.com/contact/salesoffice
ATA 377 FB17b
©2016 Hexcel Corporation – All rights reserved. Hexcel Corporation and its subsidiaries (“Hexcel”)
believe that the technical data and other information provided herein was materially accurate as of the date
this document was issued. Hexcel reserves the right to update, revise or modify such technical data and
information at any time. Any performance values provided are considered representative but do not and
should not constitute a substitute for your own testing of the suitability of our products for your particular
purpose. Hexcel makes no warranty or representation, express or implied, including but not
limited to the implied warranties of merchantability and fitness for a particular purpose, and
disclaims any liability arising out of or related to, the use of or reliance upon any of the technical
data or information contained in this document.
36
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
- High stiffness
- Durability
December 2000
Publication No. AGU 075b
HEXCEL COMPOSITES 1
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
Contents
Page
Contents 2
Design:
How a beam works 6
Design Guidelines 9
Nomenclature 10
Sample Problems 12
Computer Modelling 20
Production Methods 21 - 22
Appendix I
Mechanical Properties of Honeycomb Materials 25
Appendix II
Properties of Typical Facing Materials 26
Appendix III
Summary of Formulae 27
Further Reading 28
HEXCEL COMPOSITES 2
BENEFITS OF HONEYCOMB SANDWICH CONSTRUCTIONS
The facing skins of a sandwich panel can be compared to the holding the facing skins apart, and improving on the I-beam, it
flanges of an I-beam, as they carry the bending stresses to gives continuous support to the flanges or facing skins to
which the beam is subjected. With one facing skin in produce a uniformly stiffened panel. The core-to-skin adhesive
compression, the other is in tension. Similarly the honeycomb rigidly joins the sandwich components and allows them to act
core corresponds to the web of the I-beam. The core resists as one unit with a high torsional and bending rigidity.
the shear loads, increases the stiffness of the structure by
Adhesive
Facing skin
Flexural
Strength 1.0 3.5 9.2
Figure 2 shows the relative stiffness and weight of sandwich panels compared to solid panels.
HEXCEL COMPOSITES 3
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
MATERIALS SELECTION
1) Non-burning - which means that the product will not burn. density density
2) Self-extinguishing - which means that the material will burn Key: Aluminium - 3003/ACG; 5052; 5056
while held in a flame but will extinguish when the flame is Nomex - HRH10; HRH78;
removed. Fibreglass - HRP
HEXCEL COMPOSITES 4
Cell Size Skin Materials
A large cell size is the lower cost option, but in combination The table in Appendix II shows properties of typical facing
with thin skins may result in telegraphing, i.e. a dimpled outer materials for sandwich panel construction.
surface of the sandwich. A small cell size will give an improved
surface appearance, and provides a greater bonding area, but Skin considerations include the weight targets, possible
at higher cost. abuses and local (denting) loads, corrosion or decorative
constraints, and costs.
Cell Shape
Normally supplied with hexagonal cell shapes, a few Facing material thickness directly affects both the skin stress
honeycomb types can be supplied with rectangular cell shapes and panel deflection.
(W:L approximately 2:1), and designated OX.
Hexcel Composites offers a wide range of prepreg materials.
Refer to the Prepreg Matrix Selector Guide to identify systems
most likely to suit your application, where fibre reinforced
composites are thought appropriate.
Adhesive Materials
1. Fillet Forming
To achieve a good attachment to an open cell core such as
hexagonal cell size
= measured across flats
honeycomb, the adhesive should flow sufficiently to form a fillet
without running away from the skin to core joint.
HEXCEL COMPOSITES 5
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
SANDWICH DESIGN
Loads
Deflections
HEXCEL COMPOSITES 6
Failure modes
1. Strength
The skin and core materials should be able to withstand the
tensile, compressive and shear stresses induced by the design
load.
2. Stiffness
The sandwich panel should have sufficient bending and shear
stiffness to prevent excessive deflection.
Excessive deflection
3. Panel buckling
The core thickness and shear modulus must be adequate to
prevent the panel from buckling under end compression loads.
HEXCEL COMPOSITES 7
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
4. Shear crimping
The core thickness and shear modulus must be adequate to
prevent the core from prematurely failing in shear under end
compression loads.
5. Skin wrinkling
The compressive modulus of the facing skin and the core
compression strength must both be high enough to prevent a
skin wrinkling failure.
7. Local compression
The core compressive strength must be adequate to resist
local loads on the panel surface.
HEXCEL COMPOSITES 8
DESIGN GUIDELINES FOR A HONEYCOMB SANDWICH PANEL
- thickness limit
- Check for intracell buckling.
- weight limit
- Check for local compression loads on core.
- factor of safety
NB.
Preliminary materials selection should be based on the above
The formulae used for the sample problems that follow on
criteria in conjunction with the features considered on pages
pages 12 to 19, use simplified terms and give an order of
4 - 5 (and appendices I and II).
magnitude appreciation.
- Calculate stiffness.
HEXCEL COMPOSITES 9
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
NOMENCLATURE
a = Panel length
A = Area of applied load
b = Beam width
D = Panel bending stiffness
EC = Compression modulus of core
Ef = Modulus of elasticity of facing skin
F = Maximum shear force
GC = Core shear modulus - in direction of applied load
GL = Core shear modulus - Ribbon direction
GW = Core shear modulus - Transverse direction
h = Distance between facing skin centres
kb = Beam - bending deflection coefficient
kS = Beam - shear deflection coefficient
K1 = Panel parameter (used for simply supported plate)
K2 = Panel parameter (used for simply supported plate)
K3 = Panel parameter (used for simply supported plate)
l = Beam span
M = Maximum bending moment
P = Applied load
Pb = Critical buckling load
q = Uniformly distributed load
R = Ratio GL/GW
s = Cell size
S = Panel shear stiffness
tC = Thickness of core
tf = Thickness of facing skin
V = Panel parameter (used for simply supported plate)
d = Calculated deflection
sC = Core compressive stress
sCR = Critical facing skin stress
sf = Calculated facing skin stress
tC = Shear stress in core
m = Poissons Ratio of face material
l = Bending correction factor for Poissons Ratio effect
HEXCEL COMPOSITES 10
Summary of beam coefficients
P Pl 5 1
2 8 384 8
P Pl 1 1
2 12 384 8
Central Load
Both Ends Fixed
P
P Pl 1 1
2 8 192 4
Central Load
P=qlb One End Fixed
(Cantilever)
P Pl 1 1
2 8 2
HEXCEL COMPOSITES 11
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
Facing Skins Aluminium 5251 H24 - taking a beam as being defined as having width (b) less
than 1/3 of span (l)
Thickness t1 and t2 = 0.50mm
Ef Modulus = 70 GPa
Thickness tC = 25.4 mm
Beam
Bending Stiffness
Shear Stiffness As the core shear here will be taken by the weaker transverse
direction - take GC = GW shear modulus
S = b h GC
S = (0.5) (25.9 x 10-3) (220 x 106)
S = 2849 x 103 N
HEXCEL COMPOSITES 12
Beam continued
Deflection
Where kb and kS are deflection coefficients from page 11. d = 0.04259m + 0.000263m
If doing preliminary calculations, just work out the bending Total = approx 43mm
deflection.
If excessive, then the most efficient way to reduce deflection is
If optimising design, calculate for both bending and shear to increase core thickness, and thus increase the skin
components (as shown opposite). separation and the value of h.
Facing Stress
sf = M M = Pl = 1500 x 2 = 750 Nm
h tf b 4 4
Core Stress
tC = F F = P = 1500 = 750N
hb 2 2
t = 0.06 MPa
HEXCEL COMPOSITES 13
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
NB. For the earlier beams, and the end load conditioning to
follow, l is assumed to be 1, as any affect from Poisson's
Ration is small due to the relative narrowness of beams.
Plate
b 1000 = 0.5
a 2000
R = GL 440 = 2
GW 220
Deflection
d = 0.0024m = 2.4mm
HEXCEL COMPOSITES 14
Plate continued
Facing Stress
sf = 23.6 MPa
Core Shear
tC = 0.042 MPa
Local Compression
sC = P = qxA sC = (3 x 103) (2 x 1)
A A (2 x 1)
sC = 0.003 MPa
HEXCEL COMPOSITES 15
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
Charts providing coefficients for plates simply supported on all four sides
HEXCEL COMPOSITES 16
Figure 2 - K2 for determining facing stress s
HEXCEL COMPOSITES 17
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
q = 20kN/m length
End Loading
Facing Stress
assuming end load is taken by both skins, and applied load sf = 20 MPa
P=qxb
This is safe, as it is considerably less than skin material typical
yield strength of 150 MPa.
Panel Buckling
Pb = p² (5869.6)
(2)2 + p² (5869.6)
(220 x 106) (25.9 x 10-3) (0.5)
Pb = 14,413 N
HEXCEL COMPOSITES 18
End Loading continued
Pb = 2.79 MN
Intracell Buckling
sCR = 2 Ef tf 2
sCR = 2 (70 x 109) (0.5 x 10-3) 2
s (6.4 x 10-3)
HEXCEL COMPOSITES 19
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
For many practical cases, where the span of the panel is large
compared to its thickness, the shear deflection will be
negligible. In these cases, it may be possible to obtain
reasonable results by modelling the structure using composite
shell elements. It should be noted that the in-plane stiffness of
the honeycomb is negligible compared to that of the facing
skins.
When defining the properties of honeycomb core the following The above simplistic approach has proven to give reasonable
points should be taken into consideration:- engineering solutions for practical applications.
Gxy » 0
HEXCEL COMPOSITES 20
MANUFACTURE
Heated Press
Facing
Facing
Honeycomb Skin
Core Material Redux Film Material NB. Some further information related to production methods,
Adhesive may be found in Hexcel Composites publications: "Redux
Bonding Technology" Ref: RGU 034b and "Prepreg
Technology" Ref: FGU 017 available on request or via
www.hexcelcomposites.com
HEXCEL COMPOSITES 21
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
The component should be assembled for cure as a single shot This method is most suited to the single shot cure process
process, the necessary consolidation is obtained using a where a key objective is to achieve production items with high
vacuum. This can be cured in an oven, and additional pressure levels of tolerance and surface finish. The heat and pressure
can be applied if an autoclave is used. cure cycle in this case is applied using a variety of methods.
Typical methods are the use of heated tools with external
This method is suitable for items with prepreg or preformed mechanical pressure or non heated tools placed in a press or
composite or metallic facing skins. When flexible or formed oven to achieve the full cycle.
honeycomb core and film adhesives are used complex items
may be produced. Using a room temperature curing adhesive cold bonding may
be considered if the sandwich construction is too large to be
processed using the above methods, or if heating equipment is
unavilable.
PRESSURE
Vacuum bag
Form tool
Matched Tool
Facing
Skin
Material
Honeycomb
Core Material Redux Film
Adhesive
HEXCEL COMPOSITES 22
Sandwich Panel Edge Closure Design
HEXCEL COMPOSITES 23
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
SAFETY
Handling Precautions
When fabricating from honeycomb sandwich board materials it is advisable to wear disposable clean cotton gloves throughout the
entire operation. This helps to keep the panel clean, and affords protection for the operator's hands.
Glass fibre dust is an irritant. Avoid breathing the dust generated by cutting operations, and do not rub the eyes with hands which
may be contaminated with the dust.
The usual precautions should be observed while working with synthetic resins.
Product Safety Data Sheets have been prepared for all Hexcel Composites products and are available to company safety officers on
request.
The information contained herein is believed to be the best available at the time of printing but is given without acceptance of liability, whether
expressed or implied, for loss or damage attributable to reliance thereon. Users should make their own assessment of the technology's suitability for
their own conditions of use and, before making any commitment with regard to the information given, should check that it has not been superseded.
HEXCEL COMPOSITES 24
APPENDIX I
Other foil thicknesses and cell size are available: see specific data sheet or Selector Guide, obtainable from Hexcel Composites on request.
*Please note that the exact cell sizes for HexWeb core are the imperial measurements. The metric values are provided for reference only.
HEXCEL COMPOSITES 25
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
APPENDIX II
Epoxy UD CARBON
tape (0°) 2000 / 1300 130 / 115 0.25 0.125 0.19
60% volume fraction
Epoxy UD GLASS
tape (0°) 1100 / 900 43 / 42 0.28 0.125 0.25
55% volume fraction
Tempered
HARDWOOD Teak 110 / 40 Av. 12 0.1 12.7 8.5
HEXCEL COMPOSITES 26
APPENDIX III
Summary of Formulae
Deflection = d = 2K1 q b4 l
Ef tf h2
Facing Stress = sf = K2 q b2
ht
Core Shear = tC = K3 q b
h
Shear Crimping = Pb = tC GC b
The above formulae assume symetrical items, with thin facings of the same skin material and thickness, and core relatively much
less stiff than skins.
HEXCEL COMPOSITES 27
HexWebTM HONEYCOMB SANDWICH DESIGN TECHNOLOGY
Further reading:
HEXCEL COMPOSITES 28