H. Kim The basics on bonded e sandwich construction TSB 124REFERENCES DESIGN ANALYSIS METHODS Hexcel TSB102 Air Directionalization Hexoel TSB113 Radio Frequency Properties Hexcel TSB122 Design of Energy Absorption Systems Mil HDBK-23 Analysis of Sandwich Structures (U.S. Government Printing Office) R.J. Roark, Formulas for Stress & Strain (McGraw Hil) S. Timoshenko, Strength of Materials (Van Nostrand Reinbold) 8. Timoshenko, Theory of Plates and Shells (McGraw Hil) HONEYCOMB MECHANICAL PROPERTIES Hexcel TSB120 Mechanical Properties HONEYCOMB DATA SHEETS 1040 WR 118 Shelter Core® ~ Water Resistant Kraft Honeycomb 1300 HRH® 49 — Honeycomb of Keviar®* 49 2400. CR Ill® Corrosion Resistant Specification Grade Aluminum Honeycomb 200. 2024 Aluminum Honeycomb 2300 CR Il Corrosion Resistant MICRO-CELL" Aluminum Honeycomb 2400 Aluminum Corrugated Honeycomb 2700. FLEX-CORE® —Formable Aluminum Honeycomb 2800. TUBE-CORE® — Energy Absorption Cylinder 2900 Welded Honeycomb Core 000 HAP# — Reinforced Plastic Honeycomb 3100 HRH® 627 — Fiverglass Reinforced Polyimide Honeycomb 3200. FIBERTRUSSS HFT® — Fiberglass/Phenolic Honeycomb 3800 HFT-G— Graphite Honeycomb 3700 FLEX-CORES ~ Non-Metallic/Reinforced Prastic 4000 HAH-10 — Nomex®* Aramid Fiber/Phenolic Resin Honeycomb 4100 HRH-310 — Nomex Aramid Fiber/Polyimide Resin Honeycomb 4400 HRH-78— Nomex Commercial Grade Honeycomb 5000 ACOUSTI-CORE® 6000 ACG® Honeycomb ~ Aluminum Commercial Grade 6300 ANG" — Aluminum Naval Grade Honeycomb 7580 HEXPRES® Aluminum Sandwich Panels 7601 HEXABOND® Ill — Honeycomb with Pre-Applied Cell Edge Adhesive 7800. BLUE SEAL® Sandwich Board 7803. High-Temp Fiberglass Sandwich Board 7804 Low-Temp Fiberglass Sandwich Board 7805 Graphite Sandwich Board \Webeeve hal hs nfomatonis ne best curenty avaiable onths subject ts otferedase possiblehlpu quer thase developing the omnexprtseon the suc of sanchsrsciuesandhe specalzed krowledperequed tor esi and analyst sutec vein as adatonakoowlesge and fexpenenoe are ganed. excel males no cuaantseo esuls and assures No eoigalon or laity whatsoever conection wth this information Ths pubscaton soa cers to parte unde, or etendedo suggest ingement oh ary exsng patent 1987 REVISION Pa Gp inline at a aINTRODUCTION Bonded honeycomb sandwich construction has been a basic structural concept in the aerospace industry for the last thirtytive years. Virally every aircraft flying today depends upon the integrity and reliability offered by this structural approach, The capablity ofthe concept has been proven, and is now widely accepted ‘Asa result of this history of success, a growing interest has developed in the use of honeycomb sandwich for a broad range of commercial applications. Hexcel is participating in this interest by supplying honeycomb core adhesive and resin materials, glass/Kevar/graphitelceramic/quarz fabrics and prepregs; and bonded panels. Our efforts in bonded panels are directed solely towards new commercial opportunities which will expand the market forthe industry. This bulletin is offered as a primer on the capabilites, design and evaluation of bonded sandwich systems. Itis primarily ‘geared toward commercial sandwich applications and assumes the user has no experience in sandwich design or ‘analysis. In addition to this bulletin Hexcel offers a wide selection of technical publications on other facets of bonding technology. Please contact one of the sales offices listed on the back cover for additional assistance. Our applications engineering staff will be glad to assist you in developing a design to meet your objective. FIGURE 1 ‘SANDWICH CONSTRUCTION overcome sowesve ‘The facings of a sandwich panel used as a beam act similarly to the flanges of an! beam by taking the bending loads ~- one facing in compression and the other in tension. Expanding this comparison further, the honeycomb core corresponds to the web of the | beam. This core resists the shear loads, increases the stifness of the structure by spreading the facings apart, but unlike the | beam’s web, gives continuous support to the flanges or facings. The core-to-skin adhesive ‘igidly joins the sandwich components and allows them to act as one unit witha high torsional and bending rigidity FIGURE2 a Relative Stiffness (0) 100 700 3700 Relative Strength 100 350 925 Relative Weight 100 103 106 A striking example of how honeycomb stiffens a structure without materially increasing its weight.MATERIALS - GENERAL Honeycomb sandwich construction lends itself to an unlimited variety of materials and panel configurations. The fact that a bonded sandwich is a composite structure provides the versatility of selecting from a a wide range of core and facing material combinations. The following fundamentals should be considered inthe routine selection of cor, facing, and adhesive ENVIRONMENTAL CONSIDERATIONS: + Temperature: As in any materials system the temperature environment will play an important role in the selection of materials. Bonded honeycomb structures are generally categorized into three maximum service temperature ranges: 180°F, 250°F, and 350 to 450°F systems. Some exotic systems are usable up to 800°F for very short exposures and all systems are basically operational in low temperature environments. + Flammability: Materials used in bonded sandwich construction are usually classified into three categories: non- ‘burning -- which means that the product will not burn; self-extinguishing -- which means that the material will burn while held in aflame but will extinguish when the flame is removed: and flammable. Flammable materials are some- times further defined by defining the flame spread rate under specified conditions. '* Heat Transter: The transfer of heat through a sandwich panel is dependent upon the basic principles of convection, ‘conduction and radiation. Metalic cores with metallic facings maximize heat transfer, while non-metallics minimize heat flow characteristics. Foams crushed into non-metallic cores prior to bonding tend to further reduce heat transfer rates by eliminating convection within cells. '* Acoustics: Bonded honeycomb sandwich structures have been widely accepted as acoustical absorption systems. Hexcel’s standard Acousti-Core® product used in conjunction with perforated facings offers an acoustical panel with excellent noise reduction coupled with superior structural properties. Moisture/Humidity: Some core and facing materials offer excellent resistance to degradation dus to moisture and humidity. In addition, several of the non-metallic products listed on Page 6 are inherently moisture resistant. « Adhesive Solvents or Qutgassing: Some adhesives give off gases or solvent vapors during cure which can interact with resin systems in some non-metallic cores, or with the node adhesive in some metal honeycombs. The entire bonding process must be checked to ensure that no reduction in mechanical properties fas occurred due to incom- patibility of the materials or process actually used. ‘STRUCTURAL CONSIDERATIONS: * Strength: Honeycomb cores are mult-directional with regard to shear properties and care must be taken to insure that the core is placed in the panel to take the best advantage of this attribute. Hexcel's TSB #120Mechanical Properties of Hexcel Honeycomb Materials provides a complete description of various strength characteristics of core and lists the mechanical properties of all commercially available honeycomb core materials as well as a few of the most common facing materials. A short form of these listings are provided on Pages 5, 6, and the last page of this bulletin Fatigue: Since fatigue failures are rare in bonded honeycomb sandwich systems, general fatigue data for honeycomb cores and specific core/facing combinations are not published. If fatigue does become a consideration in a sandwich design the problem will usually always occur around a mechanical fastener or stress concentration area. * Stiftness: Sandwich structures are frequently used to maximize stiffness at very low weights. Because ofthe relatively low shear modules of most core materials, however, the deflection calculations must allow for shear deflection of the structure in addition to the bending deflections usually considered. Shear deflection can range from a few percent of bending deflection for long, thin beams, up to a figure equal to - or greater than - the bending figure for short, thick sandwiches having heavy skins, ‘ Adhesive Performance: The adhesive must rigidly attach the facings to the core material in order for loads to be transmitted from one facing to the other and to permit the structure to fulfil al the assumptions implied in the accept ance of the commonly used stress calculation methods. A low modulus or rubber cement type adhesive is therefore never used in a sandwich structure intended to carry substantial loads. The adhesives which are satisfactory for this application are all high-modulus, high-strength materials available as liquids, pastes, dry films, supported films, or pre-placed on the cell-edge by the core manufacturer (Hexcel's Hexabond® materials). Any material contemplated for use as a core-to-facing bond should generally meet or approximate the requirements of MIL-A-25463. Adhesives also come in a wide range of toughness or pee! strength, depending on the requirements to be met. AS a general rule, alow peel-strenth, or relatively brittle adhesive should never be used with very light sandwich structures which may be subjected to abuse or damage in storage, handling or serviceMATERIALS - GENERAL (continued) ECONOMIC CONSIDERATION: + Value Analysis: Honeycomb sandwich construction is not always a low cost method of construction. Its primary value lies in its optimization of structural properties at minimum weight. Generally if weight savings can be valued then honeycomb sandwich can be cost effective. The professional value analysis approach will relate initial cost with such other items as transportation cost, construction time savings, operational time savings, power savings. ‘manpower efficiency and similar down the line costs which may be overlooked during product design. Total lifetime cost calculated in this manner often shows honeycomb sandwich designs to achieve substantial overall savings. HONEYCOMB MATERIALS METALLIC HONEYCOMB CR III®: The CR ill prefix to the aluminum honeycomb designation indicates corrosion resistant aluminum honeycomb. The CR Il coating is placed on the foil before the node adhesive is applied, thereby insuring corrosion protection over the full fll surface area. All of the standard aluminum core types are available with this corrosion protection. 5062 Allay: Specification grade honeycomb in the $052 H39 aluminum alloy is available for general purpose applications, ina very wide range of cell size/density combinations in the hexagonal and FLEX-CORE configurations. The hexagonal configuration is normally provided in the non-perforated condition, however a perforated* product is available on special order. OX-CORE® and under-expanded core can also be provided upon special request. 5086 Alley: Specification grade honeycomb in the $056 H29 aluminum alloy offers superior strength over 5052 alloy honeycomb. It is also available in a broad range of cell size/density combinations in the hexagonal, and FLEX-CORE geometries. The hexagonal configuration is normally provided in the non-perforated condition, however a perforated” product is available on special order. FLEX-CORE is not available in the perforated condition 2024 Alley: The heattreatable aluminum 2024 alloy combines high room temperature properties with increased strength retention at elevated temperatures. Itis produced in several cell sizes and densities and in the T3 and T 81 tempers ACG®: Aluminum Commercial Grade honeycomb provides a low cost aluminum honeycomb product for non MIL specifi- cation requirements, Standard products are fabricated from one foil gauge and are available in A, %, Ye, % and 1 inch cell sizes. All ACG materials are provided in the perforated condition and with the CR I coating at no extra charge. ANG2": Is a CR Ill % inch cell, non-perforated, specification grade aluminum 5052 alloy for Naval applications. STAINLESS STEEL: Available in both adhesively bonded and brazed condition used for energy absorption and high temperature applications. Contact your Hexcel sales office for manufacturing capabilities. GLASS REINFORCED HONEYCOMB HFT®: A glass fabric reinforced plastic which incorporates a FIBEATRUSS® bias weave dippediinaheat resistant phenolic resto achieve the final density. This material is recommended for use at service temperatures up to 350°F but is well suited for short ‘exposuresat higher temperatures. The FIBERTRUSS configurations greally enhance the shear properties; HFT has a much higher shear modulus than HRP or HRH 10. HAPS: A glass fabri reinforced plastic honeycomb dipped in a heat resistant phenolic resin to achieve the final density. This product was developed for use at service temperatures up to 350°F. However, itis also wel suited for short exposures at higher ‘temperatures. The HAP-series honeycomb is available in the standard hexagonal configuration, as well as inthe two formable ‘geometries—OX-CORE and FLEX-CORE, * eartrate honeycomb is used when the curing 0 he core-toskin adhesive resis in volatiles which must be vente. “Registered excel TrademarkHONEYCOMB MATERIALS (continued) GLASS REINFORCED HONEYCOMB (continued) NP® A glass fabric reinforced plastic honeycomb in which the intial web impregnation is a nylon-modified phenolic Tesin and the final dip coats are polyester resin. This core type is recommended for applications in which the service temperature does nat exceed 160°F for extended time periods. The NP series honeycomb is available in the hexagonal and OX-CORE configurations. HAH 327: A glass fabric, bias weave reinforced plastic Honeycomb that incorporates a polyimide resin system for the node adhesive as wel as for both te initial and final web impregnations. This material has been developed for extended Service temperatures up to S00°F with short range capabilites to 700°F. ‘ARAMID-FIBER REINFORCED HONEYCOMB HRW® 10 (Aramid Fiber): This product consists of DuPont's NOMEX®* aramid-fiber paper treated with a heat resistant phenolic resin. It features high strength and toughness in a small cell size, low density non-metallic core. Its avail- able in the hexagonal, OX-CORE and FLEX-CORE configurations, It is recommended for service up to 300°F. HRH® 310; This material is manufactured using same fiber as HRH 10. tis produced in both hexagonal and over-expanded cell configuration. Outstanding features are its dielectric and loss tangent properties. SPECIAL APPLICATION PAPER HONEYCOMB WR II®: WR II is a water resistant core material that was designed primarily for use in the construction of Ai Trans- portable Miltary Shelters. it meets the type Il core classification of MIL. spec. MIL-H-21040 and provides less than ‘one cell water migration in 24 hours when tested per MIL-STD.-401. For special applications, Hexcel has the capability (filing this core with alight density polyurethane or phenolic foam for added thermal insulation. Ropiatered Mexeel Trademark (© *Registeres Trademark, DuPont TABLE | COMPARISON OF TYPICAL PROPERTIES OF HONEYCOMB CORE MATERIALS coma | tse | coca | ace ome | wee | ne | amaze | wie | wn cos wos. [oon | tow | aos. | mos. | wos. | ton | mot | tow wax sevice ne. | ase ave | sore | sore | ome | ware | sor | sor | or fanatity e fe fe fe fe fel e |e le moat | 6 |e | 6 |e | o |e | e fe | & pect ee eee lee ee ee |e Fags Steng «fo fso]c«le«felcele |r ea Taste won [rion | oor [tow | tow | tow [tow | tow | tow “Moisture and corason resistance ae excelent with CR ML E-txcellent. Good, F- Fale, P- PoorHONEYCOMB MATERIALS (continued) TABLE II EXAMPLE OF MECHANICAL PROPERTY TABLES FROM TSB 120 ‘he following tables contain a sampling of mechanical properties of the various honeycomb core types for which Hexcel has developed data. See TSB120 for more complete information. 5052 ALLOY HEXAGONAL ALUMINUM HONEYCOMB era. coPacssive 6 PLATE SHEAR woKEYcoms cr sania) 2g [0 oven “W birton aesieuaTion | 38 2 | strenan | suengt |eosuus| 3 | strengtm |wedus| strengtn | moauis ler.mateviat-cage| ost = isi | ms isi ms isi we am | yp am ye] we | we min | | op an | vesose-oo7 | a1 | 20 2m | 20 25] 75] 10] 20 155 | 450 | 190 © 0 | 220 1ve-sosa-0o1 | 45 | soo 375 | 545 405 | 50 | 260 | s40 265 | 700 | 200 168 | 310 vesose-oo15 | 61 | sm 630 | sr 6a} 240 | aso. | sos ass | 0 | x20 272 | 10 wvesose-o } a1 | 1400 1000 | 470 rio0 | 360 | 750] 725 oro | 135 | 455 ato | 40 avesosz-cor | 31 | 2m 20 | zm a5] 75 | 130 | 20 155 | 450 | x 9 | 220 srresose.oo1s | 44 | soo seo | 525 285] 145 | aso | 300 280 | 680 | a 160 | 00 3ri6sosz-ore | 57 | 70 560 | si oo] 220 | sw | 450 s10 | 200 | m0 2 | ses wasose.cr | 23 | 5 0 | ws | a] 15) wo wo | wo | ss 57 | w2 wasoseoors | 34 | xo 20 | a0 250] a | 150 | 225 tao | s00 | 150 105 | 240 vasose-oce | 43 } 0 a0 | 50s 370] wo | 200 | sz a5 | obo | 20 155 | a8 4505.00 | 79 | 1960 970 | 1420 1050 | a | 705 | 700 650 | 190 | wo ao | 20 aussose.cor} 10 | » | 6 | wl] 6 2] wo] » | 70 sussosz.o2 | 0 | m 1m | as ao] m| | m | ao | | a2 5056 HEXAGONAL ALUMINUM HONEYCOMB wwe-sose-00a7 | 31 | 340 250 | 060 20] o7| wo] 20 20) 0 | 5 110 | 200 wesose-oor | 45 | eo 475 | o7 son] 185 | 220 | 425 50 | 700 | 255 ats | 280 aresose-oor | 31 | a0 250 | 260 20] 97 | 170] 255 amo | 450 | 155 © 110 | 200 wasoseoor | 23} m5 us| 20 185] 58] 00] 70 10 | ao | 5 | 150 2024 HEXAGONAL ALUMINUM HONEYCOMB weno | 50 | 70 52 | 70 co] cm] as] so 0 | wo] as em | sao veceet.oos | 95 | s970 17s | 200 25] seo | 1120 | 1150 950 | 70 | oso sas | 640 aiseznzt.on5 | 35 | 200 250 | amo 200] 6 | 20 | 200 © 20 | 50 | 0 109 | 220 wacnes-onis | 28 | 220 165 | 250 175) | 10 | 2m © 0 | 20 | ow | 80 5052 ALUMINUM FLEX-CORE sasorrao-oors | 21] wo 6 | 2 | os] | 0 w] w| o w] w soszrrso-coo19 | 31 | a0 28 | ao 200] 125] 165 | 190 26 | se | wo 5 | 9 soserre0-co19 | 65 | so00 700 | vaso 705} aio | — | ao soe | 2 | 0 © 10 | 24 soserre0-o02s | 80 | 1570 1100 | 1600 120] | — | cao ae | 8 | 15 20 | ot “Not avaiable wth 2 CR Mt coatingHONEYCOMB MATERIALS (continued) TABLE Il (continued) ALUMINUM COMMERCIAL GRADE—ALUMINUM NAVAL GRADE HEXAGONAL HONEYCOMB {wren | 2 ‘COMPRESSIVE S PLATE SHEAR fovyaron | 2 [Bae Subiaed Ba =E Diretion Ww Direton Nceroan. | Ze J sweat | Srenrm [ woaans |” | Srenm | wodaus [Sveum | motos cme | S| psi 1 i | S| ost isi psi isi typ. typ. typ. bp. typ. yp. typ. typ. nos ve-003 | 52 [0 | 0 we | as | oAs 28 3a accaie-os | 36] 325 | 30 we | wo | 210 “ 0 » acco | 28} 15 | 170 « | o| B 0 8 acoso | ta | tm | a | | % 5 a0 root -03 | 14] 0 we | 3 | # “ 0 10 anc2ae | a7] so | ao ws_| 10 | 260 5 170 % HRP GLASS REINFORCED PHENOLIC HONEYCOMB wexceL COMPRESSIVE PLATE SHEAR samaran ct Said Diet “WF Diet Mateancene | Sienath ‘engin [Wosuius|| stengtn | Modulus | Strength | Modulus Density psi asi isi psi isi asi st een | op mm | ye [oe mn [op | ye min | oo weareao | 500 a0 | eo ao | sr || am ao | 1 | io 10 | 80 nnesiess | so so | om 750 | o |] a 00 | w | mo mo | as weiss | 75 ao | as 0 | 4 || 2m = mo | ot | oo | 85 wepsiea2 | wo 0 | wo x60 | 38 || mo 9 | 1 | ms a | 30 HET GLASS REINFORCED PHENOLIC HONEYCOMB EXCEL COMPRESSIVE PLATE SHEAR HONEYCOMB, - DESIGNATION Sablined = Diretin -W Direction ee Strength Modulus Strength Modulus Strength Modulus Density si ksi si ksi si si ymin e. ye min we. yp nin m7 HFTAIBSS | Cy 8 0 20 «Te 4 HFT-9/16-40 0430 “4 ms 20 x wo 15 4 HRH-327 GLASS REINFORCED POLYIMIDE HONEYCOMB HRHoe7-3/1645 | 520 400 8 | O 3 0 110 " nH 3273/1680 | 1210 1000 126 7m = «0 2 (0 2 WR I SHELTER CORE wexcEL COMPRESSIVE PLATE SHEAR onevcomB DESIGNATION Bare ‘Suablized = Dien "WE Direction aterat-cen. | Stenotn | Stength | Moduus |[ strengin ] Modus | Strength Modulus Density si asi ksi psi ksi psi ksi yp yp yp. yp ‘yo yo. yo WANL3I825 260 340 3B 70 8 100 70 WA 13/838 515 570 5 255; 19 5 a0 6HONEYCOMB MATERIALS (continued) TABLE II (continued) —HRH-10 ARAMIO FIBER REINFORCED HONEYCOMB WerCeL COMPRESSIVE PLATE SHEAR wowevcos a Tiina 7 wenerctig i T Birrion WF Die Strength Strength — [Modus || Swength | Modus | Strengin | Magus PMatriaicenDensiy| os asi si psi isi asl isl Gage tieragona [yp avin | yp min | tye yp min | yo | yp min | yo Tnoseen5 | 10 7% | wo a] — | # 6 | a7 | 9 % | 20 eino-18609) | 17s 00 | 1125 as | ew | 370 a0 | 30 | 2 a5 | 60 wruroa60@| 2 20 | sm 20 | 2 | wm wo} se | » | as wenio3e20e | 0 0 | vo 5 | 1 f mw mm] a2 | ss % | 22 anig70xs06 ett} wes os | oo | | os ws | 30 | wo ts | oo FLEXOORE HRHIO/F352.5:9) | 20 140 | 235175 2] 10 05 | 40? | sao] 1? trwrovesoasi | 355s | as wo | os | 5 | om | 40 ADHESIVE MATERIALS ‘Adhesives, as they apply to sandwich structures, are a somewhat different family of materials than are simiar materials ‘not required to bond an open cellular core toa stiff and continuous facing. Although these differences are less important with some of the newer modified epoxy materials, they remain basic, and must be understood by the designer and fabricator in order to avoid the otherwise inevitable problems. Some factors which merit attention are: 1) Fillet Forming. In order to achieve a good attachment to an open cell core, such as honeycomb, the adhesive must hhave a unique combination of surface-wetting and controlled flow during early stages of cure. This controlled flow prevents the adhesive from flowing down the cell wall and leaving a low-strength top skin attachment and an over- weight bottom skin attachment. 2) Bond Line Control. This is a need which exists because of misfitting details. It is the capability of the adhesive to resist being squeezed out from between faying surfaces when excessive pressure is applied during cure to a local area of the part, Many adhesives are formulated to achieve good core filleting and are subsequently given controlled flow by adding an open weave cloth or fibrous web, cast within a thicker film of adhesive. This scrim cloth then prevents the faying surfaces from squeezing out all the adhesive, which would result in an area of low bond strength. 3) Toughness. The word, toughness, has many meanings in the world of adhesives. Usually it refers to the resistance shown by the adhesive to permitting bondline cracks to grow under impact loading. In the area of sandwich core- to-facing bonds, it refers to the resistance shown by the adhesive toward loads which act to separate the facings {rom the core under either static or dynamic conditions. It has been found from experience that greater toughness in the bond line usually equates to greater durability, and thus to longer service lite Many types of tests have been devised to measure toughness, but the most common one used for sandwich structures is the climbing drum peel test, which has the virtue of being easily duplicated as well as possessing an obvious Felationshi tothe toughness whose value is sought. Values of peel strenoth will vary considerably, depending upon « strength of facing + toughness ofthe adhesive ‘© amount of adhesive used + density ofthe core + cll size ofthe core «+ diection of peel (with or across ribbon direction) + adequacy of surface preparation + degradation of the adherend surface subsequent to bonding Because these variables can lead to widely differing peel strength forthe very same adhesive, al of them must be properly understood and coatroled ifthe pee testis to be used and its value compared to other test results It can be readily seen that a number of points of difference separate the sandwich adhesives from other structural adhesives. Fortunately for the sandwich user, many adhesives are available which satisfactorily meet both sets of requirements. A sampling of various types of adhesives for use in honeycomb sandwich, along with their manufacturers, are listed on Page 8. aADHESIVE MATERIALS (continued) TABLE IIt COMMON ADHESIVES IN CURRENT USE ADHESIVE TYPE TRADE DESIGNATION MANUFACTURER Nitrile Phenolic Films F238, FM 47 American Gyanamid APS, AF 31, AF 92, AF 6, AF 10, A 19, AP 15: 3M Company Metibond 402 Narmco Plastilock 655, 638, 620, 650 BF Goodrich Modified Epoxy Liquid Lt eee tareay and Pastes EA 9920, EA 9909, EA 934 Hysol MA 1018, MA 2021 MeCann Adhesives Crest 148, 4713181, 3195, Crest Products EC Z2168/A, EC 35698/A, EC S578B/A, EC 3448 4M Company ‘R13968, Aided, 14468 BF Goodrich Strucol R380 Hexcel SA, Belgium HP 326, Hexcel Corporation ER S601, EA 9602.3, EA 9628 Hysol poiies Foy Fire Hh 28 MA #08 NA 458 MeCann Adhesives 250°F Cure and Below FM 24, FM 53, FM 73, FM 123, FM 137 American Gyanamid Metibond 117, M1113, M1133, M1137, M1204 Narmco Plastilock 7176. BF Goodrich 3, A714 Ciba-Geigy A 126, AF 126.2, AF 127, AF 163-2,AF310922,AF31132 | $M Company HP 347 (Cell Edge) Hexcel Corporation Structulil R382 Hexcel SA. Belgium E15 Hexcel Cofporation Modified Epoxy Film Metibond 328, 308, 329-1, 1515 Narmco 50°F Cure ‘AF 1902, AF 191A, AF 1432 AF 147, AF 191 3M Company FM G1, FM 96, FM 150-2, FM 300, FM 400 American Gyanamid Plastilock 729°3 BF Goodrich MA 529 MeCann Adhesives EA 9649 Hysol Structutilm R398 Hexcel SA, Belgium Epoxy/Polyat rim | _A1178, A12738 ‘BF Goodrich ae EA 951 Hysol 4 1000 American Cyanamid AE a Palyimide Films FM 348-18 American Cyanamid HP 955, HP 956 Hexcel Corporation Modified Urethane Pastes, | Crest 7410, 7450, 7395, Crest Products Liguids Metibond 6872, 6875, 6876 Narmco EC 35498/A, EC 35928/A, EC 35958/A 3M Company Plastilock $50 BF Goodrich Morad 336 Morton Chemical Core Splicing Adhesives | Crest S181, 3168 Grest Products Pastes and Tapes Mellbond 6602, 6607. 6601. 6603 Narmco FM 37, FM 39, FM 40, FM 41, FM 47-Type 0, | American Cyanamid FM 404 MA 550, MA 2150 MoCann Adhesives EA 9615, Thermofoam 3050, Thermotoam 3056 | Hysol ‘AF 9002, AF 3018, AF 3020, AF 9024, AF 3028, 3M Company £63499, EC35008/ A, EC35248/A, EC 3548/4 HP 905, HP 906, Hexcel Corporation Plastlock 654, 658 BF Goodrich Strucol 370, 3708 Hexcel SA, Belgium NOTE ae a a coal ng pos on tl acgs soy avn Ts dlp Ingres ace a Donde coasin al ay Indusas shy hea erty Sage en Soe get, main Wome twee so ase wit eee ‘otatng mand ily pos bong, Sots asbn ution pas Set ances som) sce tohave anes cyanate nth ‘ete sw ns sf macy nln wih cena te Scheie spp’ ante pm supe opiman ute ato ahve. PA ic aso aed ca perfor some servers Pconesn Jabibiliag eriner UC 40485 has alsa proved successil. iso used as a pr PPGSANDWICH DESIGN ‘The usual objectives of a sandwich design are to save weight, increase stiffness and reduce overall cost. In adtlition, there may be other objectives such as achieving aerodynamic smoothness or visually attractive flatness, reducing reflective noise, maximizing or minimizing heat transfer, increasing durability under exposure to acoustic energy, of ‘many others. The designer's problems sift down to relatively few, such as getting the loads in, geting the loads out, attaching small or large load-carrying members, etc. under constraints of deflection, contour, weight, and cost. Here ate afew suggestions: 1) Understand the fabrication sequence and methods. The cost of a sandwich structure is fundamentally fixed at the design stage, and a considerable difference in cost results from alternate solutions to the design problem, 2) Use the right core. Several densities of core can be used in a single panel, each appropriate to the load carried inthe area and adhesively bonded to its neighbor (where shear loads are higher than can be bridged by the skins) In many cases, however, the weight saved in lower density areas of core is added back in the form of core splice adhesive weight, In the same manner, a fitting provided to cary out a large load can be made slightly larger, neeasing the peripheral area thus avoiding the need fora high-density area of core. 3) Simplity tooling by allowing post-bonding structural additions. Several examples show panels made in a flat press with very simple tooling with a substantial fitting bonded into the panel. The same result can be achieved for lower loads by using post bonded:in fasteners as shown in Fig 20. 4) Do not hesitate to use several joining methods in the same part. Fittings to be included in a bonded sandwich may be produced from weldments, forgings, or riveted assemblies, or may themselves be bonded assemblies. Available adhesives permit secondary bonding to be performed at temperatures from 60°F up to 360°F without degrading the integrity of the bonded subassemblies. Bolted and riveted structures sometimes pose a problem, however, in that after assembly itis not advisable to immerse them in the usual surface treatment solutions. The problem is usually handled by priming the parts prior to assembly, so that they can subsequently be prepared for bonding by removing protective paper tape, and/or solvent wiping §) Use bolts and rivets for carrying loads. Where space is not available for progressive doublers or wide-area bonded ‘overlaps to carry high loads, the addition of rivets or bolts is sometimes an only solution. Their use, however, often results in lower fatigue life of the structure, in addition to increased weight. The use of chicken rivets for the sole purpose of appearance is to be particularly avoided, since they often give away much of the advantage resulting from the use of the bonded structure. A'loss of some portion of fatigue life can always be expected from addition of rivets to a good bonded design. 6) Use doublers where needed, instead of a heavier facing over the entie part. The use of doublers, although adding labor cost in assembly, often improves the part quality. Some of the most successful sandwiches ever designed such as the Bell UH-1 rotor blades, have employed as many as 16 thin doublers in a single highly loaded area, with ‘a nearly complete absence of doubler fit-up and bonding problems. Where skins are formed of glass or graphite prepreg, the problem is even simpler, since extra plies can be added to carry extra loads exactly where and as needed.SANDWICH DESIGN (continued) DESIGN REQUIREMENTS, MODES OF LOADING AND FATIGUE © Sandwich structures should be designed to meet the basic structural criteria listed below when these criteria pertain to the type of loading under consideration. FIGURE 3 t 1) The facings should be thick enough to withstand the tensile, compressive, and shear stresses induced by the design load 2) The core should have sufficient strength to withstand the shear stresses induced by the design loads. Adhesive Dan inst have sufi! stengh to cary shear sess ino core 9) The core should be thick enough and have sufficient shear + © eee 4) Compressive modulus of the core and the compressive enter eons sate arioen 1 eset Nil Se eee eae 5) The core cells should be small enough to prevent intra- Cl | cell dimpling of the facings under design load. 7 6) The core should have sufficient compressive strength to resist crushing by design loads acting normal to the panel facings or by compressive stresses induced through flexure 7) The sandwich structure should have sufficient flexural and shear rigidity to prevent excessive deflections under design load,SANDWICH DESIGN (continued) HOW SANDWICH BEAMS WORK FIGURE 4 Consider, for example, @ cantilever beam one inch wide with a length, L. and a load, P, at its end, as shown in Fig. 4 This load creates a moment, M, which in this case is equal to PL atthe fied end, It also sets up tension and com- pression stresses within the structure. The magnitude ofthese induced stresses is related tothe moment. For the sandwich beam the tensile and compressive force in the facing times the distance between the facing centroids equals the moment. Or the facing stress equals: Moment M Mel heeleloal “Thickness ofa Tacing x distance between Tacing controls SHEAR: ‘The load also imparts a shearing action within the structure. This shear force is taken up by the honeycomb which prevents the top and bottom facings from slipping. The shear force, V, may vary along the beam if a uniform load is applied, The maximum shear force for various load and support conditions is shown in Fig. 7. The shear stress in the core is related to V by the distance between the facing centroids Shear Load V ie sheet eee a ce distance between facing centroids DEFLECTION: The total deflection of a honeycomb sandwich structure is calculated by adding the deflection caused by the bending reaction and the shear reaction within the structure. Fig. 5 demonstrates the individual deflection and shows that the deflection in each case is the result of the basic elastic properties of the stressed materials involved. Thus the bending deflection is related to the modulus of elasticity of the facings, and the shear deflection is related to the core shear modulus, NOTE: Deflections of cantilever beams may vary considerably from the basic formula depending upon core charac teristics, and the details of anchoring the beam. a4 FIGURES “4 Total deflection = bending deflection + shear deflection.SANDWICH DESIGN (continued) ANALYSIS OF FLAT RECTANGULAR SANDWICH BEAMS FIGURE? ‘ BEAM CHART FIGURES VO a |, | voune | oeruction | ofuecrion san re sat | Swe | thse | Shen BENDING STRESS IN FACINGS Vw ee ke M_ where M is determined by iad 4 Oth ietore Figure? ase | orzset | oorsoz | 0.12 CORE SHEAR STRESS Ta ape M Vis trom Figure7 Coit ‘sp | oesaapt| ooz604 | 0.125 hb DEFLECTION Ky and Ks trom Figure 7 —=. ase | o2set | oozoss | 025 1 = 2RGPLA , KePL (for same skin Ertrh’b Geb materials) t ose | ose. | 00521 | 025 or KePLE | KePL © {see D below) = D * hGcb Poth p | ose | ars | os (For most long beams, the second term is relatively small, but should be checked if on — deflection is critical.) P PL 03333 1 FACE DIMPLING {ie p {osasaet| 0.06666 | 0.3333 o, =2H [i 7 a Ks =. . TEI)" | osese | o.125et | 0.005405 | 07042 FACE WRINKLING —— | ee Ej ‘ “Fa 9 ERS AOI ve EviEthe> 4, Etta 4, _Ethéb Ents Ae * Exlodt (CEST 2R LIST OF TERMS P =Total Load A = etletion Retew y= Facing Modulus {= Facing Poisson's Ratio c= Core Shear Modulus S = Cell Size I= Cenioid Distance Gen = Critical Facing Stress c= Cote Thickness Te, = Gore Shear Stress 0 = Panel Stiffness |= Moment af Inertia‘SANDWICH DESIGN (continued) DESIGN STEPS FOR BEAMS 1) Define Loads. For multipoint loadings, not shown on the preceding pages, use the formulas in Roark, Formulas and Stress and Strain. 2) Detine Beam Type. The values of Fig. 7 provide the simple starting point for these calculations. Some care in using the fixed end type of support is needed, as in actual practice total fixity isnot realized, and the resulting deflections are greater than that calculated 3) Determine Required Maximum Deflection, For most applications, the allowable deflection of the structure is usually limited to L/360. In some cases greater deflections may be used, or as in the case of snow skis, very much greater deflections may be anormal part of the function of the structure. 4) Select Skin Material. Fig. 21 gives stress and modulus data for common sandwich skins. Skin considerations include the weight target, possible abuse and local (denting) loads, corrosion or decorative constraints, and costs. Select standard thicknesses and make the initial calculation as outlined below. The facing thickness directly affects both the skin stress and the deflection. Consider possible temperature effects, 5) Caleulate First Approximation. After the first sandwich thickness is determined, another selection of tr or te may be made to arrive at more desirable or practical values of h. Most sandwich structures in ordinary usage are in the thickness range of .06° to 6 0 inches, 6) Select Skin Thickness, Keep in mind that materials such as aluminum are available in specific, standard gauges. After the skin thickness for deflection is selected, it should be checked for stress. The formula for ti on Page 12s. used, and a factor of safety determined, 7) Select Core. The calculation of tc is used to determine the core shear stress. Make preliminary selection from Tables I 8 lll using about three times the shear stress. Nole that the core strength is not the same in the “L” & “W" directions. Refine the selection including considerations of material compatibility, cell size, and types. Determine the corrections needed to account for the effects of thickness on strength (see TSB 120, Page 12). Check the factor of safety using the calculated stress and the corrected allowable stress. Use-"Engineering Design Values.” Other considerations include crushing and compression strengths, modulus in shear, weight and costs. For rolling wheel loadings the crushing strength and the skin thickness are often the most important considerations. 8) Re-check Deflection. For many applications the calculation of the expected deflection may omit the shear deflection portion. With very small deflection limitation, with very thick sandwich, or with very short spans. the shear component should be calculated and the core selection may be influenced by the shear modulus needed. {9} Face Wrinkling and ntracell Dimpling. With thin skins a local failure ofthe skin in buckling may be encountered. A check fon the Gea will determine whether this may be a design consideration, Other Considerations, Often honeycomb panels are supported on more than two sides, or may be of different plan shapes, etc. The example on Pg. 16 shows the simple support of a plate. Formulae from Roark’s Formulas for Stress & Strain, and Timoshenko's Theory of Plates and Shells may be used to derive approximations in these instances. : I (sandwich) = 222 EI (sandwich) = Db Use of these formulas for deflections may give lesser values than actually experienced since the shear deflection may be important, Table 88 of Roark gives some approximate multipliers to use for plates when supported as noted. Timoshenko's Theory of Plates and Shells can also be used for approximate moments, shears and bending deflections. “D, the plate constant or plate rigidity, is per unt width in this equation as used in Roark and Timoshenko.SANDWICH DESIGN (continued) ‘SAMPLE PROBLEMS Examples are shown for these cases: © ‘A. Simply Supported Column, 8. Simply Supported Beam. C. Simply Supported Plate Ga ae 0.020" Al. 5052-H34 Pot beer A siaio4 att! —_'v 0.020" Al. 5052-H34 iP T PAWEL TO BE ANALYZED MATERIAL PROPERTIES Facings, Al. S052-H34: Fo, Core, 3/8-5052-002-3.0: ge = 200 ps = 430 ksi i, Ey =_10.1 msi, % = 0.89 TO ksi, T= 145 psi, Fu= 85 psi, Gy= 21.2 ksi A. Simply Supported Column P = 4000 Ibs. b=4ft att 2 atl a PANEL STIFFNESS, 0 = ELLiHhb _ (10.1 * 1\O.020K 020/168) . 567 x 19° an 2(0.89) PANEL RIGIDITY, Uw = h GE b = (1.020)(21,200) (48) = 1.04 x 105 © wor lk = h Gb = (1.020)(43,000) (48) = 2.11 x 10° 1. CHECK FACING YIELDING — 4. CHECK FACING DIMPLING — P 4000 : = Fb * Hoaamy( * 288 PS! OG = [4] Ks. 24,000 FS.= SS = 115 ‘ | 2,083 gx iL 10 oe = 64.560 psi 2. CHECK COLUMN BUCKLING — oC) 378. Pez EO 64,560 psi > 24,000 -. NOT CRITICAL! V+ md v 5, CHECK FACING WRINKLING — we (667x108) Ect] Or ASGT HIT © 8040 Ibs. One owe [E] 1.04 x 10! = 0040 (70,000)0.020) FS.= 00 5 [foro 1% 10°) sa 97,500 psi 3, GHECK SHEAR CRIMPING — 97,500 psi > 24,000 -. NOT CRITICAL! @ Pex = te Ge B = (1.00)(21,200)(48) = 1.02 x 10 Ibs. 6. CHECK FACTOR-OF-SAFETY — 1.02 «10° MINIMUM F.S. (COLUMN BUCKLING) = 1.5 (14)SANDWICH DESIGN (continued) SAMPLE PROBLEMS B. Simply Supported Beam P=20(8)(4) = 640 Ibs. TOTTI EL Vmax = 0.5P = 0.5(640) = 320 Ibs. Bs Max = 0.126PL = 0.125(640)(96) = 7680 in-ibs, CHECK FACING YIELDING — 4. CHECK FACING DIMPLING — M 7680 2E Ey _ 2101 x 10") ocr ind ~ (Oa2o\ 02048), "8 Ps! =X [se] * oes [nav] * £4560 psi 24,000 64,560 psi > 24,000 -. NOT CRITICAL! Fs, = SOs 34 e 7,843 : 5. CHECK FACING WRINKLING — 2. CHECK CORE SHEAR STRESS — Ecti]* n- 320 aye Orn = O82Es | FT| © = Fb” Coanyaa)” 4 PS + f170.000)(0.020)_}" . = (0.82(10.1 x 19°) | OOOO) _ | - 97; 850.93)" _ Gea = 0.82( Diarpsn vt al ee FS. ar 2124 97,500 psi > 24,000 +. NOT CRITICAL! “Correction Factor for 1° Thick Al. H/C, TSB 120 6. CHECK FACTOR-OF-SAFETY — eed MINIMUM F.S. (FACE YIELDING) = 3.1 PLOA y PL Pend *hGeb 7. REDUCE DEFLECTION — USE 2" THICK CORE (0.0190) (640}06)° (2089), (0125)640)96) ya (10.1 » 10°)(0.020)(1.020)'(48)_(1.020)(21,200)(48) 130° oor Ut this deflection is excessive, see step 7. 033" 0.00" _{0.0190)640)(06)° (0.89) (0-126)(640(96) (10.1 = 10*)(0.020)(2.020)'(48)" (2.020)(21,200)(48) 033"SANDWICH DESIGN (continued) SAMPLE PROBLEMS. €. Simply Supported Plate {(rom Mil. HDBK-23) beatt 9 a>b 1, DETERMINE PLATE COEFFICIENTS — USER = 25 (see Figure 8) = Ent ht 20 Go = ero 100.0201 020". 9.093 2 (48 (1.020)(21,200)(0.89) FROM FIGURE 8 Ky FIGURE 9 K, FIGURE 10 K; 0.0105 0.103 037 2. CHECK PANEL DEFLECTION — 2K: pb" Eth 2(0.0105)(0.139)(48)*(0.89) : (10.1 * 10°)(0.020)(1.020)° 3. CHECK FACING STRESS — = Kap? _-(0.103)(0.139)(48)" ht (11020)(0.020) 24,000 1617 a = 1,617 psi 148 (16) UNIFORM LOAD, p= 20psf = 0.139 bs/in? oT Simply supported all four edges 4, CHECK CORE SHEAR STRESS — pb _ (0.37)(0.139)(48) acon = 2.42 psi 327 = 8540.83)" FS. = 7 24 * Correction Factor for 1” thick Al. H/C, e TSB 120 5. CHECK FACING DIMPLING — a SE 2(10.1 = 10°) [0.0207 0.89 [ 4560 pst _ 0375 64,560 psi > 24,000 ~. NOT CRITICAL! 6. CHECK FACING WRINKLING — aa: one [24] . ve qe fleseon10.020)_ 7" Cea = 0.82(10.1 1 ail 97,500 psi 97,500 psi > 24,000 -. NOT CRITICAL 7. CHECK FACTOR-OF-SAFETY — MINIMUM F.S. (FACE YIELDING) = 148SANDWICH DESIGN (continued) “TTTITI TT “Th | f t ot 4 TI Ce oa | I gor Peo r 008 1 — - LC CEI Figure 9 — Ks, for determining facing stress, OF, of tat rectangular sandwich panels @>b oa a Figure 8 Ks, for determining maximum detection, A of at retanglar sandwich pane @ Figure 10 ~ Ks for determining core shear stress, Te, or flat rectangular sandwich panels @>D Tr)SANDWICH DESIGN (continued) FITTINGS AND CLOSE-OUTS Experience has shown that one of the most troublesome and possibly the most critical part of designing a good sandwich structure is the development and selection of the fitting or close-out. The close-out usually serves many purposes or hhas special requirements imposed on it. Some of these include: + act as structural tie to adjoining or supporting structure « allow two panels to be joined straight or at right angles ‘ incorporate a hinge or be detachable + provide edge protection against impact damage ‘= seal the panel joint ++ provide a sriooth, continuous extension of the facings « be decorative In designing or selecting a close-out one has to keep in mind how the panel is going to be fabricated. Can the close-out be incorporated into the panel or be attached to it? Is it to be co-fab or post-fab? Most flat sandwich panels are bonded in heated platen presses. Hence any close-out which has raised surfaces or protrusions may not be easily incorporated into the panel. In addition, special tooling or fixtures are often required to align the close-outs and maintain the desired dimensional tolerances. For this reason, subsequently assembled, or post-fab close-out designs are most commonly used in flat panels. ‘Sandwich panels with curved surfaces, tapered cross-sections or other details which prohibit press bonding, are usually made by curing in an autoctave or vacuum bag set-up in an oven. In such a case, a special bonding tool surfaceis needed to correspond to the desired contour. This tool could then have provisions to incorporate a co-fab type panel close-out with little added cost or complexity. Fiberglass prepreg facings lend themselves particularly well to molding or shaping directly into the close-out in a single curing operation. FIGURE 11 CLOSE-OUTS AS DEFINED BY THE FABRICATION TECHNIQUE AS WELL AS END-USE Vartedadsdded 7 ofa | Oneshot bonded | ~ “ imosanowien | CET en <—| | Sem | simple suport | -BT| AFT ETE rsttab | attached or ' 1 sendwich ’ pda ‘ Fixed Support (18)SANDWICH DESIGN (continued) FIGURE 12, TYPICAL PANEL CLOSE-OUT DESIGNS POST-FAB CO-FAB ‘Simple support. Special extrusion. Panel is smooth one sid. Low cost, Wood, foam or Sag. Lom contig peri boar boded ao ‘standard angle. Pop rivet panel; or high strength abo materials. Solid. ‘Special extrusions or castings Tite Strong. Low cost. Core Dowd fo gan Donel chelsea Ide docs rem Very strong. Smooth surfaces. More costly T Moderate strenath. Costly POST-FAB | Requires routing honeycoms, ‘Special extrusions castings. Do not project beyond top and bottom Low cost. Simple channel, Can be formed around bends and corners. CChamterred close out. Go0d or fiberalass prepreg on curved ‘Smooth edge, Special shape surfaces. ute core and bond in the legs of extrusion, Low cost. No extra pieces, Smooth finish. Low cost also with only one side formed For thin panels. Can be bent by notching igs. Standard angles for tick panels and low volume. Pop rivet and bondSANDWICH DESIGN (continued) FIGURE 13 Mio | Tn): REINFORCEMENT CMI © LTT) « HIQH-STRENGTH INSERT TOS =~ ULTTTTae . METAL CHANNEL EDGE CELLS FILLED OPTIONAL HIGH-STRENGTH INSERT i HTT METAL CHANNEL: FACINGS FORMED HIGH-STRENGTH INSERT =. PO. METAL "2" CELL WALLS (CRUSHED OR MACHINEDSANDWICH DESIGN (continued) FIGURE 14SANDWICH DESIGN (continued) DOUBLERS Doublers are facing reinforcements put into or on a sandwich panel in areas of high stress considerations. A doubler should nat only distribute high local forces over a larger area, but also should do this as gradually as possible. Just lke close-outs, a doubler can be incorporated during the panel bonding or be added afterwards. They canbe internal fo external. However, note that internal doublers, usually require extra machining of the honeycomb. The exception ‘could be when prepreg facings are used and the extra layer(s) of reinforcement are simply added and co-cured, DOUBLERS IN A SANDWICH PANEL FIGURE 16 Internal Doublers on one or both sides, CoFab Requires doubler relief cuts in core. Allow ample clearance to position doubler and account for adhesive thickness i External Doublers located on "bag" side of T Cored the assembly. Co-cured with | facings. 0 1 External Doublers bonded to one or both TT Post-Fab sides of panel. Pop rivet for alignment. J FIGURE 17, Build-up of doublers on a helicopter blade root section (22)‘SANDWICH DESIGN (continued) PANEL REINFORCEMENTS FOR CONCENTRATED LOADS Foam or epoxy filled. For ‘small, localized area. Can be drilled. Solid block of toa metal or plastic bonded in place, High density honeycomb Extruded shapes for spliced into panel. Low continuous ribs. Very weight and strong strong, Edge bond core Solid block crushed and Formed sheet meta for bonded into core, Reduces tapered panels. Requires shear strength core carving FIGURE 18 mime Floor tie-down ring FASTENERS: Selection of structural fasteners depends on several factors such as panel thickness, specific strength requirements and environmental exposures. For instance, care must be taken that galvanic corrosion is not a problem. Generally, steel fasteners should not be used with aluminum facings if it can be prevented. Selecting a larger fastener is best; otherwise the steel fastener should be sealed or set in aluminum washers with wet polysulfide. Structural fasteners can be categorized as follows: FIGURE 19 Shear t Tension Torque ‘Molded-in fasteners wll provide the best structural strength since the potting compound bonds the fasteners to both facings and core. They add more weight to the panel (average 6 grams for typical panel) and are more time consuming to instal ‘Spot welded or staked inserts are used where fastening to one skin is acceptable. Grommet type fasteners consist of a plug and sleeve which are installed from opposite sides of the panel. They may be the simple force fitted type or mechanically locked to one or both facings. They are not as strong as the molded-in type since the load is transferred to a smaller portion of one or both facings. Typical weights per fastener is approximately 2arams, Variations in each category include: ‘Flush, raised or countersunk heads ‘Clearance hole or threaded through ‘= Blind, threaded — with or without self-locking device ‘+ Floating nuts which simplify critical alignment * Materials include aluminum, stainless steel, carbon steel, and special alloys ‘Some of these types are shown in Fig. 20. A wide range of thread types, sizes and fastener lengths are available in each category. Installation of fasteners is relatively simple. However, careful lay-out and locating the holes is important. Hole sizes and installation techniques vary with fastener types. Companies making these products include: HI-SHEAR CORPORATION, 2600 Skypark Drive, Torrance, Ca (213) 326-8110 SHUR-LOCK CORPORATION, 1900 E. Normandy Place, Santa Ana, Ca (714) 474-6000 REXNORD, 3000 W. Lomita Bl, Torrance, Ca 90505 (213) 530-2220 (23)SANDWICH DESIGN (continued) FIGURE 20, (24)PROPERTIES OF TYPICAL SANDWICH FACING MATERIAL FIGURE 21 "a Modus a Weight par Facing siren | Hasty y Mi Thckess mae foi | ey —psi ie tet Comments Aluminum 1100 — Hie rome | 10x10" 9 014 | ad, cost werk ex cherie reaann Sears ea) 300s — 16 reome | 10x 0" 49 ow | Far sen, god weater cst nad oon sos — 434 zaoooc | 101 1 #9 ov] tes stent, god wear ret met (061 — 15 sone} 100% 10 9 ort | Good strenat, workable, oly heat ‘ata soy easly weldee mm —13 oom | 10510 % or | bx. strength, neatretabe sot stage for working a corrosion ress 7015 —16 senor] 103x0t ‘9 ort | ian strength air corosion resist ais Carbon Ste! soo | 2x0 1 4 | Loy cast han wean, good stabi Stale: Set Sos anneal sso | 8 o% ra SB anneles som | 8 1 % 110 | High os corasion sistant 19h 15000 | 28 ioe ot 10 | Highsvength heat weteble Graphite Woven aso | at or ® coat | High cost, sength& modulus Graphite Unidirectional | we7e00 | 183 10 # e+ | gh cos, strength & modulus Fiberglass Prep pony 155 wo] sae 8 es | bx. strength, tw temp. core Epoxy FB sim | area 968 n90 | Heat resist, god strength Phenatc Fro so | 35x00" 8 o0ss | High temp, good strength Polyester Fist son | 35x00 25 0090 | Good strength tow cost povinie rare | 60000 | 35x 0" ‘8 0085 | High temp. resistant Epoxy UPtatectional F155 | soo0m | 65x 108 0 s+ | Highest stenath Kevlar F8 woe | aixioc | 100 G07 | High cost. igh tensile Kevlar F8 root | 4x0 Low weigh, tough low compression | ioegass ta geste visio woo | 02 0 9 or | very ow ens Woven coving polyester resin seo | 165x108 6 aor | very ow eos | ext tr piywood 26m | 18x 10 93 003 | Pine siywoos aa | 18x 9% ng | (See Note) | Luan plywood 2.250 18x 10 99 02 [ Temoereanardwood | 00d hardwood ow cos | erastei tt | a0 | 68 x to 00s aati sae Gypsum board [= | ox | cot | Fire resistant, ow cost | “Yield sangin slower a eile or compressive valu re ith 184 fabric and autoclave cure “Bot compressive ((°) and esie (7) show for 285 tyes, NOTE. Far alulations mvol¥ing plywood, "feciv shckness” shouldbe used exept ar locating Centos Atal Tek 12 13) 1500) tet Theta oi one 025 “Dependant an iber areal wogh of 1 g/m 4ACTOPU (125 = 12% Thorne 30/3000 Tow 7 mi).PREPREG COMPOSITES ‘Aerospace Prepregs: Tubular Prepregs Release Fabrics Tooting Prepregs BRAZING HEAT TREATING Exotic Metals Complex Assemblies, nexce. HONEYCOMBS ‘Aerospace Cores ‘Commercial Cores Custom Contouring ‘Specialty Cores FABRICATED PRODUCTS Panel Systems Structural Panels Composit Parts ‘SPECIALTY RESINS SERVICES. HE. Urethanes strutura Design Tooling Resins Mechanical & Physical Telecommunication Products ADVANCED ae Epory Systems COMPOSITE REINFORCEMENTS Kevlar Graphite $-2Glass, ORGANIC ADHESIVES: Hybrids CHEMICALS Adhesive Coatings Plastic Additives ‘Structural Adhesives Flame Retardants Specialty Tapes ‘uarternaries Custom Synthesis ADMINISTRATIVE OFFICES: Dublin, California 94568, 11855 Dublin Boulevard, (415) 828-4200 SALES OFFICES: ‘Arlington Toras T6010 Sut 70, First City Bank Bldg. 201 E. Abram, (817) 274-2578 Bel Air, Maryland 21014, 620 Boulton St, 2nd Floor, (301) 838-0050. Believe, Washington 98004, Suite 208, 3055-112th Ave., N.E. (206) 822-2244 Bethel, Connecticut 06801, Two Stony Hill Rd, (203) 798-8311 Dublin, Calfornia 94568, 11859 Dublin Boulevard, (415) 828-4200 Huntington Bleach, California 92647, Suite 308, 7711 Center Ave, (714) 898-3922 Hexoal 5 A, - Parc industriel, Rue Trois Bourdons, 8-4840, Welkonraedt, Beigium, Tel: 087-880765 Hexcel UK. - Catherine House, Guilford Ra, 63, Lightwater, Surrey, Great Britain, Te 276-74560