Abstracts Engineering

Processing and characterization of honeycomb composite systems

by Jahan Emir Shafizadeh

Honeycomb composite structures are widely used in the aerospace and sporting goods industries because of the superior performance and weight saving advantages they offer over traditional metal structures. However, in order to maximize the mechanical and chemical properties of honeycomb composites, the structures must be specially designed to take advantage of their inherent anisotropic, viscoelastic and heterogeneous qualities. In the open literature little work has been done to understand these relationships. Most research efforts have been focused towards studying and modeling the effects of environmental exposure, impact damage and energy absorption. The objectives of this work was to use a systemic engineering approach to explore the fundamental material relationships of honeycomb composites with an emphasis towards the industrial manufacturing, design and performance characteristics of these materials. To reach this goal, a methodology was created to develop model honeycomb systems that were characteristically similar to their commercial counterparts. From the model systems, some of the important chemical and mechanical properties that controlled the behavior of honeycomb core were identified. With the knowledge gained from the model system, studies were carried out to correlate the compressive properties of honeycomb rings to honeycomb core. This type of correlation gives paper, resin, and adhesive manufactures the ability to develop new honeycomb materials without requiring specific honeycomb manufacturers to divulge their trade secrets. After characterizing the honeycomb core, efforts were made to understand the manufacturing and in-service responses of honeycomb materials. Using three Design of Experiments, investigations were performed to measure the mechanisms of composite structures to propagate damage and water over a fourteen month service period. Collectively, this research represents a fundamental starting point for understanding the processing-structure-property relationships of honeycomb core.