TAILIEUCHUNG - SANDWICH PANEL FABRICATION TECHNOLOGY

Whereas spark erosion and lasermachining are suitable for any metal, the use of mechanical precision machining and the tools suitable for this type depend on the stability of the alloy. For brass and copper, natural diamondmicrotools are suitable and widely used, while for stainless steel and nickel- based alloys, hardmetal tools are needed. Figure shows a natural diamond cutter, whereas Figure shows a hard metal drill. Figure shows photos of a rhodium honeycombmicrochannel catalyst system. The channels have beenmachined bywire spark erosion and therefore show a semicircular face area that is shown in detail | SANDWICH PANEL FABRICATION TECHNOLOGY Hexcel Composites honeycomb sandwich panels are light stiff and durable. They are easy to fabricate into finished panels and even complex components simple workshop techniques and inexpensive tools and equipment are often all that is required. This guide sets out to remove any reservations about fabricating components with sandwich panels by demonstrating typical methods and procedures. Hexcel Composites was at the forefront of the development of honeycomb sandwich panels - over 25 years ago. The trademarks Hexlite and Fibrelam are now known worldwide throughout many industries. Reprinted May 2001 Publication no. LTU 018 Hexcel Registered Trademark Hexcel Composites Duxford HEXCEL COMPOSITES 1 SANDWICH PANEL FABRICATION TECHNOLOGY Contents Page Introduction 3 Guide to Sandwich Panel Selection 4 Typical Fabricated Construction 4 Jointing and Connection Methods 5 6 7 Edge Closure Methods 8 Panel Fixing Procedures 9 Cut and Fold Fabrication 10 11 Tool Requirements 12 13 Cutting and Drilling Techniques 14 Clamping for Bonded Joints 15 Sandwich Panel Finishing 16 Health and Safety 16 HEXCEL COMPOSITES 2 INTRODUCTION Many benefits can be designed into a panel but fundamentally all honeycomb sandwich panels offer outstanding stiffness and strength for low weight. Thin high strength skins are separated by and bonded to thick lightweight honeycomb cores the thicker the core the higher the stiffness and strength of the panel - for minimal weight gain. This is illustrated below Solid Material __ _ Ị Stiffness Flexural Strength Weight Core Thickness t Core Thickness 3t i 4t Many other applications ranging from the Automotive Industry Art Restoration to Hi-Fi speaker cabinets and machine parts. The fabrication of honeycomb sandwich panels is simple with many techniques borrowed from the woodworking industry. Panels are cut into finished parts with saws routers and drills. If necessary edges are .

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