Sandwich Design and Theory

STRUCTURAL DESIGN MANUAL
NORTHROP AIRCRAFT GROUP

CONTENTS

800~ SANDWICH CONSTRUCTION

801. i DESIGN OF FLATi SANDWICH CONSTRUCTION 801.1 Introduction

801.2 Local Instability of Sandwich Construction

801.2.1 801. 2. 2 801. 2. 3 801.2.4 sor. 2. 5

Face DdmpLdng Face Wrinkling Shear Crimping Equation Summary Example

802. SANDWICH CORE

802.2 Cellular (honeycomb) core

802.2.1 Introduction

802.2.2 Metallic cellular (honeyc0mb) core:properti~s

802.2.3 Nonmetallic cellula;- (honeyc9mb~ core '

properties.

3852-4 (10-77)

JAN 82 i


801. 801.1


801 DESIGN OF FLAT SANDWICH CONSTRUCTION

801.1 INTRODUCTION

Structural sandwich is a laminated construction formed by bonding two thin facings to a comparatively thick Gore as showri in the sketch below.

It is generally assumed that the facings resist all of the applied inplane loads; andfurther"that't-he"fac'ings<p.rovi-de all of thebendi.ng rigidity to the construction. The core spaces the facings and transmits shear between them so that they are effective about a conunon neutral axis. Except for sandwiches incorporating relatively thick facings, the core contributes most of the shear rigidity. The core also stabilizes the 'facings against local instability.

Core

Facing

Fac Lng

Instability failure modes are subdivided into local and general.

Section 801.2 deals with local instability which includes face dimpling, face wrinkling,and shear crimping. For each mode there is a description of the instability and a r ecommended method for establishing the cri tical stress in the facings. (Section 801.3 will cover general instability).

Plasticity effects on the critical instability stress are included where applicable. The method presented is similar to that given in Section 303.5. The plastic buckling stress (F ), theoretical elastic buckling

cr

3852-4 (10--77) JAN 82

~. J

1


801.1


stress (F /1] ), and material reference stress (FO 7) are related by

cr •

curves of F /FO 7 vs , F ''''FO 7 in Figures 801.1-1 and 801.1-2.

cr. cr • , .

These curves are shown as a function of the material Ramberg-Osgood

shape factor (n). Values of FO.7 and n for vario~s materials are listed in Tables 303.5.1.1 through 303.5.5.4 (Section 303.5). These cur:ves are used to solve for F as illustrated by the example shown in Section 801.

cr

2.5.

Core properties are given in Section 802, with sub-divisions for the various types of core. Cellular (honeycomb) core is the subject of Section 802.2. It includes both metallic and non-met.al.Hc materials in various cell configurations. Some of the standard testing procedures, used for sandwich structures, are described to indicate certain limitations pertaining to the allowables presented. Tables of strength and modulii for compression and plate shear are given for the more conunon materials and configurations of cellular cores. (Section 802.3 will cover solid and

foam cores).

This introduction also includes a reference list and a list of the

nomenclature used throughout the Section.

REFERENCES

1. R. T. Sullins, et al., "Manual for Structural Stability Analysis of Sandwich Plates and SheUs," NASA CR-1457, December 1969.

2. ~. F. Bruhn, "Analysis and Design of Flight Vehicle Structures," Tri-State Off$'et Company, June 1973.

3. Anon., Military Handbook, "Structural Sandwich Composites," MIL-HDBK-23A.

4. P. M. Jenkinson,E. W. Kuenzi, "Wrinkling of the Facings of Aluminum and Stainless Steel Sandwich Subject to Edgewise Comp:cession," Forest Products Laboratory Report Number 2171, December 1959.

5. E. W. Keunzi, Jo J. Zahn, "Classical Buckling of Cylinders of Sandwich Construction in Axial Compression - Orthotropic Cores ," Forest Products Laboratory Report Number FPL-018, November 1963.

3852:'4 (10--77)

JAN 82

2


8.01.1


NOMENCLATURE

Compression modulus of facing material, psi

Secant modulus of facing material, p~i

Tangent modulus of facing material, Jsi • i

E tc

Core modulus .of elasticity, normal to the facing~, psi

i

Core ribbon material modulus of elastic~ty, psi

F c

Sandwich flatwi~e strength, psi, (the 19wer of • flatwise core compression, cor~ tensi.on, an.d coreto-facing bond strengths)

F cr

Critical stress, psi

F cy

Facing materialyi~ld stress, psi

Core tensile strength, normal to ~aci,ngs:, psi

Fto

Core ribbon material t.ensLLe s t rerig th., psi

Facing material reference stress for plasti'c buckling, psi

h

Core shear modulus, psi$associ:ated Wiit~ th;e plane normal to the facings andpa.rallel to the d fr ect Ion of loading.

Core shear modulus, psi ,associated with the Pilane

normal to the facings and ,parallel to the "L" and

"W"core ribbon directions , respectively (see Fig'ure 802.2.1-2 'for L&W direction) I .

Df.st.ance between the rp.:i:d thicknesses of the two Eac i.ngs " inches

n

Ramberg-Osgood shape factor for the Lacirig fIlaterial, dimensionless

s

Core cell size, inscribed circle diameter, inches

t c

Core depth, inches

Facing thickness, inches

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JAN 82

3


801.1


NOMENCLATURE (Continued)

W e

Core density, pcf

w o

Core ribbon material density, pef

,

."

11

Plasticity correction factor, ;dimensionless

; .! : ! I

: , I

Elastic Poi~sori'siratio of f~cing materiaL, qim~nsion"" less (approximately 0.3 fot' m~st me~a1lJic :materials)

MA - 10~, Structural Adhesive Bonded Assemblies For Use Up· To 1800 F. NAI-1370, Adheoiye SYotern, Structural, For Useage From -'-67 to 350F. NAI-1382, Adhesive, Epoxy, Room Temperature Curing, For Bonding

And Sealing.

~NA:r-1383, Adhesive, Epoxy, Heat Resistant, Structural

NAI-14l2, Adhesive System, Structural, Stress Durable Type,

: I :, :0

for ~67 to 180 F.

3852-4 (10-77)

JAN 82

4


801.1


FIGURE 801.1-1

NONDIMENSIONAL PLASTIC BUCKLING OF FACINGS IN COMPRESSION

SANDWICH CONSTRUCTION

HONEYCOMB CORE, FACE DIMPLING

NOTE: F is subject to an upper limi t cuto-ff equal to F nand Fo •• ? values

cr cy

are obtained from Tables 303.5.1.1 through 303.5.5.4.

II 0 4

HI!'; .

r:r.. CJ r2

3852~4 (10--77)

JAN ~2

1.0

:5

n

10 20 !j,Q

0.8

0.6

0.2

o o

1.6

1.2

0.4

F Iii

cr = Elastic Buckling Stress

Fo.'? Reference Stress

5


80l.l


FIGURE 801.1-2

NONDIMENSIONAL PLASTIC BUCKLING OF FACINGS IN COMPRESSION SANDWICH CONSTRUCTION

SOLID, FOAM, OR HONEYCOMB CORE - FACE WRINKLING

NOTE: F is subject to an upper limit cutoff equal to F • nand Fo.? values

cr cy

are obtained from Tables 303.5.1.1 through 303.5.5.4.

1.2

10

n

20

00

50

0.4

o.

o

0.4 0.8 1.2 1.6

F rn

cr Elastic Buckling Stre~s

Fo.? Reference Stress

2.4

o

3852-4 (10--77)

JAN 82

6


801.2

NORTHROP ~ AIRCRAFT GROUP

801.2 LOCAL INSTABILITY OF SANDWICH CONSTRUCTION

Struc tural instabili ty 0 f sandwich construction can occur in a number of different modes. This section deals with the modes that can be designated local instability. These are face dimpling, face wrinkling, and shear crimping. It should be noted that while shear crimping is often referred to as a local mode Qlf'[ailure, it is actually a special form of general instability. Failure by local instability results in excessive local deformation that iniiates collapse of the section or precipitates general buckling.

Initial face waviness affects both face dimpling and face wrinkling,

while shear crimping is independent of this property. As the degree of ini tial face waviness is rarely known, the recommended equations are empirical and are based on the lower region of test data.

References 1, 2, and 3 contain theoretical equations that are intended to

account for face waviness. However, the very large test data scatter makes

these equations unsatisfactory for design purposes.

The accompanying text includes a description, illustration, and recommended method of analysis~for-"each type of local failure mode. The methods of analysis presented are limited to metallic face sheets and the metallic and nonmetallic cores given in Section 802. For convenience, a summary of equations and an example is given at the end of this section. Nomenclature, a refel;'ence list, and nond::i:menf:;;iQnal. plastic buckling curves, are included

in the introduction, Section 801.1.

The bonding agent used muat be capable of developing the strength of

the Core. Adhesive bonded assemblies constructed in accordance with Northrop Process Specification MA.,..108 will meet this requirement. For any other

cases the strength of the bonding agent must be verified.

Flanged honeycomb core (Stress Skin Type) is not a Northrop Standard.

The applicability of the following methodology to this type of core is not known.

3852-4 (10··77) JAN 82

1


801.2.1


801.2.1 FACE DIMPLING

F'ace dimpling, often called intracellular buckling, is a local mode of instability. It occurs only when the core is cellular (honeycomb). The facings buckle in a plate-like fashion with the cell 'walls acting as edge supports. The progressive growth of these buckles can eventually precipitate the face wrinkling mode of buckling. Note that for this mode the two facings act independently. The critical facing is the thinner of unequal facings in compression (assuming ~acings of the same mat er l al ), or the compression facing of sandwich subjected to bending.

Honeycomb Core

Faces Buckle Into Core Cells

The recommended equation for the face dimpling stress of a sandwich subjected t,o uniaxial compression is:

F cr

11

Eq.801.2.l-l Reference 1

where IJo

0.3 has: been assumed, and

(E) [ (3E Y 12]

11 = E: .. 0.500 + 0.250 1 + EST)

Eq. 801.2.1-2

This empirical equation for the onset of face dimpling gives values approximately 40 percent lower than the predictions of the classical equation for simply-supported flat plates. It is based on the test data compar Lson included in Reference 1, whic:h shows that the majori ty of the test points are within :40 percent of the classical value.

3852-4 (10··77) JAN 82

1


801.2.1


The dimpled regions retain siginificant post-buckled load capability until they precipitate face wrinkling. Note that generally, the facing material is not critical in dimpling when sltf < 14.

The equation given above is limited to facings subjec~ed to uniaxial compression. When the facings are subjected to shear in the plane of the

,

facings and Jor biaxial stress, it is recommended that one of the following

methods

Shear stress in the plane of the facings.

Assume that the principal compressive stress acts alone and consider as uniaxial compression~

,

Biaxial compression, use the interaction formula

R + R = 1 x Y

I Eq. 80L2.1-3

where R.= ~

Applied stress, subscript direction Allowable stress, . subscript di.rection

Shear with 17xial, shear ,with l;>iaxial., or bia:x:i~l stress.

Examine the principal sti·es~es and consider aJuniaxial or biaxial compression, Which ever is apprdpdate.

, ,

Plasticity'

When the theoretical elastic buckling stress (F crl 'h ) ,exceeds the 'material proportional limit,' the plastic buckling stress (F ) can be determined by

i ; cr; : i '

reference to S.D~M. Section 303~5 and using Figure Sql.l-l.' l)"sethe nondi-

mens Iona l plastic buckling curves of Figure SOl. 1.,.1 forhorieycomb cores, with the appropriate material properties from Tables 303.5.1 1 ~hrough 303.5.5.4. Note that Ef, the facing compressive modu l.us of elastic ty, is identical to

E used in Section 303.5.

c

3852-4 (10-77)

JAN 82

2


801. 2. 2


801.2.2 FACE WRINKLING

This is a local mode of instability which shows up in the· form of short (generally less than one inch) wavelengths in the facings. It is not confined to individual cells of cellular-type core, and involves the transverse (normal to the facings) strain in the core material.

Initial face waviness affects face wrinkling. However, as the degree of this waviness is rarely known, thereconunended equations are empirical. These equations are based on the lower region of test data. Theoretical equations that are intended to account for face waviness are contained in References 1, 2, and 3. However, the very large test data scatter makes these equations unsatisfactory for design purposes. Note that for the same reason, the results of wrinkling tests performed on specimens intended to duplicate the selected structure, should be treated with.caution.

r- waVelefigt~

SYMMETRIC

ANT I SYMMETRIC

As indicated in the sketch above, sandwich construction may wrinkle in a symmetric or anti symmetric mode.

Final failure from face wrinkling will usually result :from crushing of the core, tensile rupture of the core or the core-to-facing bond. These failure modes are indicated in the sketches below.

(I I Wfl I I?

Core Crushing

\1 Illlil II

\II~

(\

Tensile Rupture of Bond

Tensile Rupture of Core Proper

3852-4 (10--77) JAN 82

1

STRUCTURAL DESIGN, MANUAL

801.2.2


Solid or foam core sandwich construction:

When the core is sufficiently thick, the wrinkle pattern~ of the two facings will be independent of each other and the same critical load is obtained for the symmetric and antisymmetric modes , However, for sandwiches with thinner cores, the core strains introduced by one facing influence the wave pattern of the other facing. Under these conditions, sandwiches having solid or foam cores can be expected to wrinkle antisymmetrically.

The following equation is recommended to compute the lower bound uniaxial compressive stress at which face wrinkling will occur in sandwich constructions having solid or foam cores:

cr

TJ

EQ.80l.2.2-l

F

Reference 1

where J1

= 0.3 has been assumed

and

1/3

EQ.80l.2.2-2

Honeycomb Core Sandwich Construction

" " ,J, '

The honeycomb core elastic modulii in the plane parallel to the facings are very small in comparison with the core elastic modulus in the direction normal to the facings. This results in symmetrical wrinkles developing at stress levels that are lower than those at which the anti symmetric mode

would occur. An exception 1;0 this is the region controlled by shear crimping.

The following equation is recommended to compute the lower bound uniaxial compressive stress at which face wrinkling will occur in sandwich construction having honeycomb core:

F cr

11

EQ.801.2.2-3

Reference 2

where TJ

( E T
=
E f (EQ.801.2.2- 2)

3852-4 (10-77)

JAN 82

2


801.2.3

NORTHROP ~ AIRCRAFT GROUP

801.2.3 SHEAR CRIMPING

Shear crimping is often referred to as local mode of failtp::e. Actually it is a special form of general instability for which the buckle wavelength is very short due to a low transverse shear modulus.of the core. This mode of failure is generally the result of poor design. Therefore, the design should be adjusted so that shear crimping is not the critical failure mode.

During tests, it will sometimes occur after the development of general instability. In such instances the crimp appears at the end of the buckle pattern because of severe local transverse shear stresses. As the crimp develops, the general buckle may disappear and lead to an erroneous conclusion for the mechanism that initiated failure.

Shear crimping usually causes the core to fail in shear, and may be accompanied by a shear failure of the core-to-facing bond. Note that shear crimping is insensative to initial face waviness.

When both facings are made of the same material, the following equation is recommended to predict the critical stress for shear crimping of a sandwich under uniaxial compression.

F = cr

2

h G

. C

EQ. 801. 2.3-1 Reference 1

Where G is the core shear modulus associated with the plane perpendic

cular to the facings and parallel to the direction of loading. Note that

an approximate value of Gc is given by the equation.'

GC = GCLGCW r~'2 1 + A: 2 11'12

. l~cw + A GCL]

EQ.801.2.3-2

A =tanEl

Where e is the angle between the load direction and the longitudinal direction of the core.

3852-4 (10--77)

JAN 82

1


801.2.3

NORTHROP -----:-_AIRCRAFT GROUP

For sandwiches where the two facings are not made of the same material, an estimate of the shear crimping critical stress is given by

F cr

EQ. 801.2.3-3

Where Efn is the minimum of Ef1 and Ef2

The equations given above are limited to facings subjected to uniaxial compression. When the facings are subjected to shear in the plane of the facings and/or biaxial stress, it is recommended that one of the following methods be used.


Assume that the principal compr.essive stress acts alone and consider as uniaxial compression.


R + R x Y

1

(EQ. 801.2. r-3)

where R. = 1

Applied stress, subscript direction Allowable stress, subscript direction

Shear with axial, shear with biaxial, or biaxial stress.

Examine the principal stresses and consider as uniaxial or biaxial compression, which ever is appropriate.

Note that equations 801.2.3-1 & ~3 are functions of the sandwich shear stiffness Cn2Gc/tc) only. Therefore no plasticity correction is necessary.

3852-4 (10--77) JAN 82

2


801.2.2

NORTHROP ___

AIRCRAFT GROUP

The equations given above are limited to facings subjected to uniaxial compression. When the f:acings are subj ected to shear in the plane of the facings and or biaxial stress, it is recommended that one of the following methods be used.


Assume that the principal compressive stress acts alone and consider as uniaxial compression.


R 3 + R =1

x y

R > R

Y x

EQ.801.2.2-4

Reference 1

where R. ].

Applied stress, subscript direction Allowable stress, subscript direction

Shear with axial, shear with biaxial, or biaxial stress.

Examine the principal stresses and consider as uniaxial or biaxial compression, whichever is appropriate.

In the above equations G is the shear modulus in the direction of loading. c

An approximate value may be determined from Eq. 801.2.3-2.

Plasticity

When the theoretical elastic buckling stress (F In) exceeds the

cr

material proportional limit, the plastic buckling stress (F cr) can be

determined by reference to S.D.M. Section 303.5 and Figure 801.1-2. Use

the nondimens ional plastic buckling curves of Figure 801.1-2 for both honeycomb and solid or foam cores, with the appropriate material properties from Tables 303.5.1.1 through 303.5.5.4. Note that Ef, the facing compressive modulus of elasticity, is identical to E used in Se~tion 303.5,

c

3852-4 (10-77)

3

JAN 82.

I

I

I

.NORTHROP .,.,...AIRCRAFT GROUFl


801.2.4

FACE DIMPLING (honeydomb c6re)

Ii! j : i I

(Not criticat whens/rf < 14)

801.2.2-2 Pg. 2

EQUATION REFERENCE

i

I iimitatiods ~re Igi~en inlth~ piec~di~g text. No~e that

iJ. 1 0.;3 Jas beJn assJmed. iNo~en~la~unk d given in S~c-

i 1.1 I!:

Han 801.1.

r 1

(Uniaxial)

·
· 801.2.1-1
• Pg. 1
·
801.2.1-2
Pg. 1
,
• 801.2.1-3
Pg.2
·
· t E )' I ~ ~E )' .. 1/ 2

n = ~E: f'so+ ~.25 \1 + EST

(Re fer ence F:Lgttre-801.1--1)

(Biaxial)

FACE WRINKLLNG

F

cr = O.Sl(E E G )1/3 Tj'f tec

(Uniaxial)

801.2.2-1 Pg. 2

."( ET)1/3

Tj = .-

I I Ef

,

(Reference Figure 801.1~2)

·

3852-4 (10--77) JAN 82

1


801.2.4,

~ORTHROP ~ ,______-AIRCRAFT GROUP

I I: i

Honeycomb Core I

,Fcr JO.43 (EfE G) 1/3

~ tc c

(Uniaxial)

(Biaxial)

R > R

Y x

2 Gc
h
F = (tf + tf )t
cr
1 a C
Efn h2 GC
F =
c-r ' (Efl t£1 +-E t;t:2) t
f2 c (Uniaxial)

(Uniaxial)

Efn is the lesser of Efl and Ef2

A = tan8

where e is the angle between the load direction and the Long Ltuddna l direction of the core.

JAN 82

(Biaxial)

EQUATION REFERENCE

801.2.2-3 Pg. 2

801.2.2-2 Pg. '2

80l.2·f-4 Pg. 3

801. 2. 3-1 Pg. 1

801. 2.3-3 Pg. 2

801. 2. 3-2 Pg. 1

801.2.1-3 Pg. 2

2


801.2.5


801.2.5 EXAMPLE

For the sandwich construction indicated by the sketch given ~e1ow, find the critical local instability stress for the following load conditions:

: ;, i::

(a) uniaxial compression applied in theicor e ribbon direction

(b) shear in the plane of the facings, normal.rand parallel to the core ribbon direction. (Note that the maximum principal compre~sive stress is numerica~lyequal'tothe shear stress and is at 45°'to the core ribbon direction.)

JIIIII ..

Facing 1 (0.016" bare 7075-T6)

Core (0.5" thick, 3/8- 5052-.0007) ; Facing 2 (0.020'~ bare 2024-T4)

! , ,
FACINGS , •
,
I 1 '. 2 3 4 5 , 6 7
.
Material (=E ) -r- i ,
I Facing tf E F , FO.;7 ! n
c f cy
I
, .' ineh psi psi ps~
, ,
, :
1 'Bare 7075-T6 0.016 ' 6 71 ,000 73,100 14
, 10.5xl0
I, , :
'2 : Bare 2024-T6 0.020 6 42,000 41,500 15
, 10.7xlO
, , : • , Values for columns 4 thru 7 are obtained: from ';rables 303.5.1.1 - 1 & -2.

. :
, , CORE . , ,
8 9 10 11 12 13
a E b G b :Gb
t- s h
c tc CL ' CW I
. h' inch , i
1nc ' ,inch psi psi ! psi
0.5 0.375 0.518 7500 9000 5250
I (a) (b)

('"tfl +. t f,2 }',',

h = t + , '2 "

c

Values for columns 1 thru 13 are Design values,

Le., 0.75 times Typ cal values"from''''Pable>'SOZ..:2.2.1''1

3852-4 (10-77) JAN 82

1


801.2.5


c
FACE DIMPLING
14 15 16 17 18 19
Facing s F F 'F F
, cr cr cr cr
- -
tf TJ 7]FO•7 FO.7
psi psi
(9) Equation ~ Figure d @x(0
CD 801. 2.1-1 ~ 801.1-1
1 23.4 42,050 0.575 0.575 42,050
'2 18.8 67,000 1.61 0.985 40,900 (c) columns 16 through 19 are not required when column 15 < 14.0

(d) use appropriate curve for "n", column 7

"

3852-4 (1 0--1'7) JAN 82

2


801.2.5


, ,
..
H .;-1 o
ao o ~ :x:
N I't.i ©
:
4-l
alN
r-. H I· I.
Pt:I N HI r-: ::1.-4 1
cr::: bD e . J I
0 U 0 .1-1 .-4 ,I "
U I't.i I't.i I't.i 0 J ,I
ao
~,' ,
0 \0
I't.i N ®Ie 1 ,I
cr::: HI r-: 1 I
0 1 ,I
U 0 I 1
Q I't.i ,~
H
H r
0 .-4
Cf.l P 1
0 :N ;
'M ,. 1 1
LC') ./..J ,N 1 1
N til · I 1
ClJ I't.itl~ 'M ::I .-4 1 I
~ 0" 0
0 Pt:I ao
:z;
H
~ .
'0 :z; G 0'0
IliH
, ' ~ ~ H .;-1 00
, N o: (J) :x: or--.
I't.i '!:l ..
,:; ~ © <r 0
~ ('t"),('t")
,Ii.!
i
4-l
C") HI r-: N If),0
al 1
N o 0 H .-4, \O,~
Pt:I f'r-l I't.i ::I . -::rr--.
~ bD.-4 . .
';-10' 0 0
U I't.i ao
r:t:1 ,
1§ I':- @® :2i~
u N HIO -::tao
>-' N ~I't.i
Pt:I .
5 I't.i s::::- o 0
::c:
("')
p 1
0 N 00
.-4 ...... ·
.rJ' N 0 0
N CIS 0 N
·
HI : .;-1 ::t, .-I ..
u$::' ~ a" 0 -::r-::r
I't.i ~, ao ('t") ('t")
eo
I':l
0 .;-1
N U .-I N
til
I't.i 3852-4 (10-77)

JAN 82

,.-....
al
.-4
C::la
~
X
al
rJ)
'M
.a
.rJ
.H
0
4-1
al
.-4
,.0
til
U
'M:
.-4 '
0..
0..'
til
.rJ
0
P
.........
(J)
al
'M H
0
rJJ U
P-
o ~
.-4 0
-::t 4-l
\0
rJJ . H
al 0
'rl H
~ 0 '0 r-,
U 'M
If) .-4 g
<r ~ 0
II co ::I
0 .-I '
CD u H 0
e-, 0 U
.j..J al' 4-l
cd P
0 oo
cJ ..c: N -p
0 H ::I
0 H H
4-l .a 0
.-l .rJ 4-l
~
cd N LCl al
o N :>
·rl ;..., :=I H
.-::17 H '0 ::I
HC'"l..c: p o
cJ : • .rJ til
al
rJJ"'!o 0 .rJ
.;-1 .-l N N cd
',-1
0 U) U) H
..cOOp ~ 0..
ClJ ;' 9 0
H
rJJ O".-l .-l 0..
cd Pt:I 0 0 0..
U cJ U til
"d4-l
cd ClJ ClJ al ClJ
ocr::: rJJ U) U)
H'-':::> p :::>
,....., ........
ClJ 4-l
'-' ......... 3


801.2.5


SHEAR CRIMPING
29 30 31 32 33
Load case eg A :::: tanG Gc F
cr
psi psi
Equation Equation h
'SOl. 2. 3-2 SOl.2.3-1 or -3
0 9000i 132,SOOJ
a 0 0
0 94,600j
b 45 1.0 . 6410
.' (g) e is the angle between the direction of the maximum principal compression stress and the core ribbon direction.

(h) both facings same material, use equation S01.2.3-1, when facing materials differ, use equation 801.2.3-3.

(i) Gc = GeL' maximum compression stress is parallel to the core ribbon direction.

(j) fictitious stresses, no plasticity correction is necessary because these values are a function of the aandwd ch.rshear stiffness only.

It is obvious that face wrinkling of thel 2024-T4 facing is the critical local instability mode for both load conditions a and b.

3852-4 (10-71)

JAN 82

4

•

•

•


802.2 802.2.1


802.2 CELLULAR (HONEYCOMB) CORE

802.2.1 INTRODUCTION

Cellular (honeycomb) cores are constructed of thin sheet materials or ribbons, bonded together at the node areas and formed into honeycomb-like configurations, reference Figure 802.2.1-1.

CORE

1U8DON ----OIRECTION----

Figure 802.2.1-1 Typical Cellular Core Construction

While adhesives are generally used for the node area bond, spot welding or brazing may be used for high temperature applications of steel or titanium

cores.

Honeycomb core is produced primarily by the "expansion" method. In this process, the ribbons are stacked into a block and bonded at intervals. The block is then expanded normal to the ribbon direction to produce the desired configuration. For cores in the higher density range, the ribbons are "preformed" into corrugated sheets tlefore honding. A more comprehensive description of honeycomb cons t.ruc t.t on Is cont:alned in Reference 1.

3862--4 (10-77)

July 1978

1

•

•

•


802.2.1


Axes notation for core is shown in Figure 802.2.1-2. The~e axes are

defined as follows: the "L" axis or direction is parallel to the ribbon direc.tion, while the .'W1t axis is normal to the ribbon cHrecti.on. The "T"

axis is parallel to the core flutes.

Core configurations are available for various applications. For the

more common configurations refer to Figure 802.2.1-2.

Standard hexagonal honeycomb is the basic and most commOn cellular configuration, Figure 802.2.1-2(A). Overexpansion of the core in the ''W'' d i r e c-

ticn provides a rectangular configuration that facilitates simple curvature in the "L" direction, Figure 802.~.1-2(B). Underexpansion of the core in the "W·' direction is sometimes used to locally increase the r o r a density, generally for the purpose of increasing the core strength.

The square cell, Figure 802.2.1-2{C), is unique in that the shear properties are near isotropic. It is a narrow node area variatiQn of the hexagonal

core.

The flexible cell configuration, Figure 802.2.1-2(D), provides for exceptional form~bility into compound curvatures without buckling the cell walls.

Classification of honeycomb core is by configuration, material, cell size, and densi ty or ribbon thickness. For flexible core, the cell size .is specifil"d as thl" numbe r- of ("fOlls pf'lt" foot in the W dirl"ctinn. Other core configurations specify the cell size as the maximum diameter of a circle that can

be inscribed in a cell. However, for rectangular core configurations, it refers to the hexagonal cell size before it is overexpanded. Typical core callouts are given in the tables of core properties.

It should be noted that Northrop policy affects the fOllowing core options.

1. Core configurations are available.with, or without, perforations.

Northrop does not use perforated core. due to its susceptibility to corrosion and moisture absorption problems.

3852-4 ! 10-171

July 1978

2

•



•

Figure 802.2.1-2 Honeycomb Core Configurations Most Frequently Encountered

CORE }U:BllON DlREO'1ION~----"'~

!r

/

l...w .... · -- L ---~ .....

~----L--------4

•

(B) Rectangular Core (OveJ;expansion)

(A) Standard Hexagonal Core

I

W

5:N

(D) Flexible Core

(C) Standard Square Core

•

3852-4 (10-77)

3

July 1978


802.2.1


•

2. Aluminum ribbon for honeycomb core is available with, or without,

corrosion-resistant treatment. Northrop uses only corrosionresistant treated aluminum ribbon.

Honeycomb shear and compression properties are given in Sections 802.2.2 and 802.2.3, for metallic and nonmetallic cores. respectively. Unless specified otherwise, the strength properties are minimum guaranteed values (Sbasis) that are to be used for stress purposes. The elastic moduli are typical values and must be reduced for stress purposes, as indicated by Table footnote. It should be noted that the strength values given in the Northrop Materials Manual, Material Specifications, and Process Specifications (References 3, 4, and 5) are for qualification purposes, and may not correspond to design values.

The honeycomb core strength properties are determined as specified in MIL-STD-40l, and are partially a function of these methods. Consequently, the methods are described below and illustrated in Figure 802.2.1-3.

1. Compression

•

The setup for compressive testing is shown in Figure 802.2.1-3(A). Stabilized compressive strength (also called flatwise compressive strength) is the ultimate compressive strength of the core when loaded in the "Til direction. The stabilized compressive modulus is obtained from the initial straight-line portion of the stress-strain curve. Bonding facings to the core is the usual method of stabilization.

While the modulus is unaffected by core depth, the compressive

strength may vary. References 6 and 7 indicate that while core
depth has no effect on the compressive streng th of aluminum core, it
does have an effect in the case of stainless steel and phenolic!
fiberglass cores. The properties are also affected by t.emp e ra t.u r e , and in the case of nonmetallic cores, by moisture content. Information relating to the effects of core depth, temperature, and moisture content is include'd with the allowable tables (Sections 802.2.2 and 802.2.3), where available.

•

3852..4 (10-771

July 1978

4

•

•

•

•

Stabilization



Figure 802.2.1-3 Honeycomb Testing Methods

-
l-
V, ~

I •
r>
t -
.... (A) Compressive Tests

(c)

3852-4 110-171

July 1978

(B) Plate Shear

Beam - FlexurE

5


802.2.1


•

Note that crushing and bare compre.ssive strengths are not included in the tables. The bare compressive strength relates to an accept-

ance test criterion, where the bare edges of the core are not sta-

bilized. Crushing strength relates to the use of core for energy dissipation purposes and refers to pressure required to crush the core after initial collapse from the ultimate compressive load.

2. Shear

•

The setup for shear testing is shown in Figure 802.2.1-3(B). The shear strength (also called plate shear) is the ultimate shear strength of the core in the LT or WT planes. Except for the square cell core configuration, the shear strength in the LT direction is larger than in the WT direction. The shear modulus is obtained

from the initial straight-line portion of the load-deflection curve. MIL-C-7438F requires that the shear values for aluminum honeycomb core with a nominal density of 10.5 pounds per cubic foot or greater, shall be determined by the beam flexural shear procedure. The test setup is illustrated in Figure 802.2.1.3(C). The beam-flexure test is basically a test of facings, adhesives, and core acting as a composite sandwich structure. Core shear values obtained by this method are usually higher than those obtained by the plate shear method, Reference 1. Unless specified otherwise, all values in this section ar~ d~termined by the plat@ sh~ar m@thoo.

While the modulus is unaffected by core depth, the shear strength will vary, References 1 and 8. The shear properties are affected

by temperature, and in the case of nonmetallic cores, by moisture content. Information relating to the effects of core depth, temp@rature, and moisture content is included with the allowable tables, where available.

3. Tension

•

Core flatwise tension properties are seldom required. The core ten-

I

sian strength is frequently stronger than the adhesive bond between

the core and facings. It is also usually greater than the core compfessive strength.

3852...4 (10-171

July 1978

6

•

•

•


802.2.1


Core flatwise tension strength and modulus of elasticity may be determined with sufficient accuracy for stress purposes, from the ribbon material properties factored by the ratio of core density to ribbon material density.

Example:

F tc

w e ;:;: Fto x w-

o

w
E E c
= x
LC to W
0
where F is the core tensile strength
tc
F is the core ribbon material tensile strength
to
w is the core density
c
w is the core ribbon material den~ity
0
Etc is the core modulus of elasticity
E is the core ribbon material modulus of elasticity
to In general, the core propertiea pre5uppo5e that the core i5 of con5tant depth (distance between facings) and that the adhesive bond, core to facings, has adequate strength to develop the core strength properties .

3852..4 110-77)

July 1978

7

•

•

•


802.2.1


REFERENCES:

1. Mechanical Properties of Hexcel Honeycomb Materials, Hexcel, Report Number TSB 120, 1978 Revision.

2. Northrop Design Manual, Section 203.3 (dated 12_12_69).

3. Northrop Materials Manual, Section 14.5073 (dated 7_25_75).

4. Northrop Material Specifications, NAI 1171H (dated 7_30_76); NAI 1340B (dated 7_14_75); NAI 1397 (dated 3-6-75).

5. Northrop Process Specifications, MA.-108G (dated 6_28_77).

6. Military Handbook, MIL-HDBK-23A, Change Notice 3, (dated 6-l9-74).

7. North American Aviation, S & I D Structures Manual, Section 11 (dated 1964 - 1966).

8. American Society for Testing Materials, STP-201 (dated 9-20-56).

38524110-771

July 1978


~Ul.L.L 802.2.2.1


~ 802.2.2 METALLIC CELLULAR (HONEYCOMB) CORE PROPERTIES 802.2.2.1 HEXAGONAL CORE CONFIGURATION

•

•

TABLE 802.2.2.1-1 ALUMINUM ALLOY 5052-H39 HEXAGONAL HONEYCOMB CORE

STABILIZED PLATE SHEAR
CALLOUT DENSITY COMPRESSIVE
ilL" DIRECTION ·tw·1 DIRECTION
NOMINAL STRENGTH MODULUS STRENGTH MODULUS STRENGTH MODULUS
CELL-MATL-GAGE MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
pcf psi ksi psi ksi psi ksi
1/8 -5052-.0007 3.1 215 75 155 45 90 22
1/8 -5052-.0010 4,5 405 150 285 70 168 31
1/8 -5052-.0015 6.1 680 240 455 98 272 41
1/8 -5052-.0020 8.1 1100 350 670 135 400 54
5/32- 5052-.0007 2.6 160 55 120 37 70 19
5/32-5052-.0010 3.8 300 110 215 56 125 26.4
5/32- 5052-,0015 5.3 535 195 370 84 215 36
5/32-5052-,0020 6,9 800 285 540 114 328 46,4
5/32- 5052-.0025 8.4 1180 370 690 140 420 56
3/16- 5052-. 0007 2.0 100 34 80 27 46 14.3
3/16-5052-.0010 3,1 215 75 155 45 90 22
3/16- 5052-.0015 4.4 385 145 280 68 160 30
3/16-5052-.0020 5, 7 600 220 410 90 244 38.5
3/16-5052-.0025 6.9 800 285 540 114 328 46.4
3/16·5052-,0030 8.1 1100 350 670 135 400 54 USE 75% OF TYPI~L MODULI VALUES FOR DESIGN

Other footnotes, see next page

3852-4 (10-77)

July 1978

1

•

•

•


soa.a.z.r


TABLE 802.2.2-1 (concluded) ALUMINUM ALLOY S052-H39 HEXACONAL HONEYCOMB CORE
tlLtl DIRECTION ''W'' DIRECTION
CELL-MATL-GAGE pcf _MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
psi ksi psi ksi psi ksi
1/4- 5052- .0007 1.6 70 20 6C 21 32 11
1/4- 5052- .0010 2.3 130 45 100 32 57 16.2
1/4- 5052-.0015 3.4 250 90 180 50 105 24
1/4- 5052-.0020 4.3 370 140 265 66 155 29.8
1/4- 5052- .0025 5.2 510 190 360 82 200 35.4
1/4-5052- .0030 6.0 660 235, 445 96 265 40.5
1/4- 5052-.0040 7.9 1050 340 650 130 390 52.8
3/8-5052-. 0007 1.0 20 10 32 12 20 7
3/8-5052-.0010 1.6 70 20 60 21 32 11
3/8-5052- .0015 2,3 130 45 100 32 57 16.2
3/8-5052-.0020 3.0 200 70 145 43 85 21.2
3/8- 5052-.0025 3.7 285 105 200 55 li5 26
3/8- 5052-.0030 4.2 355 135 255 65 150 29
3/8-5052- .0040 5.4 535 200 380 86 228 36.8
3/8-50.52- .0050 6.5 750 265 500 105 300 43.5 Footnotes:

USE 75% OF TYPICAL MODULI VALUES FOR DESIGN

Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSBI20, 1978 Revision.

Test data obtained at 0.625 inch thickness

3852-4 (10-771

.Tul v 1 q78

2

•

•


802.2.2.1


TABLE 802.2.2.1-2 ALUMINUM ALLOY 5056-H39 HEXAGONAL HONEYCOMB CORE

'fIL" DIRECTION t~.' DIRECTION
NOMINAL STRENGTH MODULUS STRENGTH MODULUS S1'RENGTH MODULUS
CELL-MATL-GAGE pcf MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
psi ksi psi ksi pd ksi
1/8 - 5056- .0007 3.1 260 97 200 45 ltD 20
1/8 -5056-.0010 4.5 500 185 350 70 205 28
1/8 -5056- .0015 6.1 825 295 525 102 305 38
1/8 -5056-,0020 8.1 1300 435 740 143 440 51
5/12- ')0 5f>- .0007 2,6 185 70 152 36 80 17
5/32- 5056- .0010 3.8 375 140 272 57 155 24
5/32- 50 56-.0015 5.3 650 240 435 85 250 33
5/32-5056-.0020 6.9 1000 350 610 118 360 43
3/16- 5056-.0007 2.0 120 45 105 27 SO 13
3/16-5056- .0010 3.1 260 97 200 45 110 20
3/16-5056-.0015 4.4 490 180 340 68 198 27.5
3/16- 5056-.0020 5. 7 735 270 480 94 280 36 USE 75% OF TYPICAL MODULI VALUES FOR DESIGN

Other footnotes, see next page

3852-400-77)

July 1978

3


802.2.2.1

NORTHROP --------------- AIRCRAFT GROUP

~ TABLE 802.2.2.1-2 (concluded) ALUMINUM ALLOY 5056-H39 HEXAGONAL HONEYCOMB CORE ~

CALLOUT DENSITY COMPRESSIVE "--
"L" DIRECTION "w" DIRECTION
CELLwMATL-GAGE pet MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
1 (4- 5056-.0007 1.6 80 30 78 20 38 12
1/4- 5056-.0010 2.3 155 58 130 32 62 15
1/4- 5056-.0015 3.4 315 115 230 50 130 22
1/4-5056-.0020 4.3 465 172 325 67 190 27
1/4- 5056-.0025 5,2 645 230 425 84 245 32
3/8-5056-,0007 1.0 35 15 45 15 25 9
3/8- 5056-.0010 1.6 80 30 78 20 38 12
3/8- 5056-,0015 2.3 155 58 130 32 62 15
3/8-5056-.0020 3.0 260 92 190 43 lOU 19 ~


Values from "Mechanical Properties of Hexeel Honeycomb Materials," Hexeel Document TSB120, 1978 Revision,

Test data obtained at 0.625 inch thickness.

~

3852-4 (10-771

July 1978

4

•


802,2.2,1

F':ORHtROP

.~ AIRCRAFT GROUP

TABLE 802.2,2.1-3 ALUMINUM ALLOY 2024-T81 HEXAGONAL HONEYCOHB CORE

NOMIt,AL STRENGTH MODULUS STRENGTH MODULUS STRENGTH MODULUS
CELL-I4A TL- GAGE MINIMUM TYPICAL MINIMUM TYPICAL MINIMUN TYPICAL
pet psi ksi psi ksi psi ksi
l/'c -2024-,0015 5. C' 620 ZOO 400 82 250 33
1/8 -2024-,0020 6, 7 980 300 600 118 375 45
lib -2024-.0025 foG 1320 380 770 14S 470 54
l/t -2024-.0030 9.5 1725 480 950 no 585 64
3/16-2024- .0015 3.5 290 86 230 55 143 ~~
L.)
I
1/4 -2024-.0015 2 F 175 40 140 42 88 19
• v roo tno tes:

US[ 7 5~o OF TYPICAL MODULI VALUES FOR DESIGN

Values from "/-1echanical Properties of Hexcel Honeycomb Materials," Hexcel DocuGELt TSB120, 197e Revision.

TEst data obtained at 0.625 inch thickness •

3852-4 1'0-77.

July 1978

5

•


802.2.2.2


802.2.2.2 FLEXIBLE CORE CONFIGURATION

TASLE 802.2.2.2-1 ALUMINUM ALLOY 5052-H39 FLEXIBLE HONEYCOMB CORE

"L" DIRECTION ''W'' DIRECTION
MATL-CELL-CAGE pcf MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
5052/F40- .0013 2.1 157 65 63 18 37 10
5052/F40-. 0019 3.1 280 125 126 32 75 13
S052/F40- .0025 4.1 420 185 182 45 115 17
5052/F40-. 0037 5.7 roo 290 280 68 170 23
S052jF80- .0013 4.3 1~55 195 196 45 120 18
5052/F80-.0019 6.5 735 310 3"08 72 180 24
50S2/F80- .0025 8.0 1120 400 434 98 260 31 Footnotes:

USE 757. OF TYPICAL MODULI VALUES r'OR DESIGN

Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSB120, 1978 Revision.

Test data obtained at 0.625 inch thickness.

38524 (10-171

July 1978

1

•

•

•


802.2.2.2


TABlF. 802 2 2 2 2 ALUMINUM ALLOY 5056 H39 FLEXIBLE HONEYCOMB CORE

.. . . . - , -
"L" DIRECTION ''W'' DIRECTION
MATL-CELL-GAGE pcf MiNIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
50SUjF40-.0014 2.1 182 65 74 18 42 10
S056/F40-.0020 3.1 329 125 150 32 90 13
5056/F40-.0026 4.1 483 185 217 45 132 17
sOs6/F80-.0014 4,3 518 195 235 47 138 18
5056jF80-. 0020 6,5 910 310 364 73 213 24
50s6/F80- .0026 8.0 1260 410 518 100 307 32 Footnotes:


Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSBI20, 1978 Revision,

Test Data obtained at 0.625 inch thickne5s.

3852-4 (10-771

July 1978

2

•


802.2.3 802.2.3.1


802.2.3 NONMETALLIC CELLULAR (HONEYCOMB) CORE PROPERTIES

802.L.3.1 HEXAGONAL CORE CONFIGURATION (NONMETALLIC)

TABLE 802.2.3.1-1 GLASS REINFORCED PHENOLIC HEXAGONAL HONEYCOMB CORE

CALLOUT COMPRESSIVE
STRENGTH MODULUS STRENGTH MODULUS STRENGTH MODULUS
MATL-CELL-DENSITY MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
HRP-3/16-4.0 480 57 210 11. 5 110 5.0
HRP-3/lU-5.5 750 95 350 19.5 190 8.5
HRP-3/16-B.0 1280 164' 600 34.0 370 15.0
HRP-l/4-3.5 400 46 170 9.0 100 3.5
HRP-1/4-4.5 560 70 250 14.0 140 6.0
HRP-3/8-2.2 145 13 75 5.0 45 2,0
HRP-3/8-3.2 350 38 160 8.0 85 3.0
HRP-.3/8-4.5 550 65 260 14.0 150 6.0
HRP-3/8-6.0 750 100 340 22.5 210 10.0 Footnotes:


Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexce1 Document TSB120, 1978 Revision. Except for "L" direction plate shear minimum strength, which is the minimum of TSB120 and MIL-C-8073D.

Test data obtained at 0.500 inch thickness

Maximum long time temperature 325°F

HRP - Hexcel Trademark for this material

3852-4 (10-17)

July 1978

1

•

•

•


802.2.3.1


TABLE 802.2.3.1-2 GLASS REINFORCED PHENOLIC

(±45° BIAS WEAVE FIBER CONSTRUCTION) HEXAGONAL HONEYCOMB CORE

CALLOUT COMPRESSIVE
psi k s i psi ks i psi ksi
HFT-1/8-3.0 272 22 144 17 76 7
HFT-1/B-4.0 448 45 252 35 128 12
HFT-1/8-5.S 776 65 344 40 188 18
HFT-l/8-8.0 1336 95 448 45 268 22
HFT-3/16-1.8 96 14 84 13 40 4
HFT-3/16-2.0 112 17 94 15 44 4.3
HFT-3/16-3.0 280 34 160 23 76 8
HFT-3/16-4.0 448 44 224 28 116 12 Footnotes:


All values are preliminary.

Values from "Mechanical Properties of Hexce1 Honeycomb Materials," Hexcel Document TSBI20, 1978 Revision.

Test data obtained at 0.500 inch thickness. Maximum long time temperature 325F

HFT Hexcel Trademark for this material

3852..4 110-77)

July 1978

~ •.•••..•..•..•. .,- ...

2

.-:.-

.................................................. _._._---_ .. _._. __ _. __ .. __ ._---- _ _---_._ .. _--_. __ .

•

•

•

STRUCTURAL DESIGN MA~NUAl

802.2.3.1


TABLE 802.2.3.1-3 GLASS REINFORCED POLYESTER HEXAGONAL HONEYCOMB CORE

CALLOUT COMPRESSIVE
MATL-CELL-DENSITY HINlMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
psi ks! psi ks I psi ksi
NP -3/16-4.5 470 80 195 l3,5 90 5.2
NP -3/16-6.0 735 116 230 15.0 110 5.8
NP -3/16-9.0 1260 180 320 20.0 160 7.5
NP -1/4-4.0 390 68 180 13.0 85 5.0
NP -1/4-6,0 736 116 230 15.0 110 5.8
NP -1/4-8.0 1080 160 290 18.0 145 7.0
NP -3/8-2.5 195 34 120 10.0 70 4.0
NP -3/8-4.5 470 80 195 13.5 90 5.2 Footnotes:


Values from "Mechanical Properties of Hexce1 Honeycomb Materials," Hexcel Document TSB120, 1978 Revision.

Test data obtained at 0.500 inch thickness. Maximum long time temperature 180°F

NP Hexce1 Trademark for this material.

3852-4 (10-77)

July 1978

3

•

•

•


802.2.3.1


TABLE 802.2.3.1-4 GLASS REINFORCED POLYIMIDE HEXAGONAL HONEYCOMB CORE

CALLOUT COMPRESSIVE
psi ksi psi ksi p!5i ksi
HRH327"3/16-4.5 400 58 220 33 110 11
HRH327-3/16-6.0 625 87 345 45 170 15
HRH327-3/16-8.0 1000 126 500 62 330 22
HRH327-3/8-4.0 325 50 195 29 100 12
HRH32 7-3/8- 5.5 540 78 300 41 160 13.5 Footnotes:


Values [,rom "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSB120, 1978 Revision.

Test data obtained at 0.500 inch thickness • Maximum long time temperature 5000F

HRH327 Hexcel Trademark for this material •

3852-400-771

July 1978

................... _--------------

4

•

•

STRUCTURAl DESIGN MANUAL

802.2.3.1


TABLE 80Z.Z.3.1~5 NYLON REINFORCED PlffiNOLIC HEXAGONAL HONEYCOMB CORE

CALLOUT
COMPRESS1VE "L" DIRECTION "W" DIRECTION
IiRH10-1(S"3.0 270 20 162 7.0 85 3.5
HRHIO-l/8-4.0 470 28 225 9.2 110 4. 7
HRHIO.l/8-6.0 825 60 260 13.0 135 6.0
HRHW-1/8-8.0 1250 78 355 16,0 190 7.8
HRH10-1/8~ 9 ,0 1600 90 370 17.0 ! 240 9,0
,
HRH10~3/16-2,O 105 11 72 4.2 40 2.2
HRH1O-3/16-3.0 27D 20 130 5.0 67 3.5
HRHI0-3/16-4.0 470 28 215 7.8 no 4. 7
. I
HRH10~1/4-1. 5 55 6 45 3.0 23 1.5
HRHIO~1/4-2.0 105 11 72 I 4.2 I 36 2.8
! I
IiRH10-3/8-1. 5 I I 1
55 6 45 1.0 23 1.5
HRHIO-3/8~2.0 105 I 11 72 4.2 36 2.2 Footnotes:


Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSB120, 1978 Revision.

T~st data obtained At 0.500 inch thickness Maximum ling time temperature 300°F

HRH10 Hexcel Trademark for this material

3852 -4 {, 0-77)

July 1978

5

•

•

•


802.2.3.2


802.2.3.2 RECTANGULAR CORE CONFIGURATION (NONMETALLIC)

TABLE 802.2.3.2-1 GLASS REINFORCED PHENOLIC RECTANGULAR HONEYCOMB CORE

CALLOUT
COMPRESSIVE "L" DIRECTION "WI! DIRECTION
HRP/OX-l/4-4.5 500 43 168 8 200 15.2
HRP/OX-l/4- 5. 5 760 65 216 10.5 264 18
HRP /OX-l /4- 7.0 98.4 84 316 14 360 20
HRP/OX-3/8-3.2 340 32 112 4.5 120 9
HRP/OX-3/8-5.5 656 60 192 10 240 17 Footnotes!



Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexce1 Document TSB120, 1978 ReviSion.

Test data obtained at 0.500 inch thickness. Maximum long time temperature 325°F

HRP Hexce1 Trademark for this material.

OX Hexcel callout for rectangular (overexpanded) core •

3852-4 (10-771

July 1978

1

•

•

•


802.2.3,2


TABLE 802.2.3.2-2 GLASS REINFORCED PlffiNOLIC

(±45° BIAS WEAVE FIBER CONSTRUCTION) RECTANGULAR HONEYCOMB CORE

PLATE SHEAR
STABILIZlD.c
CALLOUT COMPRESSIVE "L" DIRECTION ''W'' DIRECTION
MATL-CELL-DENSITY MINIMUM TYPICAL MINIMUM 1YPICAL MINIMUM TYPICAL
psi kS1 pSi ksi psi ksi
HFT/OX-3/l6-6.0 880 67 232 13 268 30
HFT/OX-3/l6-7.0 1160 87 324 20 352 38 Footnotes!



Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSBl20, 1978 Revision.

Test data obtained at 0.500 inch thickness. Maximum long time temperature 325°F •

HFT Hexcel Trademark for this material.


3852-400-17)

July 1978

2


802.2.3.2


TABLE 802.2.3.2-3 NYLON REINFORCED PHENOLIC RECTANGULAR HONEYCOMB CORE

CALLOUT COMPRESSIVE
HRH lO/OX-3/l6-3.0 270 17 95 3 95 6
HRH lO/OX-l/4-3.0 250 17 90 3 90 6 Footnotes:


•

Values from "Mechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSB120. 1978 Revision,

Test data obtained at 0.500 inch thickness. Maximum long time temperature 300°F.

HRH 10 Hexcel Trademark for this material •


•

3852..4 (10-77)

July 1978

3

•

•

•

STRUCTURAL OESIGN MANUAL

802.2.3.3


802.2.3.3 FLEXIBLE CORE CONFIGURATION (NONMETALLIC)

TABLE 802.2.3.3-1 GLASS REINFORCED PHENOLIC FLEXIBLE HONEYCOMB CORE

CALLOUT COMPRESSIVE
"t,' I DIRECTION "u" DIRECTION
MATT .-CELL. DENSITY MINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
HRP/F35-2.5 192P 25 lOOP 12.SP 56P 7P
HRP/F3S-3.S 300 37 140 15 75 10
HRP/F3S-4.S 480P 49 224P 22 112P 12
HRP/F50-3.5 300 37 140 20 75 10
HRP/FSO-4.5 500 49 200 25 100 13
HRP/F50- 5. 5 700P 61P 310P 31. 5P 160P 16P Footnotes:


p - preliminary properties.

Values from "Mechanical Properties of Hexce1 Honeycomb Materials," Hexcel Document TSB120, 1978 Revision.

Test data obtained at 0.500 inch thickness. Maximum long time temperature 325°F.

HRP Hexcel Trademark for this material •

3852-4 (10-·77)

July 1978


802.2.3.3

NORTHROP

~ AIRCRAFTGROUP

• TABLE 802. 2.3.3- 3 NYLON REINFORCED PHENOLIC FLEXIBLE HONEYCOMB CORE

CALLOUT COMPRESSIVE
"LlJ DIRECTION ftWl1 DIRECTION
STRENGTH 1'1ODULUS STRENGTH MODULUS STRENGTH MODULUS
l'~TL-CELL-DENSITY HINIMUM TYPICAL MINIMUM TYPICAL MINIMUM TYPICAL
psi ksi psi ksi psi ks I
M' ____ ."
HRH lO/F35-2.5 119 12P 49 4.0P 28 1. 9P
HRH lO/F35-3.5 217P 24P lOSP 5,7P 56P 2.8P
HRH lO/F35- 4.5 390P 33P 216P 7,3P 120P 3,7P
l-fRH lO/F50-3.5 217 24 105 5.7P 56 2.SP
HRH lO/F 50- 4.5 390P 33P 216P 7.3P 120P 3.7P
HRH 10/F50- 5,0 525 37 300 8.0 160 4.1P
HRH 10/F50-5.5 560P 42P 3l2l-' 8.8P l88P 4.6P Footnotes:


• P - p r e l Im l ua r y p ro p e r t.Le s ,

Values from "Nechanical Properties of Hexcel Honeycomb Materials," Hexcel Document TSB120, 1978 Revision.

Test data obtained at 0,500 inch thickness. Maximum long time temperature 300oF.

HRH lO Hexcel trademark for this material.

•

3852 -4 \1 0-17)

July 1975

2

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