Low cost composite processing from aerospace OOA to automotive thermoplastic pages:118-125
SEICO 14 SAMPE Europe international technical conference & forum edition:35 location:Paris date:10-11 March 2014
A stack of a flexible open cell foam with a glass fibre mat on top and bottom is used as precursor for a sandwich panel. Due to the flexible state of this stack, the sandwich panels can be produced in complex 3D shapes, e.g. interior side of a car door. A solid panel is obtained by joining the different components through spray application of a rigid foam reaction mixture.
Since the core and skin of the sandwich panel under consideration are formed in situ, they cannot be characterized in advance. Therefore different sample preparation methods and measuring techniques were developped and applied.
Computed Tomography scanning and an image processing algorithm were used to measure the skin thickness. Images of multiple sandwich skins could be made in a single scan by applying an efficient sample preparation method, which considerably decreases the needed amount of time.
Tensile experiments on milled skins were performed to determine the stiffness and strength properties. The compressive properties of the skins were measured through four-point bending tests. The results of these experiments demonstrated the stability of the production process.
Ultimately a simple predictive excel tool could be developped based on the outcome of the experiments and some analytical models. This tool allows to evaluate the potential of possible new material combinations in the future.