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There are various configurations of the adhesive bonding of the aluminium foil which can lead to a variety of geometric cell shapes (usually hexagonal). Aluminium honeycombĪluminium honeycomb produces one of the highest strength/weight ratios of any structural material. Honeycomb cores can give stiff and very light laminates but due to their very small bonding area they are almost exclusively used with high-performance resin systems such as epoxies so that the necessary adhesion to the laminate skins can be achieved. Sheets can range from typically 3-50 mm in thickness and panel dimensions are typically 1200 x 2400mm, although it is possible to produce sheets up to 3m x 3m. Properties of honeycomb materials depend on the size (and therefore frequency) of the cells and the thickness and strength of the web material. This provides a greater bond area for the skins, increases the mechanical properties of the core by stabilising the cell walls and increases thermal and acoustic insulation properties. The cells of the honeycomb structure can also be filled with a rigid foam. While skins are usually of FRP, they may be almost any sheet material with the appropriate properties, including wood, thermoplastics (eg melamine) and sheet metals, such as aluminium or steel. Due to this bonded method of construction, a honeycomb will have different mechanical properties in the 0° and 90° directions of the sheet. In both cases, by varying the degree of pull in the expansion process, regular hexagon-shaped cells or over-expanded (elongated) cells can be produced, each with different mechanical and handling/drape properties. Once this dipping resin has cured, the block has sufficient strength to be sliced into the final thicknesses required. Held in its expanded form, this fragile paper honeycomb block is then dipped in a tank of resin, drained and cured in an oven.
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In the case of paper honeycombs, the stack of bonded paper sheets is gently expanded to form a large block of honeycomb, several feet thick. The slices (known as ‘block form’) are later gently stretched and expanded to form the sheet of continuous hexagonal cell shapes. In the case of aluminium honeycomb the stack of sheets is then sliced through its thickness. In these cases large thin sheets of the material (usually 1.2×2.4m) are printed with alternating, parallel, thin stripes of adhesive and the sheets are then stacked in a heated press while the adhesive cures.
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Other honeycombs (such as those made of paper and aluminium) are made by a multi-stage process. Thermoplastic honeycombs are usually produced by extrusion, followed by slicing to thickness.