ALUMINIUM HONEYCOMB PANELS

Return to Honeycomb Panels

Aluminium Honeycomb panels are used to form lightweight, high strength sandwich units that are extremely rigid. The Aluminium Core is manufactured in several grades from 3003 general applications to 5052 and 5056 for use in Military applications.

Aluminium 3003 as a core material has the following attributes

• Temperature usage up to 175 ° C
• High Thermal Conductivity
• Flame resistance
• Moisture and Corrosion Resistance
• Fungi Resistant
• High Strength
• Low weight

Aluminium Honeycomb Panels Core material wafer block is stretched into a sheet of Hexagonal structure on purpose designed computer-controlled equipment to give a consistent cell dimension. The walls of the cells can have micro perforations to allow movement of air between adjacent cells equalizing pressure in environments with rapid temperature variation.

The cell size, depth of material, thickness of cell walls and grade of Aluminium are all variable to suit specific requirements and tailored to impart the correct properties in the final manufactured units. 

The aluminium core is available in 5 cell sizes the Compressive strength follows according to the size selected as can be seen from the data below.

MANUFACTURE OF ALUMINIUM HONEYCOMB PANELS

The expanded core is bonded to the outer facings with a two pack adhesive, its properties allow it to "wick" on to the core cell walls to ensure large area of contact. The adhesive is applied on a dedicated computer controlled spray booth facility, which allows close monitoring of coat weights and accurate application to all substrates. 

During this stage any inserts or conduits can be included within the core to allow site fixing or wiring of ancillary fittings to concealed points. Panels can have structural frames incorporated in the same manner to agreed configuration.

The sandwich faces and core are laid up and accurately aligned prior to transferring by means of roller table to the press.

The final bonding process is carried out in a heated hydraulically controlled press to ensure uniformity of each panel. The panel remains in the press during the adhesive curing process, this is closely controlled taking account of press and ambient temperatures to ensure reliability of bond. 

After the curing process has been completed the panels are removed from the press, inspected and stacked with appropriate interleaving prior to transfer to Packing and Despatch area.

The Aluminium Hoenycomb panels will be wrapped and strapped suitable for mechanical handling and where required crated suitable for onward freighting. The specifications for the protection and marking will be as agreed with individual clients.

QUALITY

All operations will be carried out in accordance with an ISO 9000 accredited quality scheme. We encourage client visits, particularly during manufacture of their products; likewise any client specified external inspection authority is welcome for any individual contract. We will incorporate Client specified checking procedures, in addition to our in house monitoring, upon request, subject to mutual agreement prior to execution of the order.

SPECIFICATION

Aluminium Honeycomb Panels core as detailed can be specified in a large range of cell sizes generally the smaller the size the higher panel strength with greater resistance to impact. Core costs rise with cell size reduction and grade of aluminium used from commercial grade to certificated specifications. It is important to use the correct materials to form the sandwich panels to achieve desired results at economic cost.

Please consult with us, we will be happy to advise and provide a range of solutions with costs during initial stages, to tailor the product to your individual requirements in an economic and efficient manner.