Abstract
Composite sandwich structures offers several advantages over conventional structural materials such as lightweight, high bending and torsional stiffness, superior thermal insulation and excellent acoustic damping. In the aerospace industry, sandwich composites are commonly manufactured using the autoclave process which is associated with high operating cost. Out-of-autoclave (OOA) manufacturing has been shown to be capable of producing low cost and high performance composites. In this paper we present results of experimental testing of various sandwich materials according various standards and actual requirements in transport industry. We compared the different types of surface and paint systems, because these layers are the most important in contact with the surrounding environment and load conditions. In the experimental measurements were used various materials. For the core of the sandwich structure were selected aluminium honeycomb, aramid honeycomb and PET (Polyethylene terephthalate) foam core. Support layers were chosen two kinds of predimpregnated materials. The conditions of measurements were requirements for strength and rigidity, safety - flame resistance and reflectivity resistance. The samples were tested at the 3 - point bending test according to standard EN ISO 178, by modified test to determine the force required to rapture threaded insert, by test of reflectivity according to UIC CODE 844-4 R and according to standard EN 45545-2 fire protection of railway vehicles.
Highlights
Composite sandwich structures offers several advantages over conventional structural materials such as lightweight, high bending and torsional stiffness, superior thermal insulation and excellent acoustic damping
The majority of high performance composite structures are manufactured in autoclaves
Alternative processing methods need to be investigated in order to reduce production costs and broaden the supply base of composite structures
Summary
The majority of high performance composite structures are manufactured in autoclaves. Autoclave processing of composites uses primarily pre-impregnated unidirectional fibers or fabrics (prepregs) that are cured at 180°C and consolidated with 6 atm of pressure, usually. A large database of design allowable for autoclave prepregs is available and accessible to product designers. This well-established process requires high infrastructure investment for. Autoclaves as well as high recurring tooling costs. Alternative processing methods need to be investigated in order to reduce production costs and broaden the supply base of composite structures. This presentation addresses the application of a relatively new class of composite materials using out-of-autoclave (OOA) technologies. The advantages of OOA processes include substantially lower infrastructure, tooling, and overall manufacturing costs. [1,2] For OOA technologies using predimpregated materials (pre-preg) belong to curing of prepregs in oven and PCM (Prepreg Compression Moulding)
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