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MECHANICAL PROPERTIES CI
SOME HEAT-RESISTANT
METAL HONEYCOMB CORES
Vecember 1959
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UNITED STATES DEPARTMENT OF AGRICULTURE
FOREST PRODUCTS LABORATORY
MADISON 5, WISCONSIN
FOREST SERVICE
In Cooperation with the University q f Wisconsin
MECHANICAL PROPERTIES OF SOME
HEAT-RESISTANT METAL HONEYCOMB CORES
By
EDWARD W. KUENZI, Engineer
and
W. E. JAHNKE, Engineer
2
Forest Products Laboratory, Forest Service
U. S. Department of Agriculture
Abstract
This report presents the results of tests of commercially produced heatresistant metal honeycomb cores for use in structural sandwich construction.
Cores tested were made of four corrosion-resistant steels, a nickel-chromium
alloy, and titanium. Properties evaluated were compressive strength at
normal and elevated temperatures and shear properties at normal temperatures. Detailed descriptions of core materials and testing procedures are
given.
Introduction
To meet the stringent requirements regarding lightweight, strong, and , stiff
constructions for components of contemporary aircraft, missiles, and
space vehicles it is necessary to consider sandwich or other composite
constructions that employ cores of heat-resistant material. Such cores can
be formed from honeycomb-like material of thin, heat-resistant metal sheets.
These cores can be bonded, brazed, or welded between thin facing sheets to
produce a stiff, strong, lightweight construction.
-This work was sponsored by the U. S. Navy Bureau of Aeronautics, Orders
NAer 01807 and NAer 01898, Item 3.
2
Maintained at Madison, Wis. , in cooperation with the University of Wisconsin.
Report No. 1872
-1-
This investigation was undertaken to determine mechanical properties of
various commercially available heat-resistant metal honeycomb cores. A
knowledge of mechanical properties is required to design composite constructions properly and to serve as a base for specifications of the cores,
Cores
Twenty cores, obtained from eight manufacturers, were tested. These
included cores of corrosion-resistant steel, a nickel-chromium alloy, and
titanium. The corrosion-resistant steel cores were of alloys 17-7PH, PH157Mo, 321, and AM350 in the annealed condition and also 17-7PH alloy transformed at 1400° F. , hardened to TH1050, and hardened to RH950. Detailed
descriptions of each core are given, with properties determined, in tables
1 and 2.
Core No. 1 (table 1) was obtained in a large block and cut to 1/2-inch slices
with a fine-toothed bandsaw. All the other cores were obtained as slices
1/2 inch thick.
Each slice of core was weighed and measured to determine the core density
values given in column 2 of tables 1 and 2.
The thicknesses of the foils were measured on about half the cores and the
values are given in column 5 of tables 1 and 2. Thicknesses of foils not
measured are given as nominal thicknesses in the tables. Measurements of
foil thickness were made with a dial gage that was accurate to 0.0001 inch and
equipped with a flat spindle end that had a diameter of 1/16 inch. This spindle
was opposed by a stationary steel ball 1/16 inch in diameter. The apparatus
was arranged so that, as the foil made contact between the stationary ball and
the spindle, an electric circuit was completed, causing a lamp to glow. This
was done so that the foils of cores bonded with adhesive would have no adhesive coating included as foil thickness. If the lamp did not indicate contact
on the first measurement, the foil was not scraped, but a spot containing no
adhesive was sought. Actual measurements showed that the average foil
thickness was within +10 percent of the nominal thickness.
Core Tests
Tests of small specimens of cores were made to determine flatwise compressive strength at normal temperature (65° to 85° F.) and at 400°, 600°,
Report No. 1872
-2-
800°, 1, 000°, and 1, 200° F. , and core shear modulus and core shear strength
at normal temperature.
Although core shear strength was not measured at elevated temperatures, an
approximate value at any desired temperature can be obtained by multiplying
the strength at normal temperature by the ratio of the compressive strength
at elevated temperature to the compressive strength at normal temperature.
Core shear moduli at elevated temperature can be estimated by multiplying
the value at normal temperature by the ratio of the modulus of elasticity at
elevated temperature to the modulus of elasticity at normal temperature for
the particular foil material. The flatwise compressive modulus of elasticity
can be estimated by multiplying the modulus of elasticity of the foil material,
at temperature, by the ratio of the core density to the density of the foil
material.
Compression Tests of Cores
Specimens for determining flatwise compressive strength of the honeycomb
cores were 2 inches by 2 inches in cross section and 1/2 inch in thickness.
The specimens were cut from core slices with a high-speed, fine-toothed
bandsaw. When enough material was available, six specimens were obtained
for test at each test temperature.
The edges of the thin foils at the ends of the specimens were reinforced with
a refractory inorganic cement to prevent local end 'crippling of the foil at low
loads. The reinforced ends thus simulated the ends of the core in a sandwich
wherein, adhesive or braze would support the foil. One end of each specimen
was dipped to a depth of about one-eighth inch in a fluid mixture of the cement,
removed, and placed on a flat surface covered with waxed paper that would
not adhere to the cement. A small weight was placed on the upper end of the
specimen, and this assembly was allowed to remain undisturbed for Z4 hours
to harden the cement. Then the other end of the specimen was coated with
cement.
The compression specimens were placed on a flat, machined, steel block in a
hydraulic testing machine. The load was applied at the top end through a
spherical loading head of the suspended, self-alining type. The movable
head of the testing machine was driven at a constant rate until failure occurred.
The rate of motion was such that failure occurred in 3 to 6 minutes.
Tests at elevated temperature were conducted in an electric furnace that
rested on the lower platen of the - testing machine. The furnace heating elements
Report No. 1872
-3-
were located in the sides of the furnace and uniform heating of the furnace
was aided by an electric fan that circulated air within the furnace. Baffles
prevented direct radiation from the electric heating elements to the specimen.
Temperature of the furnace was controlled by a continuously balanced potentiometer pyrometer with its thermocouple located near the test specimen. A
powerstat was useful in controlling input to the heating elements, thus reducing
the amount of overheating to a minimum. Temperatures of 400° and 600' F.
were controlled to within 2° F. , and to within 5° F. at 800°, 1, 000°, and
1, 200' F. The test area was located near the center of the furnace and loads
were carried to the test specimen through steel tubing that passed from the
testing machine platens through holes in the furnace floor and roof.
Specimens tested at elevated temperatures of 400°, 600°, 800°, 1, 000°, and
1, 200° F. were heated to the test temperature in the furnace, exposed to
temperature for 1/2 hour, and then tested.
Failure of the compression specimens began by buckling of the honeycomb cell
walls, followed almost immediately by general instability of the cell corners,
and resulting in a crushed specimen. The refractory inorganic cement end
coating was successful in preventing local end damage to core foil ends.
Flatwise compressive strengths of the various cores tested are given in table 1.
Immediately below the average strength at elevated temperatures are given the
ratio of elevated temperature strength to strength at .normal temperature,
expressed as percentages.
Strengths at normal temperatures are also plotted as a function of average core
density in figure 1. Although there is considerable scatter in the data, there is
a definite trend of increasing compressive strength with increase in core
density. Close study of the data also shows that curves can be drawn to
represent minimum values for three groups of specimens. These curves are
shown in figure 1 for cores of annealed corrosion-resistant steel and nickelchromium alloys, for transformed and hardened corrosion-resistant steel
alloys; and for cores of titanium. The curve for transformed and hardened
steel alloys was obtained by increasing the values on the curve for annealed
steel alloys by 90 percent.
The effects of elevated temperature on flatwise compressive strength can be
determined by examining the percentage figures given in table 1, or those
figures plotted versus temperature infigure Z. The figure shows that the
effects of elevated temperature are most detrimental to cores of titanium.
Bonded cores of steel were much weaker at elevated temperatures up to 1, 000°F.
than welded cores. Figure 2 also shows that the heat resistance of transformed and hardened corrosion-resistant steel cores was about the same as
for annealed material at temperatures up to 1, 000° F. , and that at 1, 200° F.
Report No. 1872
-4-
the heat resistance of transformed and hardened steel cores was considerably
less than for annealed material. The figure shows that the alloys least
affected by temperatures up to 1, 200° F. were the nickel-chromium alloy,
Inconel, and the corrosion-resistant steel alloys AM350 and PH15-7MoA.
The graph of figure 2 is useful in establishing arbitrary heat resistance of
cores at various temperatures. Thus, at a 65 percent level of heat resistance
(ratio of strength at elevated temperature to strength at normal temperature),
cores of Inconel, AM350, and PH15-7MoA would be satisfactory at 1, 200° F.
and all other cores except titanium and bonded cores would be satisfactory at
800° F. At a heat-resistance level of 45 percent, bonded cores and titanium
cores would be satisfactory at 500° F.
It should be pointed out that the most heat-resistant cores were not necessarily
the strongest cores at elevated temperature but that they were the cores that
had their strength least affected by elevated temperature.
Shear Tests of Cores
Specimens for determining shear properties of the honeycomb cores were 2
inches by 6 inches by 1/2 inch thick, with the core ribbons placedparallel,
perpendicular, or at 45° (for some of the cores with square cells) to the long
dimension (fig. 3). The specimens were cut from core slices with a highspeed, fine-toothed bandsaw. When enough material was available, six
specimens were obtained for test in each ribbon orientation.
Shear loads were applied to the specimens through 1/2-inch-thick steel loading
plates bonded to the specimens (fig. 4, shows 1/2-inch plates horded to a
shear specimen). Bonds for most of the specimens were made with a twopart liquid epoxy resin adhesive, set under 25 pounds per square inch in a
hot press at 200° F. for 90 minutes. Such bonds were strong enough to
produce shearing failures in cores that had shear strengths as high as 400 to
500 pounds per square inch. Bonds for stronger specimens were made with
a heavy spread of a one part powdered epoxy resin adhesive that was set under
15 pounds per square inch in a hot press at 400° F. for 60 minutes. Core
shear stresses as high as 880 pounds per square inch were produced but this
was not great enough to cause shear failure of the strongest specimens.
The specimens were tested in a hydraulic testing machine. Opposite ends of
the s teel loading plates were fastened to links hung in the testing machine,
and a tensile load was applied to place shear load on the core in the 6-inch
direction. The complete apparatus is shown in figure 4. Slip of one loading
Report No. 1872
-5-
plate with respect to the other was measured, on most specimens, with a
dial gage that was accurate to 0. 0001 inch. For some of the more rigid cores
the deformation (slip) was measured with a Tuckerman optical strain gage or
a Marten's mirror deformation gage in place of the dial gage. The movable
head of the testing machine was driven at a constant rate until failure occurred.
The rate of motion was such that failure occurred in 3 to 8 minutes. Deformation readings were taken at equal load increments until failure. Failures
occurred by buckling and shearing of the cores for most specimens. Some of
the stronger specimens could not be failed and bond failure between the core
and loading plates occurred without a sign of any buckling or beginning of
failure in the core. Load-deformation curves were used to compute core
shear modulus values. Although the curves showed proportional limit loads,
the core stress at proportional limit load is not reported because it was thought
that the proportional limit load was largely determined by flow in the adhesive
used to bond the loading plates to the core and therefore would not indicate core
proportional limit stresses.
Shear modulus values and shear strengths of the cores tested are given in
table 2. Core shear strength parallel to core ribbons are plotted versus core
density in figure 5. The data show more scatter and less trend than flatwise
3
compressive strength data. Previous work on aluminum honeycomb cores —
has shown that core shear strength was proportional to flatwise compressive
strength. By assuming that the core shear strength parallel to the core
ribbons is one half of the flatwise compressive strength the curves shown in
figure 5 were obtained. These curves roughly define the slight trend indicated
in the data and represent minimum values for the three groups of specimens;
viz. , annealed steel and nickel-chromium alloys, transformed and hardened
steel alloys, and titanium.
Figure 6 shows a comparison of shear strength perpendicular to core ribbons
with shear strength parallel to core ribbons. The points represent average
values given in table 2. Previous work on aluminum honeycomb2. showed that
for cores of hexagon cells the shear strength perpendicular to core ribbons was
54 percent of the shear strength parallel to core ribbons. The line representing
this relationship is shown on figure 6 and the two values for cores of hexagon
cells agree fairly well with this line. For cores of square cells it was found
by least squares that the shear strength perpendicular to core ribbons was
85 percent of that parallel to core ribbons. This line is also shown on figure 6.
Three values obtained for shear strength at 45° to core ribbons for cores of
square cells also agree well with the values for core ribbons perpendicular to
load, as shown in figure 6.
3
—Kuenzi, Edward W. Mechanical Properties of Aluminum Honeycomb Cores,
Forest Products Laboratory Report No.• 1849. 1955.
Report No. 1872
-6-
Shear modulus values parallel to core ribbons are plotted versus core density
in figure 7. The scatter in the data obscure any direct trend but a line can be
drawn as a minimum as shown in the figure. The cores which fall below the
line drawn in figure 6 were of corrugated foil. Because of the corrugations
these cores were less rigid than cores with flat cell walls.
A comparison of core shear modulus perpendicular to core ribbons with core
shear modulus parallel to core ribbons is shown in figure 8. There is no
apparent trend but the ratio of 0. 40 between values perpendicular and parallel
to ribbons is a minimum value. This ratio was previously found for aluminum
honeycomb cores of hexagonal cells. 3 Also shown in figure 8 are points
'representing core shear moduli at 45° to core ribbons for square cell cores.
These data fall in line with data for core ribbons perpendicular to shearing load.
Report No. 187 2
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