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Investigation of the mechanical properties of polyurethane foam-filled FDM-printed honeycomb core sandwich composites for aircraft

Published online by Cambridge University Press:  25 September 2023

H. Kafalı Open the ORCID record for H. Kafalı [Opens in a new window]  and
E. Tunca Open the ORCID record for E. Tunca [Opens in a new window]
H. Kafalı*
Affiliation:
Department of Aviation Management, Mugla Sıtkı Kocman University Dalaman School of Civil Aviation, Mugla, Turkey
E. Tunca
Affiliation:
Department of Airframe and Powerplant Maintenance, Mugla Sıtkı Kocman University Dalaman School of Civil Aviation, Mugla, Turkey
*
Corresponding author: H. Kafalı; Email: hasimkafali@mu.edu.tr
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Abstract

Sandwich composites are widely used in aerospace materials thanks to their low weight and high strength properties. The purpose of this study is to observe the effects of polyurethane foam filling on honeycomb core structures produced by additive manufacturing in terms of mechanical strength and moisture absorption properties. Within the scope of the study, honeycomb structures were produced by a 3D printer using polylactic acid (PLA) filament. Then, the honeycomb core was filled with polyurethane foam, which is supplied in liquid form. After the core material was given its final form, it was combined with an epoxy and carbon fibre facesheet material using the vacuum infusion technique. After the sandwich composite production was completed, in-plane compression, three-point bending, shear, and moisture absorption tests were applied. The polyurethane foam filling greatly increased the mechanical strength, but slightly more moisture absorption occurred in this structure compared to a hollow honeycomb structure.

Keywords

aeronauticssandwich compositeadditive manufacturinghoneycombpolyurethane foam
Type
Research Article
Information
The Aeronautical Journal , Volume 128 , Issue 1321 , March 2024 , pp. 577 - 597
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Copyright
© The Author(s), 2023. Published by Cambridge University Press on behalf of Royal Aeronautical Society

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