New Improved Foam Core Materials for Advanced Processing

Abstract

Closed moulding processes put new requirements on the core materials for sandwich structures. Two new foam core material grades have been developed to meet these requirements. The first will replace the existing standard grades but with improved strength, ductility and thermal properties while maintaining the excellent stiffness of today’s product. This grade is oriented towards closed manufacturing processes with processing at lower temperatures like infusion, RTM and VARTM and post cure up to 90°C. The second grade will provide full compatibility with low and medium temperature pre-preg and RFI systems for processing up to 160°C. In addition, for the DIAB core infusion process with a grooved core material, the making up has been improved for weight sensitive applications by using an optimized finer groove pattern in the core surface to minimize resin uptake while still providing an even distribution and wet-out of the fibers.