Understanding and modeling the co-cure of honeycomb core sandwich structures

Abstract

Honeycomb sandwich structures can be manufactured by co-cure, during which prepreg facesheets are concurrently consolidated and bonded to core using film adhesive. This paper describes the major activities and findings of a research project devoted to understanding the physics of co-cure and to developing a physics-based process model. Experimental analysis methods are described, with findings illustrating governing phenomena, complex defect formation mechanisms, and strategies for successful part production. Model development is described from a top-down perspective, addressing requirements, the chosen approach, sub-model development, and integration. Overall, the paper provides practical insights into co-cure and highlights ongoing work to simulate this manufacturing approach based on physics uncovered through experimental investigation.