TRANSACTIONS ON AEROSPACE RESEARCH

2 (255) 2019, pp. 7–20

DOI: 10.2478/tar-2019-0006
© Copyright by Wydawnictwa Naukowe Instytutu Lotnictwa

REVIEW OF TESTING METHODS DEDICATED

FOR SANDWICH STRUCTURES WITH HONEYCOMB CORE

Arnold Jędral
Composite Testing Laboratory, Center of Composite Technologies,
Institute of Aviation, al. Krakowska 110/114, 02-256 Warsaw
[email protected]

Abstract
This paper is a review of testing methods dedicated for sandwich type composite structures with
honeycomb core. First, information about the composition of sandwich materials structures, their
properties, types of core materials and applications in the industry is presented. Mechanical proper-
ties were compared in the case of different types of the core material. Later, tests methods needed to
describe properties of those materials and normalization organizations which create them were men-
tioned. The testing methods were divided into two groups: mechanical and physicochemical tests.
Mechanical properties are: compressive strength (two types of test), edge compressive strength, shear
strength (in two directions) and tension strength (two types of test). Physicochemical properties are:
material density, water migration, water absorption and thermal conductivity. Testing methods were
described according to American Society for Testing and Materials (ASTM) standards. This article is
based on professional literature and the author’s experience.

Keywords: mechanical properties, sandwich panel materials, honeycomb, Kevlar, Nomex.

1. INTRODUCTION
Sandwich structures consist of two thin, stiff and strong face sheets called skins and between them
is placed light and thick core (honeycomb). The elements are connected by a thin layer of adhesive
(Fig. 1). The aim of that structure is to obtain big stiffness and strength in relation to weight.
From a mechanical point of view, sandwich structure materials can be compared to I-beam (Fig. 2).
Face sheets play the role of flanges, which means that they carry in-plane compression and tension
loads and core carries shear loads as a web in an I-beam. A bond between core and face sheets can be
made by applying specific adhesive, which combines all elements into one stiff and strong structure.
8 ARNOLD JĘDRAL

Fig. 1. Honeycomb sandwich panel structure [1]

Fig. 2. Sandwich structure panel as an I-beam [2]

Nowadays, sandwich structures can be created by using many different materials. When sandwich
structure has to be done, many aspects such as: core type, face sheets material, core material and type
of adhesive, have to be considered. Proper choice of all this factors have a huge influence for sandwich
structures properties.
Honeycomb market is fast and still growing market which offer various materials for any use. Only
Nomex honeycomb market is expected to garner $383.3 million by 2021 and register a CAGR (com-
pound annual growth rate) of 8.5% between 2016 and 2021 [3] (Fig. 3).

Fig. 3. Growth of Nomex honeycomb market size [3]

 REVIEW OF TESTING METHODS DEDICATED FOR SANDWICH STRUCTURES… 9

Face sheets can be made of metals (aluminum, stainless steel), composites reinforced with carbon
fibers, glass fibers or aramid fibers, plastics, wood or carton [1, 2, 4].
As a core can be used: foam, honeycomb or natural materials like balsa wood or cork. Foam materi-
als can be plastics like: PVC, PU, PE, PS, PES, PET, PMI, PEI, etc. [4]. It is also possible to use metals
in the form of foam but that is not popular because foams have lower strength than honeycombs and
lower work temperature (foams: > 180°C, honeycombs: > 250°C). They are used in elements working
on low loads but mostly as an isolating panels.
Honeycomb materials constitute the biggest group of core materials used in sandwich structures.
They can be used in form of a metallic and nonmetallic honeycombs. From metallic the most often
use is aluminum (3003, 5052, 5056), which can be applied in structures working in temperature up
to 180°C. Rarely metallic honeycomb is made from steel (17-PH, 316L, 347), titanium (6Al-4V,
6Al-2Sn-4Zr-2Mo), lead or copper [1, 2, 4, 5, 6]. Most commonly they are made from nonmetallic
materials. Those could be composite materials reinforced by aramid fiber (Kevlar, Nomex), carbon
fiber, glass fiber and plastics (PVC, PET, PEI) [1, 2, 4, 5, 6].
Because of high strength to mass and stiffness to mass ratios, sandwich composite materials are used
in aeronautic, cosmonautic and marine industries, sports, transport and many others [1, 2, 4, 5, 6].
Critical parameter in aviation is mass. Wherever possible, the lightest materials are applied in order to
reduce weight of the plane. Exactly for purpose sandwich materials are used. At first, those were mostly
secondary structures (failure of that kind of structure does not cause directly a failure of the whole
plane), but over the years they were used also in primary structures (Fig. 3).

Fig. 4. Application of sandwich materials in Airbus A380 (light yellow color) [7]

Honeycomb core materials are used as: leading edges, trailing edges, flaps, spoilers, cowlings, fuse-
lage, elements inside the plane (floors, ceilings, side panels) [1, 4].
Additionally, in helicopter industry they can be used as the main and tail rotor blades [1, 4].
Like in aviation, in cosmonautic industry, mass is a very important parameter. Because of that
sandwich panels are so popular there. They are used in many vehicles as flaps, external panels of the
body, leading edges, radar covers, in telescopes, drones, antennas, space stations [1, 4].
Sandwich materials are widely used in marine industry, for example in boats, ships, yachts, motor-
boats building or as elements of docks in marinas. They are usually used in interiors of ships as a hull,
hatches, claps, platforms, etc. [1, 4, 8].
10 ARNOLD JĘDRAL

The wide use of these materials has made them very common in everyday life. Nowadays sandwich
materials play a very important role in many industries and everyday life. Of all the above mentioned
types of cores, honeycombs are the most commonly and widely used.

2. SANDWICH MATERIALS TEST METHODS

To be sure that composite material meets the expectations, it has to be thoroughly investigated
before it is certified. Every material has its specific properties and on the basis of them, it is designed
to work in different environments. Sandwich materials test methods are based on two main categories:
mechanical tests and physicochemical tests.
Nowadays, many standards exist that describe how to evaluate properties of composite materials.
It can be American Section of the International Association for Testing Materials standards (ASTM),
international standards (ISO), United States military standards (MIL-STD), aerospace material
standards (AMS) and own standards of the biggest production companies such as: Boeing (BMS),
McDonnell Douglas (MMS) etc. [9-12]. Each of those standards leads to achieving comparable val-
ues of a measured unit. To unify the content of the paper, all described test methods will be based on
ASTM standards.

2.1. Physicochemical properties of honeycomb

Properties of bare core strongly correspond with properties of the whole sandwich structure. Be-
cause of that it is important to test its properties in the first place and then properties of core and skins.
Physicochemical tests refer mainly to cores.

2.1.1. Core density

Honeycomb producers treat core density test as a basic control tool after production. Frequently,
mechanical properties of honeycomb cores are proportional to their density. According to American
standards, core density can be evaluated using ASTM C271 [13].
This test is not complicated and do not require any special devices. Tests should be performed
under sterile condition at room temperature. According to ASTM standard, minimal dimensions of
the sample are 300 × 300 mm, although others are also acceptable. Height of the sample can be the
same as honeycomb sheet from which it was cut. Before measurements, samples has to be dry in case
to decrease to minimum environmental factors such as humidity. Drying in 50°C for 2h is adequate to
make them dry. Measurement of thickness, width and length shall be performed using caliper and mi-
crometer. Next step is to weigh the sample. Core density can be calculated by putting all the measured
dimensions into equation (1):

1000000 (1)
=

where: d – density [kg/m3], W – weight [g], l – length [mm], w – width [mm], t – thickness [mm].
 REVIEW OF TESTING METHODS DEDICATED FOR SANDWICH STRUCTURES… 11

According to this test, it is possible to define density of newly manufactured materials or check
authenticity of data from producers in case of whatever suspicions about some defects may arise.
After measurements, it is possible to use the same samples to check cell size, thickness of the wall
and node. Those are additional information that could be useful in properties comparison of the same
type of materials.
Assuming constant cell size, honeycomb with density around 40 kg/m3 will have compression
strength around 1.5 MPa and honeycomb with 72 kg/m3 density – 4 MPa compression strength, which
means the higher density has honeycomb the higher strength it will has.

2.1.2. Water absorption

Water inside sandwich materials is highly undesirable. It causes decrease in strength, Young mod-
ulus, change dielectric constant, etc. As a result, all sandwich structures are designed and made in such
a way so as to collect minimum of water inside the cells and to gain minimum amount through the
skin. Water absorption can be determined according to ASTM C272 [14].
Testing samples have the dimensions of 75 × 7 × 12.5 mm. The first step is to dry and then weigh
them with the highest possible accuracy. The next step is humidity treatment. According to ASTM
C272 evaluation of water absorption can be achieved in three ways.
The first method is to dip the sample in distilled or deionized water at 23 ± 3°C for 24 h. After that
time take off the sample from water, shake it (sometime water will remain in cells - especially if they
have a small size), wipe off of dripping water and weigh it.
The second method is to place a sample in a humid environment for 30 days. It can be an environ-
mental chamber with, for example, 70 ± 3°C and 85 ± 5% humidity. After 30 days, take off the sample
from the chamber and weigh it.
The third method is to dip a sample in water at 23 ± 3°C for 48 h. After that time, take it out
of water, shake it, wipe it off, dip in isopropyl alcohol, take it out of alcohol, shake again, wait until
alcohol evaporates and finally weigh it. Then, dip the sample again in water for 48 h and repeat all the
above steps until gain in weight will be less than 2% between consecutive weightings.
Water absorption can be calculated according to equation (2):

%= × 100 (2)

where: W – weight of the sample after dipping in water / placing in environmental chamber, D – weight
of dry sample.

2.1.3. Water migration

Presence of water in sandwich structures was mentioned in the previous chapter. But sometimes it
happened that water remained inside the structure. The aim of water migration test is to determine how
easily water can get inside the material. To determine water absorption in honeycomb core structures,
ASTM F1645 standard is useful [15].
Samples for water absorption test have the dimensions of 127 × 127 × 12.7 mm (core) and thin
skins of around 2 mm. A sample structure is made with honeycomb core, transparent skins (for example,
12 ARNOLD JĘDRAL

PMMA) and a layer of adhesive between skin and core. Skins should be transparent but that is not nec-
essary. That kind of skins will make observation of migrating water much easier. Adding pigment into
water will additionally increase water observations. The only requirement for the adhesive to which the
materials are combined is its resistance to water.
At the beginning of the test, a small hole in one of the skins should be drilled through the thick-
ness. The diameter of the hole should not be bigger than honeycomb cell diameter. Drilling has to
be done very precisely so as not to break cell walls. Destroyed walls will cause easier water migration
inside the sample. This hole should be placed in the center of the sample. The next step is to define the
amount of water needed to fill one cell. To do that it is necessary to weigh the sample before filling one
cell with water and then weigh it with distilled water. The last step is connection sample with burette
containing water. This connection will provide constant source of water going into the sample during
test. A source of water should be at a height of 1 m approximately (Fig. 4). The place where burette
touches the hole can be filled with adhesive or rubber to prevent water from leaking out. Leave pre-
pared setup for 24 h in room temperature. After that time, check water transfused into the sample by
weighing the sample or reading from burette scale [1, 15].

Fig. 5. Water migration test according to ASTM F1645 [AJ, 2017]2.1.4. Thermal conductivity of honeycomb

Thermal conductivity is an important property of honeycomb materials. Depending on the ma-

terial application, it is required to be an insulator or a conductor. When high conductivity is required
in the structure then metal honeycombs (aluminum, steel) are preferred. When low – nonmetallic
materials (Nomex, Kevlar, glass fiber, plastics). How to measure honeycomb thermal conductivity is
described by C518 ASTM standard [16].
Thermal conductivity test consists on measurement of heat flow through the sample. Sample need
to be placed between two metal plates which one of them is hot and another one is cold (Fig. 5). Before
the test samples need to be dry. During the test, heat moves from the hot plate to the cold one through
the sample. Thermal conductivity is calculated according to formula (3):

= (3)

where: kHC – honeycomb thermal conductivity, kT – measured thermal conductivity, tHC – core thickness,
tT –sample thickness.
 REVIEW OF TESTING METHODS DEDICATED FOR SANDWICH STRUCTURES… 13

Fig. 6. Scheme of thermal conductivity test [1]

For nonmetallic honeycombs thermal conductivity depends mostly on cell size and for metallic
honeycombs on density [1].

2.1.5. Corrosion resistance of honeycomb

Structures made from nonmetallic honeycombs do not corrode. An opposite situation takes place when
honeycomb is made from metal. To investigate influence of corrosion mass loss of sample that is exposed to
corrosive environment has to be evaluated. ASTM B117 standard is dedicated to do this test [17].
The test consists on placing samples in a special chamber where they are subjected to a corrosive en-
vironment. Usually, it happens due to an action of fumes of dissolved sodium chloride in water. Solu-
tion used for the experiment should have pH in a range of 6.5-7.2. A sample with the dimensions of
127 × 152 × 15.9 mm is placed in a chamber for at least 48 h (before that, a sample has to be weighed)
at 35 ± 2°C. After that time, the sample is taken out of the chamber and weighed. Weight loss less than
1.345 g/m2 is considered as a positive result for aluminum honeycomb.

2.2. Mechanical properties of honeycomb

Mechanical properties are the most important properties of materials used in any construction.
Based on them it is possible to find an adequate application of the material.
Sandwich structures with honeycomb core are anisotropic. This applies mainly to a core which
presents different properties in L and W direction (Fig. 6).

Fig. 7. Honeycomb structure [5]

14 ARNOLD JĘDRAL

Because of that, some properties (shear strength and tensile strength) are tested in both directions.
Due to the fact that during production, cells in W direction are bonded by the adhesive (see node bonds
in Fig. 6), strength here is lower than in L direction.

2.2.1. Shear strength of honeycomb

Shear strength is one of the most important properties for honeycombs. It provides information
about the maximum shear strength and shear modulus (Kirchhoff modulus). Those properties are ex-
tremely important during design of elements made by sandwich materials.
The test can be carried out in accordance with ASTM C273 in two variants [18]. The first one is
shear strength obtained by compression of the core, the second one by tension. In both cases, samples
have the same dimensions, the way of loading the sample differs. It is possible to test only cores them-
selves or cores with skins (sandwich structures).
Samples with the width of not less than 50 mm and the length of not less than 12 times in thick-
ness (usually 12.7 mm), have to be bonded to metal plates, through which shear loads are carried out.
Depending on core orientation, it is possible to obtain shear strength in L or W direction. An impor-
tant thing is to load a sample in such a way that stress axis passes from one corner to another, diagonally
opposite (Fig. 7).

Fig. 8. Loading modes according to ASTM C273 [18]

According to ASTM C393, shear strength can be obtained in one more way [19]. This method
based on three or four-point bending test. It is suitable for dense cores (above 160 kg/m3) [1]. Hon-
eycomb with the dimensions of 76 × 203 × 12.7 mm is bonded to aluminum skins (composite skins
are also suitable), then during the test bending occurs which causes local shear load inside the sample.
In three-point bending mode, support spacing should be 152 mm. Additionally between the sample
and the support, a rubber pad has to be placed to prevent the local sample from crushing. This method
 REVIEW OF TESTING METHODS DEDICATED FOR SANDWICH STRUCTURES… 15

is much more suitable for the whole sandwich structures (core + skin) than bare cores. To determine
shear strength of honeycomb from this method it is necessary to know stiffness of skins material which
is not easy.

2.2.2. Tensile strength (flatwise tensile test)

The test should be carried out in accordance with ASTM C297 [20]. Bare honeycombs (without
skins) or sandwich structure can be tested. In accordance with ASTM standard, a sample should have
the dimensions of 12.7 × 50.8 × 50.8 millimeters. In the first order, a sample has to be bonded to metal
blocks through which tensile loads are transferred into the sample. Surface preparation is of great im-
portance. When bare honeycomb is tested, its surface does not need any special treatment. Cleaning
with dry cloth should be sufficient. Honeycomb with skins can be prepared in two ways. The first one
is hand grinding with sandpaper. The second is sandblasting. Sandblasting needs different pressure
in different materials. For example, when skin is made by carbon fiber composite, 3 bars should be
satisfactory. When skins is metal (aluminum or steel) it should be about 6-7 bars. After grinding or
sandblasting surface should be cleaned by acetone to remove remaining material. It is important to
have good quality adhesive between blocks and a sample because without that, it will be impossible
to destroy the sample. An example of a sample in testing fixture is shown in Figure 8.

Fig. 9. Sample in testing fixture [AJ, 2017]

There are 4 types of failure in flatwise tensile test: core failure, adhesive failure of core-facing adhe-
sive, cohesive failure of core-facing adhesive and skin failure. Adhesive failure occurs when adhesive re-
mains only on one bonded surface. It can mean wrong surface preparation. Cohesive failure takes place
when adhesive remains on both bonded surfaces, it means that during test maximum tensile strength
of adhesive have been achieved. Skin failure occurs when maximum tensile strength of skin have been
achieved. In general, the only acceptable failure mode is core failure because only this situation gives
information about core strength.

2.2.3. Tensile strength (node tensile strength)

Node tensile strength test is useful for honeycomb producers. In this test, connection between cells
is determined (see node bond in Fig. 6). According to that test, it can be checked if during honeycomb
processing (cutting, bending, etc.) node bond can be destroyed.
16 ARNOLD JĘDRAL

The test should be carried out in accordance with ASTM C363 [21]. A sample with the dimensions
of 130 × 260 × 12.7 mm is placed in fixture and tensile loads are applied in perpendicular to node
bond direction. The sample is placed in fixture by loosely set pins through honeycomb cell (Fig. 9).
The only acceptable failure mode is when node bond between cells is destroyed. Node tensile strength
is calculated as a force to cross-section area ratio.

Fig. 10. Sample during test according to ASTM C363 [21]

2.2.4. Edgewise compressive strength

Edgewise compressive test is dedicated mostly for sandwich panels, rather than for bare honey-
combs. During that test, compressive loads are carried out by skins and the role of core is to keep them
together and reduce bending effect. The test should be carried out in accordance with ASTM C364
[22]. Samples usually have the dimensions of 50 × 50 × 12.7 mm. Preparation of side edges of a sample
in this test is very important. They have to be parallel to each other to avoid differences in loads. A sam-
ple is placed in fixture shown in Figure 10 and with fixture, between compressive platens. Edgewise
compressive strength is calculated as the quotient of force and area of both face sheets.

Fig. 11. Sample during test according to ASTM C364 [22]

 REVIEW OF TESTING METHODS DEDICATED FOR SANDWICH STRUCTURES… 17

2.2.5. Compressive strength

Compressive strength is second most important test of honeycomb materials. The tests are carried
out in accordance with ASTM C365 [23]. There are two types of compressive strength tests: bare com-
pression test and stabilized compression test (for sandwich panels).
In the first type, samples have the dimensions of 76.2 × 76.2 × 15.9 mm for aluminum core or
12.7 mm for nonmetallic core. A sample is placed between metal plates and compressed with a loading
speed of 0.5 mm/min (Fig. 11). In the second type samples have aluminum skin bonded to core. Skin
should have thickness in a range of 0.5-1 mm. Skins provide better maintain core cells in the same
position during compression and thus more accurate compressive strength of honeycomb. In this test it
is possible to determine honeycomb compressive strength and compressive modulus if suitable devices
were used (extensometers or deflectometers).

Fig. 12. Sample during test according to ASTM C365 [AJ, 2017]

2.2.6. Fatigue shear strength

Fatigue shear strength according to ASTM C394 [24] is an extension of ASTM C273. During
this, a test sample undergoes a cyclic shear load simulating the fatigue strength of the material. Sample
dimensions and test fixture is the same as in ASTM C273. An important thing is that while in the shear
test bare honeycomb can be tested or honeycomb with skins, in fatigue test sample cannot have skins.
It has to be directly attached to metal plates.
During the test, a sample is subjected to a shear load for a specified number of cycles. The result is
the maximum force at which failure occurs and the number of cycles after which this happened.

CONCLUSIONS
Based on a review of honeycomb test methods, the following conclusions were made:
1. Honeycomb core structures are well known nowadays and played important role in human life.
2. Because of high strength to mass and stiffness to mass ratios, honeycomb core materials are used
in many industries (aeronautic, cosmic, military, transportation, sports, marine).
3. In aviation they mostly are used as a material in secondary structures such as floor and wall panels,
trailing edges, flaps, spoilers and cowlings.
18 ARNOLD JĘDRAL

4. Over the years honeycomb core structures have become more and more important in aviation
industry so they started to be used in primary structures, helicopter rotor blades for example.
5. Sandwich panel structures can be divided into two groups: materials with artificial core (foams or
honeycombs structure) and materials with natural core (balsa wood, cork, etc.).
6. Among the honeycomb structures, materials with artificial origin are most often used (glass fiber,
aramid fiber, aluminum alloys) due to low cost and high mechanical properties.
7. Honeycomb market is fast and still growing market which is expected to get $383.3 million in
next few years and register a CAGR (compound annual growth rate) of 9.6% between 2016-2021
(for Nomex honeycomb materials).
8. There are many normalization organizations (i.e. ASTM, ISO, MIL-STD, AMS, BMS) which
define quality requirements for sandwich materials.
9. Design of structures with honeycomb core materials, requires determination of their physico-
chemical and mechanical properties.
10. From a mechanical point of view, sandwich structure materials can be compared to I-beam where
sheets play the role of flanges and core is a web.
11. Due to the structure, these materials are anisotropic and have different properties in different di-
rections, shear strength in W direction is almost twice lower than in L direction (e.g. Nomex has
1.25 MPa in L direction and 0.6 MPa in W direction).
12. Physical and chemical properties which have to be consider in design stage of component are:
water migration, material density, cell size, thermal conductivity.
13. Mechanical properties include: compressive strength, shear strength (in two directions), node
tensile strength, flatwise tensile strength, edge compressive strength and fatigue tests.
14. Mechanical strength of these materials depends on three parameters: type of material, cell size,
material density (number of fibers and resin).
14.1. Strength of honeycomb becomes higher with higher density – for honeycomb with 40 kg/m3 density,
compressive strength is 1.5 MPa, and for honeycomb with 72 kg/m3 density – 4 MPa shear strength.
14.2. Strength of honeycomb becomes smaller with a larger cell size – for honeycomb with 3.2 mm
cell size, shear strength in L direction reached 1.9 MPa, and for 4.8 mm cell size – 1.6 MPa
shear strength.
14.3. Different strength resulting from the type of honeycomb material: Nomex – 5.1 MPa shear
strength, aluminum – 4.96 MPa, PC – 2.2 MPa.

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20 ARNOLD JĘDRAL

PRZEGLĄD METOD BADAWCZYCH

DEDYKOWANYCH MATERIAŁOM PRZEKŁADKOWYM
Z WYPEŁNIACZEM TYPU HONEYCOMB

Streszczenie
Niniejszy artykuł jest przeglądem metod badawczych przeznaczonych do charakteryzacji materia-
łów przekładkowych z wypełniaczem typu plaster miodu (honeycomb). Na wstępnie zawarto informacje
o budowie materiałów przekładkowych, ich właściwościach, podziale ze względu na rodzaj materiału
wypełniacza, a także zastosowaniu w różnych gałęziach przemysłu. Porównane zostały właściwości wy-
trzymałościowe tych struktur w zależności od rodzaju materiału wypełniacza. W dalszej części wymie-
nione zostały metody badawcze potrzebne do charakteryzacji materiałów typu honeycomb oraz organiza-
cje normalizacyjne określające te metody. Zostały one podzielone na dwie kategorie: metody określające
właściwości mechaniczne oraz właściwości fizyczno-chemiczne. Do właściwości mechanicznych należą:
wytrzymałość na ściskanie (dwa rodzaje), ściskanie krawędziowe, ścinanie (w dwóch kierunkach) oraz
rozciąganie (dwa rodzaje). Do właściwości fizyczno-chemicznych należą: gęstość materiału, absorpcja
wody, migracja wody, a także przewodnictwo cieplne. Metody badawcze zostały opisane w oparciu
o normy ASTM (American Society for Testing and Materials). Przedstawione informacje opierają się
na literaturze fachowej oraz na doświadczeniu autora.

Słowa kluczowe: właściwości mechaniczne, materiały przekładkowe, honeycomb, Kevlar, Nomex.