Aluminum Honeycomb Panels Manufacturing Process: A Comprehensive Guide

Introduction

Aluminum honeycomb panels are a marvel of engineering and material science, combining lightweight properties with exceptional strength and stiffness. These panels consist of an aluminum honeycomb core sandwiched between two aluminum skins, providing a very strong structure per unit weight. This unique composition not only provides excellent durability, but also excellent thermal insulation, resistance to environmental factors, and acoustic performance.

The manufacturing process of aluminum honeycomb panels involves multiple detailed and precise steps. From the surface pretreatment of the aluminum panels to the final pressurization and curing stages, each stage is important to ensure the integrity and functionality of the finished product. This guide will take an in-depth look at the steps of aluminum honeycomb panel production, fully introducing the technology and processes used to manufacture these innovative panels, so that you can understand the aluminum honeycomb panel manufacturing process in detail, so as to produce high-quality panels suitable for a variety of demanding applications.

What Are Aluminium Honeycomb Panels

Aluminum honeycomb panels are composite panels consisting of a honeycomb core made of aluminum and sandwiched between two aluminum sheets. The panel’s core is the primary source of its strength and rigidity, while the outer aluminum sheets protect and stabilize the core, making the panel very strong yet lightweight.

The unique design of aluminum honeycomb panels enables them to withstand tremendous loads and pressures, while their lightness helps improve fuel efficiency when used in vehicles and aircraft. In addition, aluminum honeycomb panels are highly resistant to moisture, corrosion, and temperature, making them suitable for harsh or outdoor environments.

Aluminum honeycomb panels also come in a variety of thicknesses, depending on the application required, making them versatile.

The Aluminium Honeycomb Panels Manufacturing Process

➊ Surface Pretreatment Of The Board

A—Before any further processing, the surface of the aluminum sheet must be cleaned with a specialized solvent to remove any contaminants that may interfere with the adhesive during the lamination process, and the surface of the sheet must be completely dry and clean. This includes removing dust, oil and any oxide layer that may have formed. It should be noted that hydroxyl-containing solvents such as water and alcohol should never be used for cleaning, as they may leave residues that react with aluminum.

B—After cleaning, the next step is grinding (if the aluminum has a pre-treatment coating, this process is exempted). If the aluminum does not have a pre-treatment coating, the aluminum surface must be ground to form a slightly rough texture. This can increase the contact area to form a more effective bond with the adhesive and enhance the mechanical adhesion during the lamination process. However, careful grinding must be done to ensure that the entire surface of the aluminum plate is uniform and a consistent texture is achieved. This careful balance between cleanliness and texture helps achieve the strong, reliable and durable bonding required for high-quality aluminum honeycomb panels.

➋ Pretreatment Of Honeycomb Core

A—After unpacking the aluminum honeycomb core, first check whether the honeycomb core is damaged (such as dents or deformation) to ensure that there are no defects in the honeycomb core before proceeding to the next step.

B—After ensuring that the core material is intact, the next step is to handle and store it before lamination. This stage is critical to maintaining the shape and structural properties of the core material.
The core material is placed on a clean, flat surface to avoid any excessive stress that could cause deformation. Keeping the core material flat is not only to maintain its shape; it is also to ensure that when laminated with aluminum sheets, the bond is consistent and strong across the panel.

➌ Adhesive Preparation

A—The first step in preparing an aluminum honeycomb adhesive is to accurately measure the ingredients. The base A (hydroxyl component) and curing agent B (component with free isocyanate groups) must be measured using a specific weight ratio of 4:1. Measurements must be precise to ensure optimal chemical reaction and final bond strength. It is recommended to use an electronic scale, ideally with an accuracy of at least 10 grams, to correctly measure these ingredients.

B—Before combining it with the curing agent, the main agent A should be thoroughly stirred. Ensures any settled particles are evenly distributed throughout the mixture

C—After the base and curing agent are dosed, they need to be mixed and stirred thoroughly. Make sure every part of the mixture (including the part sticking to the sides and bottom of the container) is mixed evenly.

D—When applying adhesive, it is recommended to apply 300-400 grams per square meter per side. Ensure adequate coverage without overdosing.

E—After the glue is prepared, it should be used within its working time, which is generally about 20 minutes. This window is critical because beyond this period, the glue may start to set or cure, which can compromise its effectiveness in bonding the aluminum sheets to the honeycomb core. Keeping track of time from mixing to application ensures that the glue’s properties are optimal for creating a strong, durable bond.

➍ Coating

A—When applying glue, the adhesive must be evenly applied to the surface of the aluminum plate. If it is not evenly applied, it will lead to weak spots, and the bond between the honeycomb core and the aluminum plate may fail under pressure. Therefore, it is recommended to use a scraper with uniform teeth.

B—Also, make sure the amount of glue applied is consistent on both sides of the aluminum panel. This is because it will affect how well the panel bonds to the honeycomb core. Uneven distribution can cause one side to bond better than the other, which can cause the panel to warp or delaminate over time.

➎ Lamination

First align the aluminum sheet with the honeycomb core. The edges of the aluminum sheet should perfectly match the edges of the honeycomb core. Once aligned, apply even pressure to laminate the aluminum sheet to the honeycomb core. Once the aluminum sheet or core material is in contact, avoid pulling or moving them. Failure to adjust repeatedly will cause uneven spots in the bond layer, resulting in potential delamination or weak points within the panel.

➏ Pressurization

A—Once adhesive components A and B are mixed, they must be pressurized within 60 minutes. This time frame is based on a temperature of 25°C or lower. Other special circumstances can be discussed on a case-by-case basis.

B—During the lamination process, typically, the pressure should be in the range of 2 to 5 tons per square meter. This ensures a strong, even bond without damaging the delicate internal structure of the honeycomb core.

C—The pressurization process begins and the pressure must be maintained continuously. Do not adjust the pressure too early or

D.—In order to obtain better results during the pressurization process, it is recommended to stack a 22mm thick flat and heavy medium density fiberboard for every 5 aluminum honeycomb panels. This will help to bond more evenly.

➐ Pressure Relief

A—Under standard conditions, at a temperature of 20-25°C, pressurization should be maintained for approximately 5 hours. However, in a colder working environment, the pressurization time should be extended for an additional 2 hours. This adjustment compensates for the slower reaction rate of the adhesive at lower temperatures, ensuring that the glue sets effectively.

B—After pressure is released, it is recommended to wait at least 24 hours before proceeding to the next step, such as cutting or trimming the panel.

C—After the pressure is released, the panel is removed and the MDF and press table should be cleaned of any residual adhesive (commonly known as "rubber") that was squeezed out during the pressure application process.

➑ Performance Test

After the aluminum honeycomb panel is depressurized and taken out, it needs to continue to cure for 5-7 days (7-10 days in winter when the temperature is low) to ensure that the adhesive is completely solidified, so that the strength, high temperature resistance, acid and alkali resistance and other performance indicators reach the maximum value.

After the curing period, the panels are ready for performance testing. For example:

• Strength testing: This includes load-bearing assessments to measure the weight the panels can support.
• High temperature testing: Panels are exposed to high temperatures to ensure they do not degrade or lose structural integrity.
• Acid and alkali testing: Panels are checked for durability when exposed to chemically aggressive environments.

Ensure these tests confirm suitability for a variety of applications, especially in areas where environmental conditions may be extreme or the panels need to withstand significant loads.

Properties Of Aluminum Honeycomb Panels

• Lightweight: The honeycomb core provides an extremely lightweight panel with high strength, providing a light-to-weight ratio for the structure.

• Rigidity: Aluminum honeycomb panels are very strong and are able to support considerable loads without bending or warping.

• Excellent thermal efficiency: The hexagonal honeycomb core within the panel has insulating properties, keeping heat inside or outside, preventing heat from being transferred through the panel.

• Corrosion resistance: Aluminum honeycomb cores are moisture-resistant, corrosion-resistant, and can withstand harsh weather conditions and environments without deterioration.

• Shock absorption: The unique structure allows them to absorb and dissipate energy from impacts and shocks.

• Thickness and size diversity: No matter the application, aluminum honeycomb panels are available in a variety of thicknesses and sizes to meet the needs.

• Fire resistance: The fire resistance of aluminum honeycomb panels contributes to safer building practices.

• Suitable for sound insulation: These panels are also effective in reducing noise, suitable for use in environments where noise reduction is required.

Applications For Aluminum Honeycomb Panels

Aerospace
In the aerospace industry, aluminum honeycomb panels are widely used in aircraft structures due to their light weight, helping to reduce fuel consumption and increase payload capacity. They are often used in components such as floors, walls, and partitions in aircraft cabins.

Automobile
Aluminum honeycomb panels are part of chassis and body panels. They contribute to overall vehicle lightweighting, increasing speed and efficiency while maintaining safety standards through their impact absorption capabilities.

Buildings
Aluminum honeycomb panels are often used as building exterior and interior decoration materials. Aluminum honeycomb panels are durable and corrosion-resistant. Inside buildings, aluminum honeycomb panels can be used to decorate partitions or ceilings.

Industrial applications
Aluminum honeycomb panels can be used in a variety of industrial environments, including the production of clean rooms and other controlled environments. Aluminum honeycomb panels have excellent thermal insulation properties, which helps maintain the necessary conditions in environments that are sensitive to temperature fluctuations.

Exhibitions and display panels
Aluminum honeycomb panels are easy to handle and have good rigidity. In the exhibition industry, they are used to build lightweight, durable, and easy to assemble and disassemble display stands.

Conclusion

This guide details the manufacturing process of aluminum honeycomb panels, demonstrating the meticulous and rigorous procedures required to produce these multifaceted materials. From initial component preparation and cleaning to finishing and final pressurization and rigorous testing, each step plays a key role in ensuring that the finished product meets the highest quality and performance standards.

Each material in this process must meet specific standards of purity and structural integrity. The adhesive used to bond these elements is equally important, as it needs to withstand a variety of environmental and mechanical stresses after curing.

Each stage of the process not only reflects a commitment to engineering excellence, but also highlights the importance of precision in creating a lightweight and very strong material. As a result, the performance of aluminum honeycomb panels remains a critical component in the industry.

Related references

The Aluminium Honeycomb Manufacturing Process from COREX HONEYCOMB

How Is Aluminium Honeycomb Manufactured?