Relating Process Parameters to X-Core Properties through Experimental Testing and Modelling

Abstract

Besides building ultra-lightweight sportscars, Donkervoort Automobielen B.V. is developing a novel core material to be applied in complex shaped composite sandwich structures. This material goes by the name of X-Core and has the unique capability of generating the pressure required for facesheet consolidation, enabling a one-shot manufacturing process for the first time. The present research has focused on the phenomena present during the manufacturing process of the foam. In-situ temperature measurements have been carried out to gain a deeper understanding of the thermal behaviour of the material. A numerical model, based on a transient finite difference method, was then constructed to predict the temperature distribution in the material during its cure under different processing conditions, material compositions and cure cycles. The proposed model can now be applied in fine-tuning cure-cycles required to attain certain desirable X-Core properties.