The effect of X-core foam processing on surface defects in carbon fibre/epoxy sandwich composites

Redefining sandwich manufacturing with X-core

Master thesis (2017)

Authors

D.O. Berckmoes Aerospace Engineering

Contributors

J. Sinke (supervisor 1)
O.K. Bergsma (supervisor 2)
J.C. Bijleveld (supervisor 2)
R. Grooten (supervisor 2)
Faculty
Aerospace Engineering
Copyright: © 2017 Dennis Berckmoes
Process guidelines Sandwich structures X-Core Carbon-Epoxy Surface porosity
More Info
expand_more

Published Date

18-07-2017

Language

English

Reuse Rights

Other than for strictly personal use, it is not permitted to download, forward or distribute the text or part of it, without the consent of the author(s) and/or copyright holder(s), unless the work is under an open content license such as Creative Commons.

Faculty

Aerospace Engineering

Abstract

X-core is a novel foam core material developed by Donkervoort Automobielen, it enables a unique one-shot process for seamless composite sandwich structures with mould-defined features all-around. The foam is co-cured to carbon fibre/epoxy prepregs, in this form the process is currently used to make car components for the Donkervoort D8 GTO RS. One of the main challenges that is faced in the manufacture of these ‘bare carbon’ components is the visible presence of surface defects. In this research a variety of process variables are primarily correlated to the surface porosity content of the laminate. Processing guidelines pertaining to the cure cycle, core material composition, moulding and type of prepreg are formulated based on these relations. The main causes for surface porosity are identified and it is found that the process is especially sensitive to the laminate composition: Variations in stacking sequence and fibre aerial weight.