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The purpose of core materials is to separate laminates and to prevent
them buckling under load, I haven't explained that very well. To
bend two thin laminates separate by a few mm, requires considerable
compression on the inner one and extension in the outer one. The
greater the distance between them the greater the compression and/or
extension required. The surfaces must be supported to prevent them
buckling; Aluminum or Nomax honeycomb can be used, or in certain
applications foam does the job quite well. The properties of the
Carbon are utilized in this sort of laminate, excellent tensile
strength and good compressive strength.
The core I use most is blue Styrofoam, polystyrene foam used for
household insulation. For large low stress pieces it appears to
work well the epoxy bonds well to the sanded foam and it is great
for putting webs into a laminate.
I had a lot of offcuts of Nomax honeycomb. Just to see what it
was like, I made a mudguard with 1mm skin and several pieces of
6mm nomax honeycomb were bonded in at high load areas then covered
with an inner laminate of 1 mm carbon fibre. It was quite amazing
you could stand on it when it was bolted to the bike. I will try
and find it, I recovered it after the bike had been crashed, most
of it is intact it is ground through in one place and one of the
sides was broken off.
Core materials are required in moulds to give them rigidity, foam
is good for this. Pieces of foam are used to form webs, which are
laminated over and the result is like a webbed casting, rigidity
with low weight.
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Suppliers
- Composite Wings.
Ali' & Nomax
- Sevenoaks Heating Supplies.
Styrofoam
- Hexcel.
Ali' & Nomax
- Look in yellow pages under Insulation for Styrofoam
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