Page 63 - Module DMV20173

3.0 SHEET METAL PROCESSES

3.4.4 MANUFACTURING OF METAL HONEYCOMB STRUCTURES

1. A honeycomb structure consists basically of a core of honeycomb or other
corrugated shapes bonded to two thin outer skins.

2. Fig 4.35 shows the methods of manufacturing honeycomb structures: (a)
expansion process; (b) corrugation process; (c) assembling a honeycomb
structure into a laminate.
3. Because of their light weight and high resistance to bending forces, metal

honeycomb structures are used for aircraft and aerospace components, in
buildings, and in transportation equipment.

Fig 3.35 Methods of manufacturing honeycomb structures: (a) expansion process; (b)
corrugation process; (c) assembling a honeycomb structure into a laminate.

4. In the expansion process, which is the more common method, sheets first are
cut from a coil, and an adhesive is applied at intervals (node lines) on their
surfaces.
5. The corrugation process is similar to the process used in making corrugated

cardboard.
6. The sheet metal first passes through a pair of specially designed rolls, becoming
a corrugated sheet; it is then cut into desired lengths.

BPLK 95 DMV 20173