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

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

Berckmoes, Dennis (TU Delft Aerospace Engineering; TU Delft Aerospace Structures & Materials)

Sinke, J. (mentor)
Bergsma, O.K. (graduation committee)
Bijleveld, J.C. (graduation committee)
Grooten, R. (graduation committee)

Delft University of Technology

Aerospace Engineering

2017-07-18

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.

X-Core
Carbon-Epoxy
Sandwich structures
Surface porosity
Process guidelines

http://resolver.tudelft.nl/uuid:c6600476-9e12-4ccb-9fb8-c24b1b1be3e1

2022-07-18

Student theses

master thesis

© 2017 Dennis Berckmoes