Aerospace & aviation

The increasing replacement of conventional metal structures with composites, and particularly carbon fiber reinforced plastic (CFRP), has been an ongoing trend in airplane and helicopter engineering for years. In the area of high performance fiber composites, sandwich structures are the preferred choice for light yet stiff designs.

The selection of the optimal sandwich structure is usually based on the different conditions associated with load-bearing capacity, production, and component design. The aerospace industry has long made use of ROHACELL® as a lightweight, structural core material that also reduces the cost of sandwich materials because of its processing reliability.

CRITERIA FOR THE MOST SUITABLE DESIGN

The aircraft industry is facing new challenges relating to production and maintenance costs. Evonik’s high-performance lightweight foam core ROHACELL® enables to reach your target. Before working with ROHACELL® the most suitable design has to be using the following the criteria: Mechanical stresses from service, Desired component geometry (e.g., to generate aerodynamic surfaces), Level of subassembly integration, and Selected curing conditions and, manufacturing process.

As an example, helicopter rotor blades are increasingly produced from sandwich composite materials. In this case, the ROHACELL® core assists with the placement of the UD-fibers and fabrics at the lay-up. With the defined oversize of the core the elastic behaviour and the thermal expansion will generate an in mold-pressure. It will consolidate the single layers when resin flow is starting. In the service the core stabilizes the blade skins and spar from local buckling. ROHACELL® matches up the performance and the good fatigue behaviour of the used composites material.

SANDWICH DESIGNS PREFERRED IN THE AIRPLANE AND HELICOPTER CONSTRUCTION

 

CONSTRUCTION CONCEPTRIGIDITYWEIGHTLAYUP COSTJOINTING COST
Full Sandwich Design+++++++
Skin Sandwich++++0
Profile Reinforcement++0+

++ Very Good | + Good | 0 Satisfactory

COST-EFFECTIVE MANUFACTURE OF HIGHLY INTEGRAL STRUCTURES ROHACELL allows the cost effective production of highly integral structures. The savings in subsequent phases, such as assembly, component testing (NDI), and coating, can be considerable. As an example, the surface quality of a foam sandwich structure (without the telegraphing effects that occur with honeycomb cores) can result in significant savings in the surface preparation for coating. The various grades of ROHACELL , such as WF, RIST, RIMA, and HERO offer optimized cell sizes for resin absorption, both in pre-preg processing and for resin infusion. The PMI foam is able to withstand the typical curing temperatures of 180° C used in the aerospace industry up to compressions of 10 bar (depending on density) without significant creep. The high-temperature resistance of the material ensures that the curing pressure remains stable even in the presence of possible exothermal reactions, which guarantees the highest laminate quality. This results in reduced waste and stable processes that allow for efficient and streamlined component production.

Grades used in this industry

FAQs

The majority of grades of Rohacell are with us ready to be processed, including IG, IG-F, HF, WF, RIMA & XT. We are very pleased to say we have the capability in most cases to offer next day delivery anywhere in the UK as standard.

Only a few niche grades are not held in stock and will be subject to a MOQ and lead time, but we will make you aware of this at the point of your order; we will always listen to your applications and help with alternate suggestions if you require material quickly and we don’t have it in stock.

With the highly popular and widely used grades IG, IG-F & HF, no order is too small! Other grades may be subject to a MOQ and this can vary depending on the grade. Please get in touch and we will gladly take time to discuss your exact requirements and tailor your purchase for you.

We are very proud of our state of the art factory, especially after our recent expansion and we have a number of machines that will cut and prepare Rohacell along with the skilled hands of our staff. Our plant includes a Horizontal Band Saw, Sanding Plant, Circular Saw & Laser Machine. This technology allows us to engineer Rohacell to within a guaranteed +/-0.5mm tolerance, or better still, +/-0.2mm on request. With our Laser machine, we can cut complex 2D shapes with minimal waste material.

Anything you require, on request. Our cutting plant means that we can machine Rohacell to any length, width and thickness within our largest sheet sizes of 2500mm x 1250mm as well as oversized 2600mm x 1300mm on request. Maximum dimensions & thickness can depend on the grade, so ask our advice. If you need a specific sized sheet with a thickness not listed, let us know and we will accommodate for you.

Beyond our ISO Standards, Industry and Quality Assurance certifications, our continued success if built on our core business values of delivering market leading products coupled with first class customer care, from our team of dedicated and passionate individuals. We take time to listen to your needs, however big or small those are and work hard to maintain a rapport with our clients. Our facilities in Norwich mean we can cater for purchases from all over the world. We are impartial, independent and confidential; we are Emkay.

Get in touch with us on the number or email at the top of our webpage. In office hours, we have a friendly team at the end of the phone who have a vast combined expertise with Rohacell and if we don’t know the answer, we will know where to find it for you! We will talk you through the order, payment and delivery process so that you stay fully in the loop.