Nomex vs. aluminum honeycomb

1.Aluminum Honeycomb - Rigidity and Strength

Aluminum is a naturally occurring element that was discovered in the 1800s; nevertheless, it was not produced as foil until the 1900s, when a Swiss company realized that aluminum foil could be used as a protective barrier and was suited for packaging. In the 1940s, Britain pioneered aluminum bonding technology for aircraft construction, while the Americans developed the sandwich formation for their aircraft, which used an aluminum honeycomb structure within the panels. Aluminum honeycomb has been employed in panels for construction, rail, automotive, and marine applications since then. The following are the primary benefits of aluminum honeycomb:

• High strength-to-weight ratio

• Corrosion resistant

• Elevated temperature performance

• Fire and fungus resistant

• Will not absorb moisture

• Can be machined and formed

Scientists have continued to increase materials' strength-to-weight ratios for high-performance applications; man-made composites have been developed to fulfill market demands while also improving the capabilities of naturally occurring materials.

2.Nomex® is a thermally resistant, lightweight, and formable material

In the 1960s, the American chemical and pharmaceutical conglomerate DuPont sought a nylon fiber with thermal resistance capabilities that would not melt, drip, or support combustion in the air. This ground-breaking flame-resistant meta-aramid material was ideal for fire-resistant clothing for emergency personnel and was widely adopted around the world. When exposed to severe heat, the fibers react and their properties alter; heat is retained in the fabric, providing the wearer with additional seconds of heat transfer protection. Nomex® is utilized by firefighters, military pilots, combat vehicle crews, industrial employees exposed to flash fire and electric arc risks, racing drivers, and even Neil Armstrong on his first trip to the moon! It comes in paper, felt, fabric, and fiber forms.

Motors, generators, transformers, and other electrical manufacturers employ Nomex® fibers for electrical insulation in several industries, including asphalt and cement facilities, as well as chemical and steel companies.

Both types are available in honeycomb form in industrial and aerospace grades.

Nomex® honeycomb paper is utilized for lightweight structural support and aids in the performance of vehicles that use it, particularly aircraft and racing cars. Click here for Lightweight Honeycomb Panels. It has a high strength-to-weight ratio and is resistant to corrosion, fungus, and mold, just as aluminum honeycomb, but it also offers the following advantages:

• Flame retardancy

• Good thermal insulation

• Formable for 3-D shapes

3.When to use aluminum honeycomb vs. Nomex®?

Because Nomex® is slightly more expensive than the aluminum honeycomb, it is typically used where increased thermal resistance and formability are required. These additional costs are mostly the result of a slightly more sophisticated production process, more waste, and more expensive certification, particularly for aerospace grades.

Both types of honeycomb have similar properties, but each has a distinct advantage; Nomex® is 20% lighter than aluminum honeycomb and can be fitted to 3D shapes and curved surfaces more easily. It can also be shaped, molded, stabilized, and spliced to other Nomex slices of varying cell sizes to produce a variety of strength solutions. Aluminum honeycomb has stronger strength and rigidity than steel honeycomb and is thus better suited for places that may sustain impact or require energy absorption. Julong Honeycomb also produces SuperFlex, a flexible aluminum honeycomb that can fit curved surfaces and 3D shapes.

Depending on the specific performance required, a blend of both forms of honeycomb is utilized at times. For example, in a Formula 1 car, the nose cone and chassis would be made of aluminum honeycomb for impact durability, while the body panels and fin would be made of Nomex® for its low weight advantage.

Nomex® honeycomb is utilized in aircraft parts such as wings, doors, flooring panels, interior walls, helicopter blades, and tail booms; it is also used in boat building to generate buoyancy, which increases speed. Typically, Nomex® honeycomb is sandwiched between two layers of carbon fiber sheet or comparable material.

Aluminum and Nomex® honeycomb are both appropriate for a wide range of applications, and Julong Honeycomb stocks both. Contact us to determine which is best for your needs.