Tubular composite core stiffens launch vehicle structure
ChamberCore, an alternative to traditional sandwich laminates, also improves vibro-acoustic damping.
By Barry Berenberg, Web Editor/Technical Writer | September 2004
Step 1
Source: Delta Velocity
Core ply patterns (left) are creased against a metal straight edge (right) in preparation for wrapping onto the core mandrels (creased core shown nearest table edge) .
Step 2
Source: Delta Velocity
Splice pieces are wrapped onto the core mandrel at the cylinder/cone junction.
Step 3
Source: Delta Velocity
The core plies are pressed into place on the core mandrels.
Step 4
Source: Delta Velocity
The cores are tightly wrapped by pressing them into a forming tool -- the same tool used to cast the core mandrels.
Step 5
Source: Delta Velocity
Wrapped cores are pressed together in preparation for layup on the fairing.
Step 6
Source: Delta Velocity
The blocks of cores are laid up over the inner facesheet. Release film is temporarily placed under the cores so their positions can be adjusted.
Step 7
Source: Delta Velocity
With the outer facesheet in place, the fairing is ready for bagging and cure.
Step 8
Source: Delta Velocity
After cure, the fairing is trimmed, an access door is cut into the side, and metal rings are bonded onto the ends. An inflatable ball provides bond pressure for the interior rings.
Step 9
Source: Delta Velocity
Cork is applied to the fairing for thermal protection during flight.
