| Honeycomb structural material is stimulated by the mechanical excellences of natural honeycomb, with great advantages in terms of light weight, high strength and specific stiffness (stiffness per unit volume), anti-vibration, thermal- and sound-insulation, etc. Continuous Basalt Fiber (CBF), one of the top four high strength fibers of the world, was used to make pre-fabricated honeycomb composite for high performance and low price products, such as train/ship floor, thermal-insulation, ship hull, military applications.The general objectives are to explore the weave-ability of basalt fiber and produce marketable pre-fabricated honeycomb composites. The specific executive objectives are·To improve the weave-ability of CBF made in China and optimize the recipe (or ingredients) of sizing agent for CBF fabrics.·To produce a three-dimensional honeycomb fabric using a CAD/CAM laboratory machine.·To design a liquid resin, applicable at room temperature and atmospheric pressure.·To manipulate the consolidation process of material composition for ultimate compression property, using statistic orthogonal test.The fiber durability under friction and congregation of individual fibers were significantly improved. A number of typical basalt fabrics, in terms of structure, were manufactured using CAD/CAM weaving machine at laboratory scale, especially three-dimensional honeycomb fabric frame for composition. A carefully designed resin E-51/T31 was made to formulate prefabricated honeycomb composite under room temperature and atmospheric pressure, which is useful for products commercialization in the near future.An optimal prefabricated honeycomb composite is recommended after a series analyses and tests, which gives density 1.25g/cm~3 specific weight per unit volume 0.249g/cm~3 compression strength 19.53MPa, compression modulus 417.92MPa, cell wall compression strength 196.33MPa. cell wall compression modulus 4234.40MPa. |
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