ECSS E HB 32 22A Insert Design Handbook

ECSS-E-HB-32-22A
20 March 2011
Space engineering
Insert design handbook
ECSS Secretariat
ESA-ESTEC
Requirements & Standards Division
Noordwijk, The Netherlands
ECSSEHB3222A
20March2011
Foreword
ThisHandbookisonedocumentoftheseriesofECSSDocumentsintendedtobeusedassupporting
material for ECSS Standards in space projects and applications. ECSS is a cooperative effort of the
EuropeanSpaceAgency,nationalspaceagenciesandEuropeanindustryassociationsforthepurpose
ofdevelopingandmaintainingcommonstandards.
This handbook has been prepared by the ECSSEHB3222 Working Group, reviewed by the ECSS
ExecutiveSecretariatandapprovedbytheECSSTechnicalAuthority.
Disclaimer
ECSSdoesnotprovideanywarrantywhatsoever,whetherexpressed,implied,orstatutory,including,
butnotlimitedto,anywarrantyofmerchantabilityorfitnessforaparticularpurposeoranywarranty
that the contents of the item are errorfree. In no respect shall ECSS incur any liability for any
damages,including,butnotlimitedto,direct,indirect,special,orconsequentialdamagesarisingout
of,resultingfrom,orinanywayconnectedtotheuseofthisdocument,whetherornotbasedupon
warranty,businessagreement,tort,orotherwise;whetherornotinjurywassustainedbypersonsor
propertyorotherwise;andwhetherornotlosswassustainedfrom,oraroseoutof,theresultsof,the
item,oranyservicesthatmaybeprovidedbyECSS.
Publishedby: ESARequirementsandStandardsDivision
ESTEC,P.O.Box299,
2200AGNoordwijk
TheNetherlands
Copyright: 2011bytheEuropeanSpaceAgencyforthemembersofECSS
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Change log
ECSSEHB3222A Firstissue.
20March2011
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Table of contents
Change log .................................................................................................................3
1 Scope.....................................................................................................................27
2 References ............................................................................................................28
3 Terms, definitions and abbreviated terms..........................................................29
4 Insert system ........................................................................................................66

4.1 Insert systems and components............................................................................... 66
4.1.1 Inserts......................................................................................................... 66
4.1.2 Insert system components.......................................................................... 68
4.1.3 Loading modes ........................................................................................... 69
5 Insert......................................................................................................................70
5.1 General..................................................................................................................... 70
5.2 Types........................................................................................................................ 70
5.2.1 General....................................................................................................... 70
5.2.2 Group A ...................................................................................................... 70
5.2.3 Group B ...................................................................................................... 72
5.2.4 Group C ...................................................................................................... 72
5.2.5 Potting methods.......................................................................................... 73
5.2.6 Injection ...................................................................................................... 73
5.3 Sizes......................................................................................................................... 74
5.3.1 General....................................................................................................... 74
5.3.2 Standards ................................................................................................... 74
5.3.3 Strength ...................................................................................................... 75
5.3.4 Standardised diameters.............................................................................. 76
5.3.5 Standardised heights.................................................................................. 77
5.4 Materials................................................................................................................... 78
5.4.1 General....................................................................................................... 78
5.4.2 Aluminium alloys......................................................................................... 79
5.4.3 Titanium alloys............................................................................................ 79
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5.4.4 Steels.......................................................................................................... 80
5.4.5 Material selection........................................................................................ 80
5.5 Surface protection .................................................................................................... 80
5.5.1 General....................................................................................................... 80
5.5.2 Aluminium alloy .......................................................................................... 81
5.6 References ............................................................................................................... 82
5.6.1 General....................................................................................................... 82
5.6.2 ECSS standards ......................................................................................... 82
6 Sandwich panels ..................................................................................................83

6.1 Sandwich properties................................................................................................. 83
6.1.1 Insert load-bearing capability...................................................................... 83
6.1.2 Sandwich dimensions................................................................................. 84
6.2 Face sheet properties............................................................................................... 84
6.2.1 Tensile and compressive loading ............................................................... 84
6.2.2 Shear loading ............................................................................................. 86
6.2.3 Other loads ................................................................................................. 88
6.3 Core properties......................................................................................................... 89
6.3.1 Types of cores ............................................................................................ 89
6.3.2 Hexagonal core .......................................................................................... 89
6.4 Core shear modulus ................................................................................................. 93
6.4.1 Data sources .............................................................................................. 93
6.5 Core shear strength.................................................................................................. 93
6.5.1 Data sources .............................................................................................. 94
6.6 Core tensile strength ................................................................................................ 94
6.6.1 Data sources .............................................................................................. 94
6.6.2 Aluminium core........................................................................................... 94
6.6.3 Non-metallic cores...................................................................................... 94
6.7 Core compressive strength ...................................................................................... 95
6.8 Core to face sheet bond ........................................................................................... 95
6.9 References ............................................................................................................... 95
7 Embedding of inserts ...........................................................................................96

7.1 Potting compounds................................................................................................... 96
7.1.1 Commercial products.................................................................................. 96
7.1.2 Modification of properties ........................................................................... 98
7.2 Potting and equivalent dimensions........................................................................... 98
7.2.1 Insert load capability................................................................................... 98
7.2.2 Increasing insert tensile capability............................................................ 100
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7.3 Effective potting radius, or equivalent dimension ................................................... 100
7.3.1 Minimum value ......................................................................................... 101
7.3.2 Average value........................................................................................... 101
7.3.3 Relationship of minimum and average values.......................................... 102
7.4 Real potting radius, or equivalent dimension.......................................................... 103
7.4.1 Minimum value ......................................................................................... 103
7.4.2 Average value........................................................................................... 103
7.4.3 Relationship between minimum and average values ............................... 103
7.5 Potting height ......................................................................................................... 104
7.5.1 Full potting ................................................................................................ 104
7.5.2 Partial potting............................................................................................ 105
7.5.3 Minimum value ......................................................................................... 105
7.5.4 Average value........................................................................................... 105
7.5.5 Relationship of minimum and average values.......................................... 105
7.6 Potting mass........................................................................................................... 107
7.6.1 Effect of core and insert characteristics.................................................... 107
7.6.2 Total mass of insert system...................................................................... 109
7.7 References ............................................................................................................. 109
7.7.1 General..................................................................................................... 109
7.7.2 ECSS standards ....................................................................................... 109
8 Mechanics of sandwich structures ...................................................................110

8.1 Structural sandwich concept .................................................................................. 110
8.1.1 Properties of constituent materials ........................................................... 111
8.1.2 Fundamentals of classical antiplane sandwich theory ............................ 112
8.2 Structural failure modes ......................................................................................... 116
8.2.1 Global failure modes................................................................................. 117
8.2.2 Local failure modes .................................................................................. 117
8.3 Load introduction aspects and discontinuities ........................................................ 117
8.3.1 General..................................................................................................... 117
8.3.2 Local bending response ........................................................................... 118
8.3.3 Antiplane-type theory................................................................................ 119
8.3.4 Finite element analysis ............................................................................. 119
8.3.5 Elastic foundation model .......................................................................... 119
8.3.6 Transverse flexibility ................................................................................. 119
8.3.7 Higher-order sandwich beam theory ........................................................ 119
8.4 Sandwich plates with potted inserts ....................................................................... 120
8.4.1 Classification of potted insert types .......................................................... 120
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8.4.2 Load transfer ............................................................................................ 121
8.4.3 External load cases .................................................................................. 121
8.4.4 Example.................................................................................................... 123
8.4.5 Purpose of the potting compound............................................................. 128
8.4.6 Design guidelines ..................................................................................... 128
8.5 Remarks ................................................................................................................. 129
8.5.1 General..................................................................................................... 129
8.5.2 Antiplane theories..................................................................................... 129
8.5.3 Higher-order theories................................................................................ 130
8.5.4 ESAComp ............................................................................................... 130
8.6 References ............................................................................................................. 131
8.6.1 General..................................................................................................... 131
8.6.2 ECSS standards ....................................................................................... 133
9 Design aspects ...................................................................................................134

9.1 Design parameters ................................................................................................. 134
9.1.1 Metal face sheets ..................................................................................... 136
9.1.2 Composite face sheets ............................................................................. 136
9.2 Main load directions ............................................................................................... 137
9.2.1 Out-of-plane load...................................................................................... 137
9.2.2 In-plane load............................................................................................. 138
9.3 References ............................................................................................................. 138
9.3.1 General..................................................................................................... 138
9.3.2 ECSS standards ....................................................................................... 138
10 Design considerations .....................................................................................139

10.1 Insert arrangement ................................................................................................. 139
10.1.1 Load capability.......................................................................................... 140
10.2 Load conditions ...................................................................................................... 141
10.2.1 General..................................................................................................... 141
10.2.2 Design guide............................................................................................. 143
10.3 Mounting modes..................................................................................................... 147
10.3.1 General..................................................................................................... 147
10.3.2 Flush-mounted insert................................................................................ 147
10.3.3 Recessed insert........................................................................................ 147
10.3.4 Protruding insert ....................................................................................... 148
10.3.5 Bonded flange .......................................................................................... 149
10.4 Junction of components ......................................................................................... 149
10.4.1 General..................................................................................................... 149
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10.4.2 Minimum value ......................................................................................... 150
10.5 Adequate insert design........................................................................................... 151
10.5.1 Insert arrangement ................................................................................... 151
10.5.2 Typical spacecraft design ......................................................................... 151
10.5.3 Examples.................................................................................................. 152
10.6 Selection of inserts ................................................................................................. 152
10.6.1 General..................................................................................................... 152
10.6.2 Sufficient static strength ........................................................................... 153
10.6.3 Safety factor ............................................................................................. 154
10.7 Minimum and average insert capability .................................................................. 154
10.7.1 Minimum ................................................................................................... 154
10.7.2 Average .................................................................................................... 155
10.8 Pre-design .............................................................................................................. 155
10.8.1 Load path for in-plane forces.................................................................... 156
10.8.2 Load path for transverse forces................................................................ 158
10.8.3 Transverse and in-plane load interaction ................................................. 159
10.8.4 Proximity and edge effects ....................................................................... 159
10.9 Failure modes......................................................................................................... 159
10.9.1 General..................................................................................................... 159
10.9.2 Failures under out-of-plane loads............................................................. 160
10.9.3 Failures under in-plane loads ................................................................... 165
10.10 References ............................................................................................................. 167
10.10.1 General..................................................................................................... 167
11 Design flow chart..............................................................................................168

11.1 Introduction............................................................................................................. 168
11.2 Flow chart: Predefined sandwich and loads ........................................................... 168
11.3 Flow chart: Variable main parameters.................................................................... 170
11.4 References ............................................................................................................. 171
11.4.1 General..................................................................................................... 171
12 Tensile strength................................................................................................172
12.1 Normal tensile load................................................................................................. 172
12.1.1 General..................................................................................................... 172
12.1.2 Failure modes........................................................................................... 172
12.1.3 Shear rupture: core surrounding the potting............................................. 173
12.1.4 Tensile rupture: core underneath the potting............................................ 174
12.1.5 Tensile rupture: potting underneath the insert.......................................... 175
12.2 Basic parameters ................................................................................................... 175
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12.2.1 Out-of-plane loads: Insert strength ........................................................... 178
12.3 Minimum and average design values ..................................................................... 180
12.3.1 Overview................................................................................................... 180
12.3.2 Minimum insert design values .................................................................. 180
12.3.3 Average insert values ............................................................................... 181
12.4 Safety factors ......................................................................................................... 182
12.4.1 Load capability.......................................................................................... 182
12.4.2 Failure modes........................................................................................... 183
12.5 Permissible tensile loads ........................................................................................ 183
12.5.1 General..................................................................................................... 183
12.5.2 Insert capability graphs............................................................................. 183
12.5.3 Design values ........................................................................................... 183
12.6 Influence of insert height ........................................................................................ 184
12.6.1 Insert capability graphs............................................................................. 184
12.6.2 Different insert heights.............................................................................. 184
12.7 Composite face sheet............................................................................................. 186
12.7.1 Effect of anisotropy................................................................................... 186
12.7.2 Loading by moments ................................................................................ 186
12.8 References ............................................................................................................. 186
12.8.1 General..................................................................................................... 186
13 Compressive strength......................................................................................187
13.1 Normal compressive load ....................................................................................... 187
13.1.1 General..................................................................................................... 187
13.1.2 Partially-potted inserts .............................................................................. 187
13.1.3 Potting strength ........................................................................................ 187
13.1.4 Increased face sheet thickness ................................................................ 187
13.1.5 Insert capabilities...................................................................................... 188
13.2 Permissible compressive loads .............................................................................. 188
13.2.1 Graphs of permissible static insert loads.................................................. 188
14 Shear strength ..................................................................................................190

14.1 Shear (in-plane) load.............................................................................................. 190
14.1.1 Effect of in-plane load............................................................................... 190
14.1.2 Effect of face sheet material ..................................................................... 191
14.1.3 Effect of partial clamping .......................................................................... 191
14.2 Permissible shear load ........................................................................................... 191
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14.3.1 Strength .................................................................................................... 192
14.3.2 Face sheets .............................................................................................. 195
14.3.3 CFRP face sheets .................................................................................... 195
14.3.4 Effect of panel layout ................................................................................ 200
14.3.5 Sensitivity of insert strength in face sheets .............................................. 201
14.3.6 Effect of thin CFRP face sheet ................................................................. 202
14.4 References ............................................................................................................. 203
14.4.1 General..................................................................................................... 203
15 Bending strength..............................................................................................204
15.1 Bending load .......................................................................................................... 204
15.2 Permissible bending load ....................................................................................... 205
15.4 References ............................................................................................................. 207
15.4.1 General..................................................................................................... 207
16 Torsional strength ............................................................................................208

16.1 Torsional load......................................................................................................... 208
16.2 Permissible torsion load ......................................................................................... 208
16.2.1 General..................................................................................................... 208
16.2.2 Metallic core ............................................................................................. 208
16.2.3 Non-metallic core...................................................................................... 209
16.3 Composite face sheets........................................................................................... 209
16.4 References ............................................................................................................. 210
16.4.1 General..................................................................................................... 210
17 Combined loads................................................................................................211
17.1 Inclined load ........................................................................................................... 211
17.2 General load combinations..................................................................................... 212
18 Edge influence ..................................................................................................214

18.1 Edge distance: Out-of-plane loading ...................................................................... 214
18.2 Edge distance: Shear loaded ................................................................................. 215
18.2.1 General..................................................................................................... 215
18.2.2 Metallic face sheets .................................................................................. 216
18.2.3 Non-metallic face sheets .......................................................................... 216
18.3.1 Out-of-plane loading ................................................................................. 217
18.3.2 In-plane loaded inserts ............................................................................. 217
18.4 References ............................................................................................................. 217
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18.4.1 General..................................................................................................... 217
19 Insert groups.....................................................................................................218
19.1 Two inserts: Loaded in same direction ................................................................... 218
19.1.1 General..................................................................................................... 218
19.1.2 Close inserts............................................................................................. 218
19.1.3 Distant inserts........................................................................................... 219
19.1.4 Effect of load............................................................................................. 219
19.2 Two inserts: Loaded in opposite directions ............................................................ 220
19.2.1 General..................................................................................................... 220
19.2.2 Close inserts............................................................................................. 221
19.2.3 Distant inserts........................................................................................... 221
19.3 Series of inserts: Loaded in same direction ........................................................... 221
19.3.1 Overview................................................................................................... 221
19.3.2 First and last inserts ................................................................................. 221
19.3.3 Intermediate inserts .................................................................................. 222
19.3.4 Example.................................................................................................... 222
19.4 Series of inserts: Loaded in opposite directions ..................................................... 223
19.4.1 Overview................................................................................................... 223
19.4.2 First and last insert ................................................................................... 224
19.4.3 Intermediate inserts .................................................................................. 224
19.5 Insert groups: Loaded in same direction ................................................................ 224
19.5.1 General..................................................................................................... 224
19.5.2 Equal and equidistant inserts ................................................................... 224
19.6.1 Out-of-plane loading ................................................................................. 226
19.6.2 In-plane loaded inserts ............................................................................. 226
19.7 References ............................................................................................................. 226
19.7.1 General..................................................................................................... 226
20 Stiffness ............................................................................................................228
20.1 Introduction............................................................................................................. 228
20.1.1 Overview................................................................................................... 228
20.1.2 Rotational stiffness ................................................................................... 228
20.1.3 In-plane stiffness ...................................................................................... 228
20.1.4 Out-of-plane stiffness ............................................................................... 228
20.2 Analysis and test .................................................................................................... 229
20.2.1 General..................................................................................................... 229
20.2.2 Analysis .................................................................................................... 229
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20.2.3 Testing...................................................................................................... 229
20.2.4 Comparison of analysis and test values ................................................... 229
20.2.5 Composite face sheets ............................................................................. 230
20.3 References ............................................................................................................. 230
20.3.1 General..................................................................................................... 230
21 Fatigue...............................................................................................................231
21.1 Insert fatigue life ..................................................................................................... 231
21.1.1 General..................................................................................................... 231
21.1.2 Potting ...................................................................................................... 231
21.1.3 Honeycomb core ...................................................................................... 231
21.2 Core local stress: Normal loads to plane................................................................ 232
21.2.1 General..................................................................................................... 232
21.2.2 Core circular stress................................................................................... 232
21.2.3 Example.................................................................................................... 233
21.3 Load-stress sequence: Constant amplitude ........................................................... 236
21.3.1 General..................................................................................................... 236
21.3.2 Mean stress ratio ...................................................................................... 236
21.3.3 Maximum peak load ................................................................................. 237
21.4 Load-stress sequence: Spectra of constant amplitude........................................... 237
21.4.1 General..................................................................................................... 237
21.4.2 Example.................................................................................................... 237
21.5 Fatigue life: Constant load amplitude ..................................................................... 237
21.5.1 Fatigue damage........................................................................................ 237
21.5.2 Fatigue life ................................................................................................ 238
21.5.3 Re-evaluation of core strength variation................................................... 239
21.5.4 Insert fatigue life: Metallic cores ............................................................... 240
21.5.5 Insert fatigue life: Non-metallic cores ....................................................... 251
21.6 Fatigue damage accumulation ............................................................................... 252
21.7 Non-metallic core ................................................................................................... 252
21.9 References ............................................................................................................. 254
21.9.1 General..................................................................................................... 254
21.9.2 ECSS standards ....................................................................................... 255
22 Environmental effects ......................................................................................256

22.1 Insert under thermal conditions .............................................................................. 256
22.1.1 General..................................................................................................... 256
22.1.2 Mechanical loading in a thermal environment .......................................... 256
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22.1.3 Mechanical loading after exposure to a thermal environment .................. 256
22.1.4 Mechanical loading after thermal cycling.................................................. 256
22.2 Thermal: Reduction of permissible load ................................................................. 258
22.2.1 Effect on permissible loads....................................................................... 258
22.2.2 Coefficient of thermal degradation............................................................ 258
22.3 Other conditions ..................................................................................................... 259
22.4.1 In-plane load under thermal conditions .................................................... 260
22.5 References ............................................................................................................. 260
22.5.1 General..................................................................................................... 260
22.5.2 ECSS standards ....................................................................................... 260
23 Manufacturing procedures ..............................................................................262

23.1 Sequence ............................................................................................................... 262
23.1.1 General..................................................................................................... 262
23.1.2 Sandwich panels ...................................................................................... 262
23.2 Fit inserts................................................................................................................ 263
23.2.1 General..................................................................................................... 263
23.2.2 Positioning ................................................................................................ 263
23.2.3 Perforated core......................................................................................... 264
23.2.4 Non-perforated core ................................................................................. 264
23.3 Inject potting compound ......................................................................................... 265
23.3.1 General..................................................................................................... 265
23.3.2 Process..................................................................................................... 266
23.3.3 Flow characteristics .................................................................................. 266
23.4 Cure cycle .............................................................................................................. 267
23.4.1 General..................................................................................................... 267
23.4.2 Resin system: Shur-Lok SLE 3010........................................................... 267
23.4.3 Potting foam: Lekutherm X227+T3........................................................... 267
23.4.4 Other resin systems.................................................................................. 267
23.5 Corrective actions................................................................................................... 268
23.5.1 General..................................................................................................... 268
23.5.2 Final machining ........................................................................................ 268
23.6 Reference sample .................................................................................................. 268
23.6.1 General..................................................................................................... 268
23.6.2 Materials ................................................................................................... 269
23.6.3 Manufacture.............................................................................................. 269
23.6.4 Number of samples .................................................................................. 269
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23.6.5 Pull-out strength test................................................................................. 269
23.7 Proof load ............................................................................................................... 270
23.8 Inspection ............................................................................................................... 270
23.9 Repair..................................................................................................................... 271
23.9.1 General..................................................................................................... 271
23.9.2 Undamaged core or face-sheet ................................................................ 271
23.9.3 Damaged core and face sheet ................................................................. 272
23.9.4 Replace or reposition inserts .................................................................... 272
23.10 Defects ................................................................................................................... 273
23.10.1 Poor storage of potting compound ........................................................... 273
23.10.2 Poor potting compound distribution .......................................................... 274
23.10.3 Poor positioning of insert .......................................................................... 275
23.10.4 Oversized bore hole size .......................................................................... 276
23.11 References ............................................................................................................. 276
23.11.1 General..................................................................................................... 276
23.11.2 ECSS standards ....................................................................................... 277
24 Sandwich panel machining..............................................................................278

24.1 Drilling bore holes................................................................................................... 278
24.1.1 Bore hole geometry .................................................................................. 278
24.2 Processing.............................................................................................................. 279
24.2.1 Combined tool .......................................................................................... 279
24.2.2 Single tools ............................................................................................... 280
24.2.3 Drill face sheet then cut honeycomb core ................................................ 280
24.2.4 Drill face sheet and honeycomb core ....................................................... 281
24.2.5 Coordinate drilling machines .................................................................... 281
24.4 Process control....................................................................................................... 282
24.4.1 Potential problems.................................................................................... 282
24.5 References ............................................................................................................. 283
24.5.1 General..................................................................................................... 283
24.5.2 ECSS standards ....................................................................................... 283
25 Potting ...............................................................................................................284
25.1 General................................................................................................................... 284
25.1.1 Environmental conditions ......................................................................... 284
25.1.2 Face sheet protection ............................................................................... 284
25.1.3 Degreasing of inserts................................................................................ 284
25.2 Manufacturing process ........................................................................................... 284
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25.3 Potting compounds................................................................................................. 285
25.3.1 Flow characteristics .................................................................................. 285
25.3.2 Resin system: Shur-Lok SLE 3010........................................................... 286
25.3.3 Potting foam: Lekutherm X227+T3........................................................... 286
25.3.4 Other potting materials ............................................................................. 286
25.4 References ............................................................................................................. 287
25.4.1 General..................................................................................................... 287
25.4.2 ECSS standards ....................................................................................... 288
26 Incoming inspection.........................................................................................289
26.1 Tests....................................................................................................................... 289
26.1.1 Material specifications .............................................................................. 289
26.1.2 Additional tests ......................................................................................... 289
26.2 Honeycomb core .................................................................................................... 289
26.2.1 Core properties......................................................................................... 289
26.2.2 Insert strength........................................................................................... 290
26.3 Potting resin ........................................................................................................... 290
26.3.1 Strength .................................................................................................... 290
26.3.2 Hardness .................................................................................................. 291
26.4.1 Material characteristics............................................................................. 291
26.4.2 Composite laminate properties................................................................. 291
26.4.3 Consumables............................................................................................ 292
26.5 References ............................................................................................................. 292
26.5.1 General..................................................................................................... 292
26.5.2 ECSS standards ....................................................................................... 292
27 Manufacture control .........................................................................................293

27.1 Testing.................................................................................................................... 293
27.1.1 General..................................................................................................... 293
27.1.2 Mechanical ............................................................................................... 293
27.1.3 Non-destructive ........................................................................................ 293
27.1.4 Development tests.................................................................................... 293
27.2 Reference samples ................................................................................................ 294
27.3 Mechanical testing.................................................................................................. 294
27.3.1 Tensile pull-out test .................................................................................. 295
27.3.2 Shear test ................................................................................................. 296
27.3.3 Torsion test............................................................................................... 298
27.4 Non-destructive testing........................................................................................... 299
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27.4.1 Radiography ............................................................................................. 299
27.6 References ............................................................................................................. 300
27.6.1 General..................................................................................................... 300
27.6.2 ECSS standards ....................................................................................... 300
28 Quality control ..................................................................................................301

28.1 General................................................................................................................... 301
28.1.1 Materials and processes........................................................................... 301
28.1.2 Documentation and traceability ................................................................ 302
28.1.3 Personnel ................................................................................................. 302
28.1.4 Health and safety...................................................................................... 302
28.2 Control of bore hole................................................................................................ 302
28.2.1 Inspection criteria ..................................................................................... 302
28.3 Control of potting .................................................................................................... 303
28.4 Core incoming inspection ....................................................................................... 306
28.4.1 Minimum core strength values.................................................................. 306
28.4.2 Inspection sequence................................................................................. 306
28.4.3 Perforated cores ....................................................................................... 307
28.5 Core normalised density......................................................................................... 307
28.5.1 Procedure ................................................................................................. 307
28.6 References ............................................................................................................. 308
28.6.1 General..................................................................................................... 308
28.6.2 ECSS standards ....................................................................................... 309
29 Testing...............................................................................................................310
29.1 General................................................................................................................... 310
29.2 Insert static strength tests ...................................................................................... 310
29.2.1 Out-of-plane tests ..................................................................................... 310
29.2.2 In-plane tests ............................................................................................ 311
29.2.3 Bending tests............................................................................................ 314
29.2.4 Torsion tests ............................................................................................. 314
29.3 Geometric effects: Insert static strength tests ........................................................ 315
29.3.1 Edge distance........................................................................................... 315
29.3.2 Insert proximity ......................................................................................... 315
29.4 Dynamic tests......................................................................................................... 317
29.4.1 Sinusoidal loads ....................................................................................... 317
29.4.2 Static residual strength test ...................................................................... 317
29.5 References ............................................................................................................. 318
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29.5.1 General..................................................................................................... 318
Annex A Inserts .....................................................................................................319

A.1 Introduction............................................................................................................. 319
A.2 Commercial products ............................................................................................. 319
A.3 Non-standard.......................................................................................................... 321
A.4 References ............................................................................................................. 327
Annex B Permissible loads...................................................................................328

B.1 Introduction............................................................................................................. 328
B.2 Index to permissible-load graphs ........................................................................... 329
B.3 References ............................................................................................................. 330
Annex C Analytical determination .......................................................................331

C.1 Introduction............................................................................................................. 331
C.2 Fully potted insert ................................................................................................... 332
C.3 Partial potting ......................................................................................................... 335
C.4 Potting failure ......................................................................................................... 338
C.5 Compressive loading.............................................................................................. 341
C.6 Reliability ................................................................................................................ 342
C.7 References ............................................................................................................. 343
Annex D Estimation of static load-carrying capability .......................................344

D.1 Introduction............................................................................................................. 344
D.2 Out of plane loading ............................................................................................... 345
D.3 Fully potted inserts ................................................................................................. 348
D.4 Partially potted inserts ............................................................................................ 349
D.5 Potting failure ......................................................................................................... 352
D.6 Compressive load: Additional criteria ..................................................................... 355
D.7 Reliability considerations ........................................................................................ 356
D.8 Design graphs ........................................................................................................ 358
D.9 Other external loads ............................................................................................... 359
D.10 References ............................................................................................................. 360
Annex E IATP .........................................................................................................362

E.1 Introduction............................................................................................................. 362
E.2 Materials................................................................................................................. 362
E.3 Testing.................................................................................................................... 364
E.4 Test data ................................................................................................................ 366
E.5 References ............................................................................................................. 373
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Annex F Case studies ...........................................................................................374
F.1 Introduction............................................................................................................. 374
F.2 ARIANE 1 Equipment Bay...................................................................................... 376
F.3 ARIANE 4 Equipment Bay...................................................................................... 377
F.4 ASAP 4................................................................................................................... 383
F.5 ASAP 5................................................................................................................... 388
F.6 ROSETTA Lander .................................................................................................. 392
F.7 SPOT 5................................................................................................................... 398
F.8 UMS ....................................................................................................................... 401
F.9 SILEX ..................................................................................................................... 403
F.10 HRG ....................................................................................................................... 410
F.11 NILESAT ................................................................................................................ 413
F.12 EXAMPLE: Insert verification ................................................................................. 417
F.13 References ............................................................................................................. 421
Annex G Formulae.................................................................................................422
G.1 Introduction............................................................................................................. 422
G.2 Nomenclature ......................................................................................................... 422
G.3 List of mathematical formulae ................................................................................ 425
Annex H Insert test fixtures ..................................................................................437

H.1 Introduction............................................................................................................. 437
H.2 Test fixture: Tension-Compression load................................................................. 437
H.3 Test fixture: In-plane shear load ............................................................................. 446
H.4 Test fixture: Bending .............................................................................................. 455
H.5 Test fixture: Torsion................................................................................................ 469
H.6 References ............................................................................................................. 488
Figures
Figure 4-1: Insert system: Components ................................................................................. 67
Figure 4-2: Insert system: Summary of loading modes.......................................................... 69
Figure 5-1: Typical insert........................................................................................................ 72
Figure 5-2: Standardised insert diameter ............................................................................... 76
Figure 5-3: Standardised insert height ................................................................................... 77
Figure 5-4 Preferred set of insert heights............................................................................... 78
Figure 6-1: Sandwich and core: designation .......................................................................... 84
Figure 6-2: Face sheet properties: Isotropic, anisotropic and quasi-isotropic
characteristics...................................................................................................... 85
Figure 6-3: Possible failures modes: Anisotropic face sheets under shear-loading............... 87
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Figure 6-4: Core strength: Deviation (%) of actual strength from guaranteed values ............ 90
Figure 7-1: Potting geometry.................................................................................................. 99
Figure 7-2: Effective potting radius as a function of insert diameter .................................... 102
Figure 7-3: Real potting radius as a function of insert diameter........................................... 104
Figure 7-4: Potting height as a function of the honeycomb core height ............................... 106
Figure 7-5: Mean weight of potting masses versus core height and insert diameter ........... 107
Figure 7-6: Correction coefficient for weight of insert heights .............................................. 108
Figure 8-1: Schematic of structural sandwich panel subjected to both in-plane and out-
of-plane external loading ................................................................................... 110
Figure 8-2: Sign conventions for sandwich beam element................................................... 112
Figure 8-3: Deformed sandwich beam element: deflection contributions from both
bending and shearing ........................................................................................ 113
Figure 8-4 Shearing deformation of sandwich beam element.............................................. 114
Figure 8-5: Failure modes: Honeycomb core sandwich panels ........................................... 116
Figure 8-6: Schematic of 'local bending effects in sandwich beam subjected to 3-point
bending .............................................................................................................. 118
Figure 8-7: Schematic of potted insert types for sandwich panels used for spacecraft
applications........................................................................................................ 121
Figure 8-8: Model definition of sandwich plate with through-the-thickness insert............... 122
Figure 8-9: Example: Lateral displacements of a symmetric sandwich plate with insert
subjected to compressive out-of-plane load ...................................................... 124
Figure 8-10: Example: Core stress components of symmetric sandwich plate with insert
subjected to out-of-plane compressive force ..................................................... 125
Figure 8-11: Example: Radial bending moment resultants in face sheets of symmetric
sandwich plate with insert subjected to out-of-plane compressive force ........... 127
Figure 9-1: Basic aspects of insert design, analysis and testing.......................................... 136
Figure 9-2: Insert load cases................................................................................................ 137
Figure 9-3: Insert out-of-plane load ...................................................................................... 137
Figure 9-4: Insert in-plane load ............................................................................................ 138
Figure 10-1: Typical insert arrangements............................................................................. 140
Figure 10-2: Insert load conditions ....................................................................................... 142
Figure 10-3: Sandwich panel with metallic face sheets: General design rules .................... 144
Figure 10-4: Insert design under in-plane load..................................................................... 145
Figure 10-5: Insert design loaded by moments .................................................................... 145
Figure 10-6: CFRP face sheets: Effect of small chamfer on insert flange on load
transfer to face sheet ......................................................................................... 146
Figure 10-7: Insert mounting modes .................................................................................... 148
Figure 10-8: Connections ..................................................................................................... 150
Figure 10-9: Selection of inserts: Partially potted................................................................. 153
Figure 10-10: Selection of inserts: Through-the-thickness................................................... 153
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Figure 10-11: Pre-design: Through-the-thickness insert under bending .............................. 157
Figure 10-12: Pre-design: Face sheet shear-out failure mode............................................. 158
Figure 10-13: Pre-design: Through-the-thickness insert under transverse force ................. 159
Figure 10-14: Failure modes: Moment load ......................................................................... 160
Figure 10-15: Failure modes: Load transfer in out-of-plane case ........................................ 161
Figure 10-16: Failure modes: Insert as a function of core height ......................................... 162
Figure 10-17: Failure modes: Non-correlation between number of the filled cells and
number of the failing cell walls........................................................................... 163
Figure 10-18: Failure modes: Unsymmetrical potting and crossed cell................................ 164
Figure 10-19: Failure modes: In-plane and torsion loads..................................................... 165
Figure 10-20: Failure modes: CFRP face sheets ................................................................. 166
Figure 11-1: Flow chart: Predefined sandwich and loads .................................................... 169
Figure 11-2: Flow chart: Variable main parameters ............................................................. 170
Figure 12-1: Failure modes in relation to the core height..................................................... 173
Figure 12-2: Out-of-plane capability: Contributions of the main components on
improved core shear .......................................................................................... 179
Figure 12-3: Out-of-plane capability: Contributions of the main components on
improved core tension ....................................................................................... 180
Figure 12-4: Influence of insert height on insert capability ................................................... 185
Figure 13-1: Compressive strength: Protruding insert.......................................................... 189
Figure 14-1: Shear-loaded inserts: Clamping conditions ..................................................... 190
Figure 14-2: Correlation between calculated and tested in-plane capabilities with fibre
orientation .......................................................................................................... 193
Figure 14-3: Correlation between calculated and tested in-plane capabilities with fibre
strength.............................................................................................................. 194
Figure 14-4: Nomenclature: Ultimate in-plane load against failure in tension ...................... 196
Figure 14-5: Shear strength: Stress concentration factor..................................................... 197
Figure 14-6: Shear strength: Failure angle........................................................................... 198
Figure 14-7: Shear strength: Critical stresses for intracellular buckling (dimpling) under
uniaxial compression ......................................................................................... 199
Figure 14-8: Shear strength: Influence of edge distance ..................................................... 201
Figure 14-9: In-plane capability: Contributions of the main components on improved
core shear.......................................................................................................... 202
Figure 15-1: Inserts loaded in bending: Clamping conditions .............................................. 205
Figure 15-2: Bending load: Schematic of load-transfer ........................................................ 206
Figure 15-3:Bending load: Insert footprint on moment loading ............................................ 207
Figure 16-1: Torsional load: Nomenclature .......................................................................... 209
Figure 17-1: Insert submitted to an inclined load ................................................................. 211
Figure 18-1: Edge distance: Effect on insert static strength capability................................. 215
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Figure 19-1: Insert groups: Reduced insert capability - two adjacent inserts loaded in
the same direction ............................................................................................. 220
Figure 19-2: Insert groups: Series of inserts loaded in same direction ................................ 222
Figure 19-3 Insert groups: series of inserts loaded in opposite directions ........................... 223
Figure 19-4: Insert groups: Interference coefficient for a group of equal and equidistant
inserts ................................................................................................................ 225
Figure 21-1: Static strength values with core height ............................................................ 233
Figure 21-2: Schematic: Design load spectrum ................................................................... 236
Figure 21-3: Insert fatique life: Insert diameter 9 mm........................................................... 243
Figure 21-4: Insert fatique life: Insert diameter 11 mm......................................................... 245
Figure 21-5: Insert fatique life: Insert diameter 14 mm......................................................... 247
Figure 21-6: Insert fatique life: Insert diameter 17.5 mm...................................................... 249
Figure 21-7: Insert fatique life: Insert diameter 22.5 mm...................................................... 251
Figure 21-8: Fatigue life: Non-metallic GFRP core .............................................................. 253
Figure 21-9: Fatigue life: Non-metallic Nomex core ........................................................... 254
Figure 22-1: Thermal effects: Reduction of insert capability ................................................ 257
Figure 22-2: Thermal effects: Reduction of potting resin strength ....................................... 258
Figure 22-3: Thermal effects: Coefficient of thermal degradation ........................................ 259
Figure 23-1: Basic manufacturing sequence........................................................................ 263
Figure 23-2: Inserts with connected potting mass................................................................ 264
Figure 23-3: Venting of non-perforated core ........................................................................ 265
Figure 23-4: Reference sample: Pull-out strength test specimen ........................................ 270
Figure 23-5: Insert repair: Geometry .................................................................................... 272
Figure 24-1: Sandwich panel machining: Combined drill and punch tool............................. 279
Figure 24-2 Sandwich panel machining: Series of single tools and their uses .................... 280
Figure 27-1: Manufacture control: Out-of-plane test fixture for tension (pull-out) tests ........ 295
Figure 27-2: Manufacture control: Out-of-plane test fixture for compression or fatigue
tests ................................................................................................................... 296
Figure 27-3: Manufacture control: In-plane test fixture for shear Bending test .................... 297
Figure 27-4: Manufacture control: Bending test fixture ........................................................ 298
Figure 27-5: Manufacture control: Torsion test fixture.......................................................... 298
Figure 28-1: QA: Poor potting causing strength degradation ............................................... 304
Figure 28-2: QA: Honeycomb core - incoming inspection.................................................... 307
Figure 28-3: QA: Core density correction factor for degree of expansion ............................ 308
Figure 29-1: Testing: Insert static out-of-plane strength fixture............................................ 311
Figure 29-2: Testing: Insert static in-plane strength fixture .................................................. 312
Figure 29-3: Testing: ASTM insert static in-plane strength fixture ....................................... 313
Figure 29-4: Testing: Bending fixture ................................................................................... 314
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Figure 29-5: Testing: Edge distance fixture.......................................................................... 315
Figure 29-6: Testing: Insert proximity tensile fixture............................................................. 316
Figure 29-7: Testing: Insert proximity tensile-compression fixture ....................................... 316
Figure 29-8: Testing: Determination of points for residual strength test............................... 318
Figure A-1 : Carbon fibre tube inserts: Comparison of design principles ............................. 323
Figure A-2 : Carbon fibre tube inserts: Fitting of spreadable CFRP tube............................. 324
Figure A-3 : Carbon fibre tube insert: Type 1 cap ................................................................ 325
Figure A-4 : Carbon fibre tube insert: Type 2 cap ................................................................ 325
Figure A-5 : Carbon fibre tube insert: Type 2 insert cap and carbon fibre sleeve ................ 326
Figure C-1 : Fully potted insert ............................................................................................. 333
Figure C-2 : Partially potted insert........................................................................................ 336
Figure D-1 Out-of-plane loading: Circular sandwich plate with through-the-thickness
insert .................................................................................................................. 346
Figure D-2 : Partially potted insert: out-of-plane loading ...................................................... 349
Figure E-1 : Manufacture control: Insert tensile pull-out test fixture ..................................... 364
Figure F-1 : Case study: ARIANE 1 equipment bay / ASAP 4 - tensile (pull-out) test
method............................................................................................................... 376
Figure F-2 : Case study: ARIANE 4 Case 1 ......................................................................... 378
Figure F-3 : Case study: ARIANE 4 Case 2 ......................................................................... 379
Figure F-4 : Case study: ARIANE 4 - tensile (pull-out) test method..................................... 380
Figure F-5 : Case study: ARIANE 4 - shear test method ..................................................... 380
Figure F-6 : Case study: ASAP 4 (AR4) 1............................................................................ 384
Figure F-7 : Case study: ASAP 4 (AR4) 2............................................................................ 384
Figure F-8 : Case study: ASAP 4 (AR4) - tensile (pull-out) method A.................................. 385
Figure F-9 : Case study: ASAP 4 (AR4) - tensile (pull-out) method B.................................. 386
Figure F-10 : Case study: ASAP 5 ....................................................................................... 389
Figure F-11 : ROSETTA Lander: Two structural components ............................................. 392
Figure F-12 : ROSETTA Lander: Tension-compression, shear, bending and torsion
tests ................................................................................................................... 393
Figure F-13 : Carbon fibre tube insert (type 2): With cap for unilateral fixing....................... 396
Figure F-14 : Carbon fibre tube inserts: Definition of the critical insert failure load, Fc......... 397
Figure F-15 : Case study: SPOT 5 - Case ........................................................................... 399
Figure F-16 : Case study: SPOT 5 - Structure I/F platform .................................................. 400
Figure F-17 : Case study: UMS - SST 1............................................................................... 402
Figure F-18 : Case study: UMS - SST 2............................................................................... 402
Figure F-19 : Case study: SILEX - insert.............................................................................. 404
Figure F-20 : Case study: SILEX GEO MPCS insert ........................................................ 405
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Figure F-21 : Case study: HRG - Insert................................................................................ 411
Figure F-22 : Case study: HRG - Test method..................................................................... 413
Figure F-23 : Case study: NILESAT battery 1...................................................................... 415
Figure F-24 : Case study: NILESAT battery 2...................................................................... 416
Figure F-25 : Example: Insert verification dimensions ...................................................... 417
Figure H-1 : Test fixture: Tension-compression load master drawing............................... 438
Figure H-2 : Test fixture: Tension-compression load part 1 .............................................. 439
Figure H-9 : Test fixture: In-plane shear load master drawing .......................................... 446
Figure H-10 : Test fixture: In-plane shear load part 1........................................................ 447
Figure H-18 : Test fixture: Bending master drawing.......................................................... 456
Figure H-19 : Test fixture: Bending part 1 ......................................................................... 457
Figure H-28 : Test fixture: Bending part 10 ....................................................................... 466
Figure H-29 : Test fixture: Bending parts 11, 12 and 13 ................................................... 467
Figure H-30 : Test fixture: Bending part 14 ....................................................................... 468
Figure H-31 : Test fixture: Torsion master drawing ........................................................... 470
Figure H-32 : Test fixture: Torsion part 1 .......................................................................... 471
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Figure H-41 : Test fixture: Torsion part 10 ........................................................................ 480
Tables
Table 4-1: Insert system: General definition........................................................................... 68
Table 5-1: Types of inserts..................................................................................................... 71
Table 5-2: Potting methods .................................................................................................... 73
Table 5-3: List of insert standards .......................................................................................... 75
Table 5-4: Inserts: Aluminium alloy 'equivalents'.................................................................... 79
Table 5-5: Typical insert materials and surface protection..................................................... 81
Table 6-1: Effect of sandwich components on insert load-bearing capability......................... 83
Table 6-2: Failure mode and shear-load capability of tested CFRP face sheets ................... 88
Table 6-3: Mechanical properties of common aluminium alloy hexagonal-type cores ........... 91
Table 6-4: Mechanical properties of common non-metallic hexagonal-type cores ................ 92
Table 7-1: Example: Insert potting compounds for space applications .................................. 97
Table 7-2: Example: Effect of increased potting radius on insert tensile capability.............. 100
Table 9-1: Summary of the basic insert design parameters................................................. 135
Table 10-1: Failure modes of insert joint .............................................................................. 160
Table 12-1: Properties for determining potted insert capability: Tensile load....................... 176
Table 12-2: Perforated cores: Effective and real potting radius versus insert diameter....... 177
Table 12-3: Non-perforated cores: Effective and real potting radius versus insert
diameter............................................................................................................. 177
Table 12-4: Out-of-plane capability: Effect of components on core shear ........................... 179
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Table 12-5: Out-of-plane capability: Effect of components on core tension......................... 179
Table 14-1: In-plane capability: Effect of components on core shear .................................. 201
Table 20-1: Insert stiffness: SILEX test configuration .......................................................... 229
Table 20-2: Insert stiffness: Comparison of analysis and test.............................................. 230
Table 21-1: Fatigue: Stress concentration factors for local stress ....................................... 235
Table 21-2: Fatigue: Coefficients to determine peak load.................................................... 240
Table 21-3: Links to fatigue life data .................................................................................... 241
Table 21-4: Insert diameter 9 mm: Fatigue correction factors.............................................. 242
Table 21-5: Insert diameter 11 mm: Fatigue correction factors............................................ 244
Table 21-6: Insert diameter 14 mm: Fatigue correction factors............................................ 246
Table 21-7: Insert diameter 17.5 mm: Fatigue correction factors......................................... 248
Table 21-8: Insert diameter 22.5 mm: Fatigue correction factors......................................... 250
Table 23-1: Insert capability: Effect of poor storage of potting compound ........................... 273
Table 23-2: Insert capability: Effect of poor distribution of potting compound...................... 275
Table 23-3: Insert capability: Effect of poor positioning of insert.......................................... 275
Table 23-4: Insert capability: Effect of oversized bore hole.................................................. 276
Table 26-1: Incoming inspection: Potting resin strength tests.............................................. 291
Table 28-1: QA: Potting failure and detectability .................................................................. 304
Table 29-1: Testing: Dynamic test load levels and number of cycles .................................. 317
Table A-1 : Commercially available inserts used in space ................................................... 320

Table A-2 : Non standard inserts used in space applications .............................................. 322
Table B-1 : Core height: Permissible tensile loads - transition points .................................. 329
Table B-2 : Core height: Example - permissible tensile loads.............................................. 329
Table B-3 : Design graphs: Index to permissible static loads............................................... 330
Table C-1 : Correlation coefficients ...................................................................................... 342
Table C-2 : Reliability coefficients ........................................................................................ 343
Table D-1 : Correlation coefficients ...................................................................................... 357
Table D-2 : Reliability coefficients ........................................................................................ 357
Table E-1 : IATP: Materials .................................................................................................. 363
Table E-2 : IATP: Shear test panel configurations ............................................................... 365
Table E-3 : IATP: Pull-out test panel configurations............................................................. 366
Table E-4 : IATP: Shear test data ........................................................................................ 367
Table E-5 : IATP: Pull-out test data...................................................................................... 369
Table E-6 : IATP: Shear test results versus design allowables............................................ 371
Table E-7 : IATP : Pull-out test results versus design allowables ........................................ 372
Table F-1 : Case study: ARIANE 1 equipment bay/ASAP 4 Allowable tensile load.......... 376
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Table F-2 : Case study: ARIANE 4 materials and configuration ....................................... 377
Table F-3 : Case study: ARIANE 4 equipment bay - Allowable tensile load ........................ 381
Table F-4 : Case study: ARIANE 4 equipment bay - Allowable shear load.......................... 382
Table F-5 : Case study: ASAP 4 materials and configuration ........................................... 383
Table F-6 : Case study: ASAP 4 - interference and edge effects......................................... 387
Table F-7 : Case study: ASAP 5 materials and configuration ........................................... 388
Table F-8 : Case study: ASAP 5 - Allowable tensile load..................................................... 390
Table F-9 : Case study: ASAP 5 - interference and edge effects......................................... 391
Table F-10 : Carbon fibre tube inserts: Out-of-plane tension ............................................... 395
Table F-11 : Carbon fibre tube inserts: Out-of-plane compression ...................................... 395
Table F-12 : Carbon fibre tube inserts: In-plane shear load................................................. 396
Table F-13 : Carbon fibre inserts: Weibull analysis criteria .................................................. 397
Table F-14 : Case study: SPOT 5 materials and configuration ......................................... 398
Table F-15 : No details given, [29-29]. Case study: UMS Materials and configuration ..... 401
Table F-16 : Case study: SILEX Materials and configuration............................................ 403
Table F-17 :Case study: SILEX - Allowable tensile load ...................................................... 406
Table F-18 : Case study: SILEX - Allowable shear load ...................................................... 407
Table F-19 : Case study: SILEX - Allowable bending moment ............................................ 408
Table F-20 : Case study: SILEX - Allowable torsion moment .............................................. 409
Table F-21 : Case study: HRG Materials and configuration.............................................. 410
Table F-22 : Case study: HRG - Tensile load ...................................................................... 412
Table F-23 : Case study: NILESAT materials and configuration....................................... 414
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1
Scope
The ECSSHB3222A recommends engineering inserts and practices for European programs and
projects. It may be cited in contracts and program documents as a reference for guidance to meet
specificprogram/projectneeds.
The target users of this handbook are engineers involved in the design, analysis and verification of
launchers and spacecraft in relation to insert usage. The current knowhow is documented in this
handbookinordertomakeexpertisetoallEuropeandevelopersofspacesystems.
Itisaguidelinesdocument,thereforeitincludesadvisoryinformationratherthanrequirements.
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2
References
Duetothestructureofthedocument,eachclauseatitsendcontainsthelistofreferencecalledupon.
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3
Terms, definitions and abbreviated terms
The following provides an explanation of the terms, acronyms and abbreviations used in this ECSS
handbook; they are not definitions. Terms are listed in alphabetical order and interposed with
explanationsoftheacronymsandabbreviationsusedinthehandbook.
A
AA
AluminiumAssociation,USA
ABASISDESIGNALLOWABLE(Avalue)
mechanicalpropertyvalueabovewhichatleast99%ofthepopulationofvaluesisexpectedto
fall,withaconfidencelevelof95%
[ECSSEST32]
ADHEREND
Plateadhesivelybondedtoanotherplate
[ECSSQ7071]
ADHESION
The state in which two surfacesare held together at an interface by forces or the interlocking
actionofanadhesiveorboth
ADHESIVE
Asubstancecapableofholdingtwosurfacestogether
NOTE: Used to retain carbonfibre tube inserts in sandwich panels instead of the
conventionalpottingcompoundsusedforstandardtypesofinserts
ADHESIVE(FILM)
Asyntheticresinadhesive,usuallyofthethermosettingtypeintheformofathinfilmofresin
with or without a fibrous carrier or support; used for bonding the face sheets of sandwich
panelstothecore
NOTE: Filmadhesivesusuallyhavesometacktoenabletheirplacementduringassembly.
ADHESIVE(FOAMING)
A synthetic resin adhesive, usually of the thermosetting type which when cured produces a
foamlikematerial.[See:ADHESIVE(SYNTACTIC)]
ADHESIVE(SYNTACTIC)
A synthetic resin adhesive, usually of the thermosetting type that contains a hollow filler
material, often in the form of small glass microballoons, which when cured producesa foam
likematerial
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NOTE: Thesetypesofmaterialsarewidelyusedasapottingcompoundforretaininginserts
insandwichpanels.
AECMA
Association Europen des Constructeurs Matriel Arospatiale; European Association of
AerospaceIndustries
AFNOR
AssociationFranaisdeNormalisation;Frenchnationalstandardsorganisation
AIR
Frenchstandardsorganisation
AISI
AmericanIronandSteelInstitute,USA
ALLOWABLELOAD
maximumloadthatcanbepermittedinastructuralpartforagivenoperatingenvironmentto
prevent rupture, collapse, detrimental deformation or unacceptable crack growth [ECSSP
001]]]
ALLOWABLESTRESS
The maximum stress that can be permitted in a structural part for a given operating
environment to prevent rupture, collapse, detrimental deformation or unacceptable crack
growth[ECSSP001]
ALLOWABLES
Material values that are determined from test data at the laminate or lamina level on a
probabilitybasis(e.g.AorBvalues),followingASTMorotherteststandardsacceptedbythe
finalcustomer.[Seealso:ABASISDESIGNALLOWABLE;BBASISDESIGNALLOWABLE;A
VALUE,BVALUE]
ALLOY
Mixtureofabasemetallicelementwithoneormoreothermetallicornonmetallicelements
ALODINE
Aproprietorychemicaloxidisingprocess,i.e.anonelectrolyticprocess,forsurfacetreatment
which results in an electrically conductive, chromated (mixedmetal, chromiumoxide) film,
typicallylessthan1mthick
ALUMINIUM(Al)
Metallic element, melting point 660C, density 2700 kg m3. Uses: ubiquitous aerospace alloy
base, important component in oxidation resistant alloys and coatings and as part of basic
strengtheningmechanismfornickelbasedsuperalloys
AMBIENT
1Thesurroundingenvironmentalconditions,e.g.pressure,temperatureorrelativehumidity
2 usual work place temperature and humidity environmental conditions, e.g. room
temperature
ANISOTROPIC
Havingmechanicalorphysicalpropertieswhichvaryindirectionrelativetonaturalreference
axesinthematerial
ARALDITE
Arangeofepoxybasedstructuraladhesives;developedbyCibaGeigy,nowVantico
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ARAMID
A type of highly oriented aromatic polymer material. Used primarily as a highstrength
reinforcing fibre, of which Kevlar 49 and Twaron HM are most commonly used in
aerospaceapplications
AREALWEIGHT
Ameasurementoftheweightperunitareaofafabricorfabricprepreg;expressedasg/m
ARIANE
FamilyofEuropeanlaunchvehicles
ASTM
AmericanSocietyforTestingandMaterials;USAstandardsorganisation
B
BBASISDESIGNALLOWABLE(Bvalue)
mechanicalpropertyvalueabovewhichatleast90%ofthepopulationofvaluesisexpectedto
fall,withaconfidencelevelof95%
[ECSSEST32]
BALANCEDLAMINATE
Whereplieswithpositiveanglesarebalancedbyequalplieswithnegativeangles.Whileangle
plylaminateshaveonlyonepairofmatchedangles,balancedlaminatescanhavemanypairs,
plus0and90degrees.Abalancedlaminateisorthotropicininplanebehaviour,butanisotropic
inflexuralbehaviour
BATCH
Materialsproducedduringauniquesequence:
1.Fibre:Theamountwhichisproducedbytheconversionofanumberofprecursortowsunder
standard, controlled, processingplant conditions in one continuous operation, including any
surfacetreatmentandsizingofthefibre
2.Prepreg:Aquantity,irrespectiveofwidth,thatisproducedundernochangeconditionsin
onecontinuousoperationoftheimpregnatingplantfromonebatchofresinmixandonebatch
of fibre. A batch is expected to conform to a fixed manufacturing process and to have
homogeneous properties within prescribed tolerances over its whole width and length. A
maximumallowablelengthforaprepregbatchissometimesspecified
3.Resin:Aquantityofresinineitherfilmorliquidformproducedfromonemixofresins,resin
modifiersandcuringagents
BIDIRECTIONALLAMINATE
A reinforced plastic laminate with the fibres oriented in two directions in the plane of the
laminate;acrosslaminate.[Seealso:UNIDIRECTIONALLAMINATE]
BLIND
Fasteners:Installedfromonesideofacomponentonly
BONDLINE
The area between two materials that have been adhesively bonded; includes the layer of
adhesivebetweentheadherends
BOREHOLE
Aholemachinedinasandwichpanelofasuitablesizetoacceptaninsert
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BS
Britishstandard,controlledbytheBritishStandardsInstitute(BSI)
BSI
BritishStandardsInstitute,UK
BUCKLING
1Unstabledisplacementofastructuralpart,suchasapanel,causedbyexcessivecompression
or shear. Microbuckling of fibres in a composite material can also occur under axial
compression
2 Fibre: a failure mechanism which occurs under compressive loads where the reinforcing
fibresinacompositearedisplacedtransversly;fibrebucklingmodesareknownasextension
modeandshearmode.
C
CADMIUM(Cd)
Metallicelement,meltingpoint321C,density8650kgm3,Uses:alloyingadditions,protective
coatings:NOTFORSPACEUSE
CARBON/EPOXY
Acompositematerialcomprisingofacarbonfibrereinforcementinanepoxypolymermatrix
CARBONFIBRE
Fibre produced by the pyrolysis of organic precursor fibres, such as rayon, polyacrylonitrile
(PAN)andpitch,inaninertenvironment.Thetermisoftenusedinterchangeablywiththeterm
graphite;carbonfibresandgraphitefibresdo,however,differ.Thebasicdifferenceslieinthe
temperature at which the fibres are made and heattreated, and in the amount of elemental
carbonproduced.Carbonfibrestypicallyarecarbonisedintheregionof1315Candassayat93
to95%carbon,whilegraphitefibresaregraphitisedat1900Cto2480Candassayatmorethan
99%elementalcarbon
CARBONFIBRETUBEINSERT
AnonstandardtypeofinsertdevelopedbyDLRfortheRosettaLanderproject,[Seealso:A.03;
F.06]
CASA
ConstruccionesAeronauticasSA,(E);nowEADSCASA
CATALYST
Asubstancethatchangestherateofachemicalreactionwithoutitselfundergoingpermanent
changeinitscomposition;asubstancethatmarkedlyspeedsupthecureofacompoundwhen
addedinaquantitysmallcomparedwiththeamountsofprimaryreactants
CEN
ComitEuropendeNormalisation(EuropeanCommitteeforStandardization)
CFRP
Carbon fibrereinforced plastic. Letter G in this handbook stands for Glass, whereas in
Americanpublicationsitisusedforgraphite.[Seealso:GFRP]
CIS
standardsorganisation,Russia
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COCURE
Simultaneouscuringandbondingofacompositelaminatetoanothermaterialorparts,suchas
honeycombcoreorstiffeners,eitherbyusingtheadhesivepropertiesofthecompositeresinor
byincorporatinganadhesiveintothecompositelayup
COLLECTEDVOLATILECONDENSABLEMATERIAL(CVCM)
quantityofoutgassedmatterfromatestspecimenthatcondensesonacollectormaintainedata
specifictemperatureforaspecifictime
NOTE: CVCM is expressed as a percentage of the initial specimen mass and is calculated
fromthecondensatemassdeterminedfromthedifferenceinmassofthecollectorplatebefore
andafterthetest.
[ECSSQST7002]
COMPOSITESANDWICHCONSTRUCTION
panels composed of a lightweight core material, such as honeycomb, foamed plastic, and so
forth, to which two relatively thin, dense, highstrength or highstiffness faces or skins are
adhered
[ECSSEST3208]
CORE
1Alightweightmaterialinbetweenthefacesheetsofasandwichpanel,e.g.honeycombcore,
foam.Metallicorcompositesheetmaterialsarebondedtothecoretoformasandwichpanel
2Coresareoftenclassedaseithermetallicornonmetallicandarecommerciallyavailableina
widerangeofmaterialsandconfigurations,e.g.honeycombwitharangeofcellsizesandfoil
thicknesses,withorwithoutperforations
CORE(HEXAGONAL)
Acorematerialinwhichtheshapeoftheindividualcellsishexagonal
CORE(METALLIC)
Anycorethatismadeofmetal,e.g.oftenmadeofanaluminiumalloy
CORE(NONMETALLIC)
Anycorethatismadeofamaterialotherthanmetal;usuallymadeofglassreinforcedplastic
(GFRP)orNomexforspaceapplications
CORE(NONPERFORATED)
Acorematerialinwhicheachofthecellsisnotconnectedtoitsneighbours;airtrappedwith
thecellsofasandwichpanelcannotbeventedeasilywhenplacedinvacuum
CORE(PERFORATED)
Acorematerialinwhicheachofthecellsisconnectedtoitsneighboursbyoneormoresmall
holes in the cell walls; enables the removal of air trapped with the cells of a sandwich panel
whenplacedinvacuum
CORESPLICE
A joint or the process of joining one type of core to another; usually achieved by adhesive
bondingusinganadhesivewithgapfillingproperties
CROSSLINKING
1Appliedtopolymermolecules,thesettingupofchemicallinksbetweenthemolecularchains.
When extensive, as in most thermosetting resins, crosslinking makes one infusible super
moleculeofallthechains
2Thechemicalreactionthatoccursinthermosettingpolymersduetotheheatappliedduring
thecure
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CROSSPLY
Compositescontainingpliesofmaterial,normallyprepreg,atanglesof0and90
CROSSPLYLAMINATE
Special laminate that contains only 0 and 90 plies. This bidirectional laminate is orthotropic
and has nearly zero Poissons ratio. The other simple bidirectional laminate is the angleply,
whichpossessesonepairofbalancedoffaxisplies
CTE
See:COEFFICIENTOFTHERMALEXPANSION
CTEMISMATCH
1 difference in coefficient of thermal expansion between two or more materials within a
specifiedtemperaturechange,e.g.polymersandmetals.[ECSSQ7071]
2Thedifferenceincoefficientofthermalexpansionbetweenareinforcementandthematrixor
a coating and substrate within a specified temperature rise, e.g. carbon fibre (low/zero CTE)
andAlalloy(large+veCTE)
CURE
1changingthepropertiesofapolymerbasedmaterialbychemicalreactionaccomplishedby
heatorcatalyst(orboth)andwithorwithoutpressure,e.g.resin,adhesive,coating.[ECSSQ
7071]
2 chemical reaction during which a liquid resin is transformed to a solid material by the
processofcrosslinking
CURECYCLE
1periodwithadistinctivetime,temperatureandpressureprofiletoobtainspecific
propertiesofapolymerbasedmaterial,e.g.resin,adhesive,orcoating.[ECSSQ7071]
2 he cure cycle can include defined heatup and cooldown rates, isothermal holds for
specified periods and application and removal of negative or positive pressures at defined
timesortemperatures
3pottingcompounds:Dependsonthechemicalformulationoftheresinusedforpottingandif
theresinorassemblycanbecuredatelevatedtemperaturewithoutcausingdamage;atypical
cure cycle for potted inserts, using a twopart epoxybased resin system, is several hours at
roomtemperature
CURINGTEMPERATURE
Temperatureatwhichacast,mouldedorextrudedproduct,aresinimpregnatedreinforcement
oranadhesiveissubjectedtocuring
CURINGTIME
Thelengthoftimeapartissubjectedtoheatorpressure,orboth,tocuretheresin;intervalof
timebetweentheinstantrelativemovementbetweenthemovingpartsofamouldceasesand
theinstantpressureisreleased
NOTE: Furthercurecantakeplaceafterremovaloftheassemblyfromtheconditionsofheat
orpressure.[See:POSTCURE]
CVCM
CollectedVolatileCondensableMatter
CYCLICLOADING
fluctuating load (or pressure) characterized by relative degrees of loadingandunloading of a
structure
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NOTE For example, loads due to transient responses, vibroacoustic excitation, flutter,
pressurecyclingandoscillatingorreciprocatingmechanicalequipment.
[ECSSEST3201]
D
DAMAGE
A structural degradation or anomaly caused by service conditions or by abnormal operation,
e.g.impactdamagecausedbydroppedtoolsorotherforeignobjects
DAMAGETOLERANCE
The ability of a material, component or structure to retain an acceptable level of structural or
environmentalresistancepropertiesundertheeffectsofoperationalconditions,withoutriskof
failinginacatastrophicmanner,[See:DAMAGETOLERANT]
DAMAGETOLERANCECONTROL
The application of design methodology, material and processing control, manufacturing
technology,andqualityassuranceprocedurestopreventprematurestructuralfailureduetothe
initiationorpropagationofflawordamageduringfabrication,testingandservicelife
DAMAGETOLERANT
characteristic of a structure for which the amount of general degradation or the size and
distribution of local defects expected during operation, or both, do not lead to structural
degradationbelowspecifiedperformance
ECSSEST3201]
DAN
DeutscheAirbusNorm;GermanAirbusstandard
DEBOND
General:adefectiveareaofanadhesivebondwheretheadherendsarenolongerheldtogether.
Anareaofseparationwithinorbetweenpliesinalaminate,orwithinabondedjoint,causedby
contamination, improper adhesion during processing, or damaging interlaminar stresses [See
also:DELAMINATION]:
1Adhesivebond:adelaminationbetweentheadherends
2Sandwichpanel:adelaminationthatoccursbetweenthecoreandthefacesheet;causedby
contaminationordamagetoeitherthefilmadhesiveusedtojointhefacesheetlaminatetothe
core,facesheetlaminateitself,bondareaofthecoreormechanicaldamagetocorecellwalls,by
crushingormorelocaldamage
DEFECT
A manufacturing anomaly (crack, void, delamination) created by processing, fabrication or
assemblyprocedures.[Seealso:FLAW]
DEGRADATION
reduction of material properties (e.g. mechanical, thermal or optical) that can result from
deviationsinmanufacturingorfromrepeatedloadingorenvironmentalexposure.[ECSSQ70
71]
DELAMINATION
Physicalseparationorlossofbondofthelayersofmaterialinalaminate;locallyoroverawide
area
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DESIGNALLOWABLE
Material values that are determined from test data at the laminate or lamina level on a
probabilitybasis(e.g.AorBvalues),followingASTMorotherteststandardsacceptedbythe
finalcustomer.[Seealso:ABASISDESIGNALLOWABLE;BBASISDESIGNALLOWABLE;A
VALUE,BVALUE]
DESIGNVALUES/PROPERTIES
Material, structuralelement and structural detail properties that have been determined from
test data and chosen to assure a high degree of confidence in the integrity of the completed
structure
DIELECTRIC
Amaterialinwhichtheelectricalconductivityiszeroornearzero
DIMPLING
Sandwichpanels:thedisplacementunderloadofthefaceskinsbetweenthecellularstructureof
ahoneycombcore
DIN
DeutschesInstitutfrNormung;Germannationalstandardsorganisation
DLR
DeutschenZentrumfrLuftundRaumfahrt.Germanaerospaceorganisation
E
EGLASS
Electrical glass; a grade of glass fibre. A borosilicate glass containing less than 1% alkali
(combined sodium and potassium oxides); the type most used for glass fibres for reinforced
plastics;suitableforelectricallaminatesbecauseofitshighresistivity
ECSS
European Cooperation for Space Standardization. A cooperative effort of the European Space
Agency, National Space Agencies and European industry associations for the purpose of
developingandmaintainingcommonstandards,[See:ECSSwebsite:www.ecss.nl)
EDGECLOSEOUT
[See:EDGECLOSURE]
EDGECLOSURE
Sandwich panels: Protects the core from accidental damage, serves as a moisture seal and
providesedgereinforcementtoenabletransferanddistributionofedgeattachmentloads;also
knownasedgecloseoutandedgemember
EDGEMEMBER
[See:EDGECLOSURE]
EDGEDISTANCE
Thedistancebetweenaninsert,ormorepreciselythecentrelineofthepotting,andtheedgeof
asandwichpanel
ELASTICMODULUS
Stiffness
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ELASTICRELATION
Fully reversible, singlevalue, stressstrain relation. Loading and unloading follow the same
path; there is no hysteresis, or residual strain. Although nonlinear relation is admissible, the
relationforcompositematerialsisessentiallylinear
ELEMENT
1 A part of a more complex structural member, e.g. skin, stringers, shear panels, sandwich
panels,jointsorsplices,GlossaryRef.[Ref1]
2 A composite of subsystems, capable of performing an operational role only in conjunction
with other elements, e.g. SpaceVehicle, Ground Segment, Space Station Pressurised Module,
GlossaryRef.[Ref1]
ELONGATION
Deformation caused by stretching; the fractional increase in length of a material stressed in
tension. (When expressed as percentage of the original gauge length, it is called percentage
elongation)
EMATVCargoCarrier
Engineering model, Automated transfer vehicle integrated cargo carrier for ISS; International
SpaceStation
EN
EuroNorme(Europeanstandard),[See:CEN]
ENN
ERNONorm;standarddevelopedbyMBBERNO(Bremen),nowAstriumGmbH
ENVIRONMENT
External, nonaccidental conditions (excluding mechanical loading), separately or in
combination, that can be expected in service life and that can affect the structure, e.g.
temperature,moisture,UVradiationandfuel
ENVISAT
Polar Platform ESA Polar Platform satellite to carry the Envisat1 Earthobservation
instruments.DesignedtolaunchonAriane5anduseESAsDataRelaySatellitesystemforthe
transmissionofdatatoEarth.
EOS
Earthobservationsatellite
EPOXY
1 General: A family of thermosetting resins made by polymerisation of epoxides or oxiranes
withothermaterialssuchasamines,alcohols,phenols,carboxylicacids,acidanhydrides,and
unsaturatedcompounds;usedforthematrixphaseofcompositesandstructuraladhesives
2 Potting compounds: usually twopart epoxy resin systems combined with a suitable filler
that,whencured,producesafoamlikematerial,[Seealso:ADHESIVE(SYNTACTIC)]
ESACOMP
A software package for the analysis and design of composite laminates and laminated
structural elements; developed for ESA/ESTEC by Helsinki University and distributed by
ComponeeringInc
ESTEC
EuropeanSpaceResearchandTechnologyCentre,Noordwijk,NL
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EXOTHERMIC
A type of chemical reaction that produces heat, e.g. can occur during the crosslinking, or
curing,ofpolymerbasedresins,suchasepoxy
F
FABRIC
Anymaterialofwovenconstruction
FACE
1Outerplyofalaminate.
2Coveringsheetsofasandwichpanel
FACESHEET
Acompositelaminateormetalsheetthatformstheexternalsurfacesofasandwichpanel
FACING
A sheet material, usually thin and made of composite or metal, that is attached to a core
materialtoformasandwichpanel;alsoknownasfacesheet
FACTOROFSAFETY
Theratioofthedesignorultimateloadstothelimitorappliedloads.[See:LOADS]
FAILURE(STRUCTURAL)
Therupture,collapse,seizure,excessivewearoranyotherphenomenonresultinginaninability
tosustainlimitloads,pressuresandenvironments
[ECSSEST32]
FASTENER
itemthatjoinsotherstructuralitemsandtransfersloadsfromonetotheotheracrossajoint
[ECSSEST3201]
FATIGUE
1 cumulative irreversible damage incurred by cyclic application of loads to materials and
structures
NOTE1Fatiguecaninitiateandextendcracks,whichdegradethestrengthofmaterialsand
structures.
NOTE2Examples of factors influencing fatigue behaviour of the material are the
environment,surfaceconditionandpartdimensions.
[ECSSEST3201]
2Progressivecrackingmechanismcausedbyalternatingstress
FATIGUELIFE
Thenumberofcyclesofdeformationrequiredtobringaboutfailureofthetestspecimenunder
agivensetofoscillatingconditions
FATIGUESTRENGTH
1 The maximum cyclic stress a material can withstand for a given number of cycles before
failureoccurs
2Theresidualstrengthofamaterialthathasbeensubjectedtofatigue
FATIGUESTRESSRATIO
Theratiooftheminimumtothemaximumfatiguestress,usuallydenotedbyR
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FAULT
Manufacturing: an error or departure from the intended specified process which results in a
defectivematerialorstructure
FE
Finiteelement
FEA
Finiteelementanalysis
FEM
Finiteelementmodelormodelling
FEDERAL
AnAmericanspecification
FIBRECONTENT
Percentvolumeoffibreinacompositematerial.Mostcommoncompositesinusetodayhavea
fibre content between 45 volume % and 70 volume %. Percent weight of mass of fibre is also
used
FIBRECONTROLLED
A laminate layup where the properties are largely determined by those of the fibre, e.g.
0/45/0/45/0
FIBREREINFORCEDPLASTIC(FRP)
Afibrereinforcedthermosettingorthermoplasticpolymermatrixcompositematerial
FILLER
1 Fabric: Yarn oriented at right angles to the warp in a woven fabric; also known as fill, [See
also:WEFT]
2 A material incorporated into a synthetic resin to modify the inherent viscosity and flow
characteristics,e.g.usuallyintheformofglassmicroballoonsforpottingcompoundsusedto
embedinsertsinsandwichpanels
FILMADHESIVE
Asyntheticresinadhesive,usuallyofthethermosettingtypeintheformofathinfilmofresin
withorwithoutafibrouscarrierorsupport.
NOTE: Filmadhesivesusuallyhavesometacktoenabletheirplacementduringassembly
FINISHING
Finalmanufacturingprocesseswhichresultinacomponentreadyforassembly.Oftenusedto
describeminormachiningorcleaningoperations
FLAW
A local discontinuity in a composite structure such as; a scratch, notch, crack, void,
delamination,ordebonding.
NOTE: Somefracturemodelsalsodefineanotchasaflaw,e.g.WEK[Seealso:DEFECT]
FLOW
1Themovementofresinunderpressure,enablingallpartsofamouldorcavitytobefilled,
e.g.flowofpottingcompoundaroundaninsertwheninjectedintoaborehole.
2 Flow or creep is the gradual but continuous distortion of a material under continued load,
oftenatelevatedtemperatures.
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FLUSH(MOUNTED)INSERT
Thepositioningofaninsertsuchthattheuppersurfaceoftheinsertislevel,orflush,withthe
surfaceoftheupperfacesheet
FOAMINGADHESIVE
A synthetic resin adhesive, usually of the thermosetting type which when cured produces a
foamlikematerial.[See:ADHESIVE(SYNTACTIC)]
FOOTPRINT
Theareaofthenut,collarortailofaninstalledmechanicalfastenerthatisincontactwiththe
substratematerial;bearingsurface
FRP
Fibrereinforcedplastic
FULLPOTTING
Themaximumpossiblepottingheightisidenticaltothecoreheight,c;alsoknownasblindor
borne
FULLYPOTTEDINSERT
Aninsertinwhichthepottingmaterialisincontactwiththeinsideofthebottomfacesheet,
G
GAUGELENGTH
Part of a test specimen in which the characteristics of the material are determined; often
instrumentedwithstraingauges,extensometers
GELPOINT
The stage at which a liquid begins to exhibit pseudoelastic properties, also conveniently
observedfromtheinflectionpointonaviscosityversustimeplot
NOTE: AlsocalledGELTIME
GELTIME
Theexposureperiodrequiredataprescribedtemperaturetoconverttheresinfromafluidtoa
definedpartialcurestage
NOTE: Resinflowduringcurecanonlyoccursubstantiallybeforegelling
GENERALISEDHOOKESLAW
The most general linear elastic stressstrain relation for an anisotropic material from which
materialswithvarioustypesofsymmetriescanbederived
GFRP
Glassfibrereinforcedplastic
NOTE: InthishandbookG=glass,butinUSpublicationsG=graphite.[Seealso:CFRP]
GLASSFIBRE
Reinforcement fibres of which E, R and S grades are normally used in composites for
aerospaceapplications
NOTE: Eglass:electricalgrade;RandS:highstrengthgrades
GLASSTRANSITIONTEMPERATURE(Tg)
The temperature at which increased molecular mobility results in significant changes in the
propertiesofacuredresinsystem
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GRP
Glass reinforced plastic; an industrial composite not a highperformance structural composite
foraerospaceapplications,[See:GFRP].Sometimesusedfortabsontheendsofsomecomposite
testspecimens
H
HARDENER
1 A substance or mixture added to a plastic composition to promote or control the curing
actionbytakingpartinit
2Asubstanceaddedtocontrolthedegreeofhardnessofthecuredfilm[Seealso:CATALYST]
HEXAGONALCORE
A core material in which the shape of the individual cells is hexagonal, e.g. aluminium
honeycombcore
HIGHMODULUSCARBONFIBRES(HM)
Arangeofcarbonfibreswhichhaveatensilemoduligreaterthan310GPa,typically
HIGHSTRENGTHCARBONFIBRES(HS)
Arangeofcarbonfibreswhichhavetensilestrengthsupto3500MPaandtensilemoduliinthe
rangeof200GPato255GPa,typically
HIGHTENACITYCARBONFIBRES(HT)
A range of carbon fibres which includes HS high strength fibres and VHS very high strength
fibres
HM
Highmodulus;arangeofcarbonfibresthatalsoincludesUHMultrahighmodulusfibres
HONEYCOMB
Manufactured product of resinimpregnated sheet material (paper, glass or aramidbased
fabric)orsheetmetalformedintohexagonalshapedcells;usedasacorematerialinsandwich
construction;alsoknownasNIDAinEurope
HONEYCOMBSANDWICH
A sandwich construction in which the core material between the face sheets has a hexagonal
cellularformthatresembleshoneycomb
HRG
HauteRsolutionGomtrique,themainpayloadoftheSPOT5earthobservationsatellite
NOTE: ThestructureissimilartoHRVandHRVIRonSPOT3andSPOT4,respectively.
HS
Highstrength;arangeofcarbonfibres
HT
High tenacity (high strength/high strain); a range of carbon fibres which includes HS high
strengthfibresandVHSveryhighstrengthfibres;alsoknownashightension
HYGROSCOPIC
Tendingtoabsorbmoisturefromtheair
HYGROTHERMAL
Thecombinationofmoistureandtemperature
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I
IATP
Insertallowabletestprogramme,conductedintwostagesIATP1andIATP2;anESAfunded
study
IDH
Insertdesignhandbook
ILSS
Interlaminarshearstrength
IM
1Intermediatemodulus;arangeofcarbonfibresthathavetensilemoduliintherangeof255
GPato310GPa,typically
2IntegrationModel
INHOUSE
Aprocessorteststandardcreatedandusedwithinaparticularorganisation;oftenconsidered
asconfidentialandsonotdisclosedtootherparties
INSERT
1 An integral part of a plastic moulding, consisting of metal or other material which can be
mouldedintopositionorpressedintothemouldingafterthemouldingiscomplete
2Afixingdeviceortypeoffastenersystem,commonlyusedinsandwichpanels
INSERT(FLUSH)
Aninsertpositionedsuchthatitssurfaceislevelwiththatofthefacesheet
INSERT(FLUSHMOUNTED)
An insert positioned in a sandwich panel such that the upper surface of the insert is level, or
flush,withthesurfaceoftheupperfacesheet
INSERT(OVERFLUSH)
Aninsertpositionedabovethesurfaceofthefacesheet;alsoknownasprotrudinginsert
INSERT(PROTRUDING)
Aninsertpositionedsuchthattheendoftheinsertextendsbeyondthesurfaceofthesandwich
panel;alsoknownasproudoroverflush
INSERT(SUBFLUSH)
Aninsertpositionedsuchthattheendoftheinsertisbelowthesurfaceofthefacesheet;also
knownasrecessedinsert
INSERT(THROUGHTHETHICKNESS)
Aninsertwhichpassesthroughtheentiresandwichpanelthicknessalsoknownastransverse,
doublesidedorspool.
INSERT(TYPE)
The various types of inserts can be grouped by the means that they are embedded into a
sandwichpanel:
(A)forsimultaneousbondingduringsandwichproduction,alsoknownascocure;
(B) for an existing sandwich using either a thermosetting resin (usual potting process of
standard inserts) or for nonstandards inserts by an equivalent bonding process, e.g. carbon
fibretubeinserts;
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(C)formechanicalclampingorscrewingintoanexistingsandwich.
INSPECTION
Averificationmethodforphysicalcharacteristicsthatdeterminescompliancewithrequirement
without the use of special laboratory equipment, procedures, items or services. Inspection
makesuseofstandardmethodstoverifyrequirementsforconstructionfeatures,documentand
drawingcompliance,workmanship,physicalconditions,GlossaryRef.[Ref1]
INSPECTIONPROCEDURE
This document lists all the requirements to be verified by Inspection, grouping them in
categoriesdetailing the Verification Plan activity sheets, with planning of theexecutionanda
definitionoftheassociatedprocedures,GlossaryRef.[Ref1]
INSPECTIONREPORT
Thisdocumentdescribeseachverificationactivityperformedwheninspectinghardwareduring
manufacturing/integration and contains proper evidence that the relevant requirements are
satisfiedandtheindicationofanydeviation,GlossaryRef.[Ref1]
INTERLAMINARSHEARSTRENGTH(ILSS)
Theshearstrengthexistingbetweenlayersofalaminatedmaterial
INTERMEDIATEMODULUSCARBONFIBRES(IM)
Arangeofcarbonfibreswithtensilemoduliintherangeof255GPato310GPa,typically
IR
InfraRed
ISO
Internationalstandardsorganization
ISOTROPIC
Property that is not directionally dependent. [Having the same physical or mechanical
propertiesinallmaterialdirections].Metalsareoftenassumedtobeisotropic.Thisisnormally
not the case, but they do generally show considerably less anisotropy than fibrereinforced
composites
ISOTROP
[See:ISOTROPIC]
J
JIG
A fixture or tool that retains a material, sample or structure, e.g. for testing or during
processing;alsoknownasrigorfixture
JIS
JapaneseInstituteofStandards
K
K49
Kevlar49
KEVLAR
AgradeofaramidfibrefromE.I.DuPontdeNemours[Seealso:ARAMID]
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KFRP
Kevlarfibrereinforcedplastic
L
LAMINA
[See:PLY]
LAMINATE
Plateconsistingoflayersofuniormultidirectionalpliesofoneormorecompositematerials
LAYUP
1Handormachineoperatedprocessofplybyplylayingofamultidirectionallaminate
2Plystackingsequenceorplyorientationsofalaminate
LIGHTALLOY
Generaltermformetalalloysoflowdensity,e.g.aluminium,magnesium,whichusuallyhave
highspecificstrengths(ratioofstrengthtodensity)
LIMITEDSHELFLIFE
Aperiodoftime,usuallystatedbythemanufacturerorsupplier,thatwhenelapsedmeansthat
amaterialcannolongerbeprocessedtoproduceconsistentlystablefinalproperties,[Seealso:
SHELFLIFE]
LIMITLOAD
[See:LOADS]
LIMITLOAD(LL)
maximumload(s),whichastructureisexpectedtoexperiencewithagivenprobability,during
theperformanceofspecifiedmissionsinspecifiedenvironments.
[ECSSEST32]
[Seealso:LOADS]
LIMITSTRESS
[See:LIMITLOAD]
LINEARELASTICFRACTUREMECHANICS(LEFM)
Engineeringprincipletodescribethepropagationofasinglecrackthroughamaterial,usuallya
metalalloy,inwhichitisassumedthatallthematerialisbehavingelastically
LN
LuftNorm;aGermanstandard
LOADS
Strengthrequirementsarespecifiedintermsof:
1LimitLoads:Themaximumexternalloadstobeexpectedduringoperationaluse
2 Ultimate Loads: Limit loads multiplied by prescribed FACTORS OF SAFETY, e.g. the
ultimateloadsareoftenestablishedbyapplyingafactorofsafetyof1,5onlimitloads
LOADDEFLECTIONCURVE
Agraphicalrepresentationoftheextensionofamaterialunderanappliedload;oftenrecorded
duringthemechanicaltestingofasample
LOADSTRAINCURVE
Agraphicalrepresentationoftheextensionofamaterialunderanappliedload
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M
MACHINING
removal of material in a controlled manner by one or more mechanical, electrical or chemical
methods,e.g.turning,milling,drilling,electrochemicaldischarge,andultrasonic.[ECSSQ70
71]
MANMT
PartoftheGermanMANTechnologiecompany
MARGINOFSAFETY
Ratioofexcessstrengthtotherequired(calculated)strength
MASS(ofinsertsystem)
Calculatedby(pottingmass+massofinsertcomponents)(massoffacesheetremoved+mass
ofcoreremoved)
MASS(ofpotting)
Describes the volume of cured potting compound used to retain a potted insert within a
sandwichpanel;alsoknownaspottingmass
MATERIAL
raw, semifinished or finished purchased item (gaseous, liquid, solid) of given characteristics
fromwhichprocessingintoafunctionalelementoftheproductisundertaken
[ECSSP001]
MATERIALDESIGNALLOWABLE
materialpropertythathasbeendeterminedfromtestdataonaprobabilitybasisandhasbeen
chosentoassureahighdegreeofconfidenceintheintegrityofthecompletedstructure
[ECSSEST3208]
MATHEMATICALMODELLING
Analyticalverificationbasedonmathematicalmodellingofthesystem.Modellingisperformed
on the basis of known mathematical techniques, providing a representation of the system
featuresunderinvestigation,GlossaryRef.[Ref1]
MBBERNO
Part of the German MBB aerospace organisation located in Bremen. Original authors of the
insertdesignhandbook;nowpartofAstriumGmbH
MD
Multidirectional
MECHANICALLOAD
Mechanicallyappliedload,distinguishedfromcureorenvironmentinducedload
MECHANICALPART
pieceofhardwarewhichisnotelectrical,electronicorelectromechanical,andwhichperformsa
simple elementary function or part of a function in such away that it can be evaluated as a
whole against expected requirements of performance and cannot be disassembled without
destroyingthiscapability
[ECSSP001]
METALLICCORE
Anycorethatismadeofmetal,e.g.oftenmadeofanaluminiumalloy
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MICROBALLOONS
Afillermaterialmadeofverysmall,hollowglassspheresthatismixedintosyntheticresinsto
modifytheflowandviscositycharacteristicsoftheresultingpottingcompounds;alsoknownas
microspheres
MILA81596
Aluminumfoilforsandwichconstruction;USAspecification
MILA8625
Anodiccoatingsforaluminiumandaluminiumalloys;describesanodisingprocessesforinserts;
USAspecification
MILC5541
Chemical conversion processes on aluminium alloys; describes chromating processes for
inserts;USAspecification
MILC7438
Corematerialaluminum,forsandwichconstruction;USAspecification
MILC81986
Core Material plastic honeycomb: nylon paper base for aircraft structural applications; USA
specification
MILHDBK17
CompositeMaterialsHandbook;USAspecification
MILHDBK23
StructuralSandwichComposites;USAspecification.
NOTE: MILHDBK23isunderreviewforpartialincorporationasVolume6ofMILHDBK17
MILHDBK5
MetallicMaterialsandElementsforAerospaceVehicleStructures;USAspecification
MILstandardsandspecifications
InformationregardingcurrentMILdesignationspecifications(http://store.milstandards.com/)
MODULUS
Anelasticconstantdefinedastheratiobetweentheappliedstressandtherelateddeformation,
suchasYoungsmodulus,shearmodulus,orstiffnessmoduliingeneral
MOISTUREABSORPTION
Moistureabsorptioncausesthepropertiesofepoxytochange;itcanbedetrimentalincausing
theglassytemperatureoftheepoxytobesuppressed,andbeneficialbycounteractingswelling
duringstresses
MOISTURECONTENT
The amount of moisture in a material determined under prescribed conditions and usually
expressedasapercentageofthemassofthemoistspecimen,i.e.themassofthedrysubstance
plusthemoisturepresent
MOULDRELEASEAGENT
Lubricantappliedtomouldsurfacestofacilitatereleaseofthemouldedpart
M.S
Marginofsafety
MULTIDIRECTIONAL
1Havingmultipleplyorientationsinalaminate
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2 Composite laminates in which the properties are controlled by the orientation of the
reinforcementfibres,i.e.fibrecontrolled
N
NAS
NationalAerospacestandard
NDI
Nondestructiveinspection,[See:NONDESTRUCTIVE]
NDT
Nondestructivetesting,[See:NONDESTRUCTIVE]
NF
NormeFranaise;Frenchnationalstandard
NIDA
Europeantermforhoneycomb;atypeofcoreusedinsandwichpanels
NOMEX
An aramid fibre blend from E.I. Dupont de Nemours. Used as the reinforcement material in
nonmetallichoneycombcoresforsandwichconstructions
NONASSESSEDPROCESS
A process that has no history of previous use in the space environment, and for which no or
insufficientdataareavailablerelevanttotherequiredprojectapplication
NONMETALLIC(CORE)
Anycorematerialthatisnotmadeofmetal.Corematerialsofsandwichpanelsusedforspace
applicationsarenormallymadeofNomexorglassfibrereinforcedplastic
NONDESTRUCTIVE
Techniquesusedtoqualitativelyevaluateorquantitativelymeasurepropertiesordetectdefects
in materials, structural components or whole structures which do not cause a permanent
change to the item under test, e.g. ultrasound, holography, eddy current. The terms NDI
(inspection), NDT (testing), NDC (characterisation) and NDE (evaluation) tend to be
interchangeable.Nondestructiveinspectionsystemscanbemanuallyinterpretedorautomated
tosomeextent.Allrequirecalibration,andthedetectionlimitforeachtechniquevaries.
NOTE: Noonetechniqueiscapableofdetectingalltypesofdefects.
NSA
NormalisationSudAviation;Frenchstandard
O
OFFAXIS
Notcoincidentwiththeaxisofsymmetry
NOTE: Alsocalledoffangle
OFFGASSINGPRODUCT
organicorinorganiccompoundevolvedfromamaterialorassembledarticleorexperimentor
rack
[ECSSQST7029]
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OFFGASSING
1 General: Depending on the application, there are restrictions on the gaseous products
releasedfrommaterialsorfinishedarticlesinoperationalvacuumconditionsthatcan:
contaminateotherequipment,[Seealso:OUTGASSING];
contaminatetheairduringpreparatoryoroperationalconditionsformannedspacecraft.
2evolutionofgaseousproductsforanassembledarticlesubjectedtoslightradiantheatinthe
specifiedtestatmosphere
[ECSSQST7029]
NOTE: Itappliestomaterialsandassembledarticlestobeusedinamannedspacevehicle
crewcompartment.
ONAXIS
Coincidentwiththeaxisofsymmetry;alsoknownasonangle,[See:ORTHOTROPIC]
ORTHOTROPIC
Adescriptionofmaterialsymmetrywherethexaxisandyaxisofalaminatecoincidewiththe
longitudinalandtransversedirectionsofthematerial;alsoknowasonaxis
ORTHOTROPY
Havingthreemutuallyperpendicularplanesofsymmetry.Unidirectionalplies,fabric,crossply
andangleplylaminatesareallorthotropic
ORTHOGONALWEAVE
Afabricinwhichthewarpandweftdirectionsare90toeachother
OUTGASSING
1 General: Depending on the application, there are restrictions on the gaseous products
releasedfrommaterialsorfinishedarticlesinoperationalvacuumconditionsthatcan:
contaminateotherequipment(outgassing)
contaminate the air during preparatory or operational conditions for manned spacecraft,
[Seealso:OFFGASSING]
2Releaseofgaseousspeciesfromaspecimenunderhighvacuumconditions[ECSSQST70
02]
P
PA
ProductAssurance
PAN
Panaviastandard
PART
hardware item that cannot be disassembled without destroying the capability to perform its
requiredfunction
[ECSSP001]
PARTIALPOTTING
Thepottingheightisgenerallysmallerthanthecoreheight,c;alsoknownasblind,borneor
singlesided
PARTIALLYPOTTEDINSERT
Aninsertinasandwichpanelinwhichthereissomecoreremainingunderthepottedinsert,
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PASTE
Adhesive:asingleortwocomponentadhesivethatoftenincludesathickeningagent,suchas
microballoons,thatbehavesasaviscousliquid
PATRIAFINAVICOMP
Finnishaerospaceanddefencecompany
PEELPLY
Sacrificial sheets of material, usually a fabric, applied to the external surfaces of composites;
afterprocessingpeelpliesareremovedtoprovideaclean,contaminantfreesurface
PERMISSIBLELOAD
A load, proven by analysis and testing, with a known statistical confidence, that can be
supportedbyamaterialorassemblywithoutresultinginunacceptabledamageordegradation
throughouttheintendedperiod;alsoknowasallowableload
PLASTIC
A material that contains as an essential ingredient an organic substance of high molecular
weight, is solid in its finished state, and at some stage in its manufacture or processing into
finishedarticlescanbeshapedbyflow;madeofplastic
PLY
Asinglelayerofalaminatedstackofcompositematerial(orasinglepassforafilamentwound
configuration)
PLYDROP
Thepositioninsidealaminatewhereaplyisterminated,e.g.tocreateataperedthickness
PLYGROUP
Groupformedbycontiguousplieswiththesameangle
POISSONSRATIO
The ratio between the extension (Strain) of an elastic material in the axial direction and the
accompanyingcontractionsinthetransversedirectionswhenuniaxialstressisapplied.
NOTE: Thetransversestrainisaconstantfractionofthestraininthelongitudinaldirection,
e.g.forperfectlyisotropicelasticmaterials,Poissonsratio(xaxis)is0,25,whereasmostalloys
haveavalueofabout0,33,GlossaryRef.[Ref2]
POLYMER
high molecular weight organic compound, natural or synthetic, with a structure that can be
representedbyarepeatedsmallunit,themer
NOTE: E.g.polyethylene,rubberandcellulose
[ECSSEST3208].
NOTE: Synthetic polymers are formed by addition or condensation polymerisation of
monomers.Somepolymersareelastomers,someplastics
POLYMERISATION
A chemical reaction in which the molecules of a monomer are linked together to form large
moleculeswhosemolecularweightisamultipleofthatoftheoriginalsubstance
POSTCURE
Anadditionalelevatedtemperaturecure,usuallywithoutpressure,toimprovefinalproperties
or complete the cure. Complete cure and ultimate mechanical properties of certain resins are
attainedonlybyexposureofthecuredresintohighertemperaturesthanthoseofcuring
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POTLIFE
lengthoftimeacatalysedresinsystemretainsaviscositylowenoughtobeusedinprocessing
NOTE: AlsocalledWorkingLife.
[ECSSQ7071]
POTTEDINSERT
Aninsertthatisretainedinasandwichpanelbyavolumeofcuredpottingcompound
POTTEDINSERT(CLASSICAL)
The usual means of incorporating a standardtype of insert into a sandwich panel using a
pottingprocess;alsoknownasconventionalpottedinsert
POTTING
Theprocessofembeddinginsertsintoasandwichpanelusingapottingcompound
POTTING(FULL)
Themaximumpossiblepottingheightisidenticaltothecoreheight,c;alsoknownasblindor
borne
POTTING(MASSOF)
Thevolumeofcuredpottingcompoundusedtoretainapottedinsertwithinasandwichpanel
POTTING(PARTIAL)
Thepottingheightisgenerallysmallerthanthecoreheight,c;alsoknownasblind,borneor
singlesided
POTTINGCOMPOUND
A polymer resin system (base, hardener, catalyst) usually epoxybased, that often contains a
filler or thickening agent to modify the viscosity and flow characteristics; used for retaining
insertsinsandwichpanels
POTTINGMASS
A calculated quantity determined from the core properties (height and cell size) and insert
diameterandwhethertheinsertispartiallyorfullypotted
POTTINGPROCESS
The sequence of operations by which inserts are embedded into sandwich panels, e.g.
positioningoftheinsertinamachinedhole,mixingofresinandaddingthefiller,injectioninto
thesandwichpanel,curing(usuallyseveralhoursatroomtemperature)
POTTINGRESIN
A polymerbased resin system (base, hardener and catalyst) that is combined with a suitable
filler(tomodifytheviscosityandflowcharacteristics)toformapottingcompoundsuitablefor
pottingofinsertsintosandwichpanels;usuallyanepoxybasedresinsystem
PREPREG
wovenorunidirectionalplyimpregnatedwitharesin,usuallyadvancedtoBstage,readyfor
layuporwinding
NOTE: Shortforpreimpregnated.
[ECSSQ7071]
prEN
ProvisionalordraftENstandard
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PRIMER
Acoatingappliedtoasurfacebeforetheapplicationofanadhesive,lacquer,paint,enamelor
theliketoimprovetheperformanceofthebond
PROCESS
setofinterrelatedorinteractingactivitieswhichtransforminputsintooutputs
NOTE1Inputstoaprocessaregenerallyoutputsofotherprocesses.
NOTE2Processesinanorganizationaregenerallyplannedandcarriedoutundercontrolled
conditionstoaddvalue.
NOTE 3 A process where the conformity of the resulting product cannot be readily or
economicallyverifiedisfrequentlyreferredtoasaspecialprocess.
[ECSSP001]
PROOFTEST
test of flight hardware under the proof load or pressure, to give evidence of satisfactory
workmanshipandmaterialqualityortoestablishtheinitialcracksizesinthehardware
[ECSSEST32]
PROTRUDINGINSERT
Aninsertpositionedsuchthattheflange(s)oftheinsertprotrudesbeyondthesandwichpanel
surface;alsoknownasproudoroverflush
psi
Poundspersquareinch
PSSIDH
ReferstoESAPSS031202Issue1Revision1(September1990);apreviousversionoftheinsert
designhandbook
PVC
Polyvinylchloride
Q
QA
Qualityassurance
QC
Qualitycontrol
QUALIFICATION
Verification phase with the objective to demonstrate that the design meets the applicable
requirementsincludingpropermargins,GlossaryRef.[Ref1]
QUASIISOTROPICLAMINATE
Alaminateapproximatingisotropybyorientationofpliesinseveralormoredirections
R
Rratio
ratiooftheminimumstresstomaximumstress
[ECSSEST3201]
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RECESSEDINSERT
Aninsertpositionedbelowthesurfaceofthefacesheet;alsoknownassubflushinsert
RECOVEREDMASSLOSS(RML)
totalmasslossofthespecimenitselfwithouttheabsorbedwater
NOTE1 Thefollowingequationholds:
RML=TMLWVR.
NOTE2 TheRMLisintroducedbecausewaterisnotalwaysseenasacriticalcontaminantin
spacecraftmaterials.
[ECSSQST7002]
REFERENCESAMPLE
Usedtoassessthepottingprocess.Areferencesampleisproducedusingidenticalmaterialsto
theassembly(insert,facesheets,core,adhesive)atthesametimeasthemanufacturedassembly
andundergoesallthesameprocesses,e.g.machining,potting,curing;alsoknownaswitness
sample
REINFORCEDPLASTIC
Aplasticwithstrengthpropertiesgreatlysuperiortothoseofthebaseresin,resultingfromthe
presenceofreinforcementsembeddedinthecomposition
REINFORCEMENT
Astronginertmaterialbondedintoaplastic,metalorceramictoimproveitsstrength,stiffness
and impact resistance. Reinforcements are usually long fibres of glass, boron, graphite or
aramid, in woven or non woven form. To be effective, the reinforcing material must form a
strongadhesivebondwiththematrix
NOTE: Reinforcementisnotsynonymouswithfiller.
RELATIVEHUMIDITY(RH)
A measure of the moisture content of an atmosphere with respect to the fully saturated
atmosphereatthesametemperatureandpressure;expressedasapercentage
RELEASEAGENT
A material which is applied in a thin film to the surface of a mould to keep the resin from
bondingtoit
RELEASEFILM
A thin sheet of material applied to a composite surface to enable its removal from a mould;
usedinautoclaveprocessing
REPAIR
Operationsperformedonanonconformingitemtoplaceitinusableandacceptablecondition
accordingtoanauthorisedrepairprocedure/standard.Repairisdistinguishedfromrework
NOTE: Repair can consist of a component change with all its associated connections
includingthefixingdownofaliftedpadortrack.
RESIDUALFATIGUESTRENGTH
The retention ofstatic strength byalaminate that has been subjected to a certain fatigueload
history
RESIDUALSTRENGTH
The retention of static strength by a material or assembly that has been subjected to a load
history or environment, e.g. cyclic mechanical loading (fatigue test); thermal cycling; thermal
soak
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RESIDUALSTRESS
1Astressthatremainsinthematerialorstructure,owingtoprocessing,fabricationorprior
loading
2 Composites: Resulting from cooldown after cure and change in moisture content. On the
micromechanicallevel,stressistensileintheresinandcompressiveinthefibre.Onthemacro
mechanical level, it is tensile in the transverse direction to the unidirectional fibres, and
compressiveinthelongitudinaldirection,resultinginaloweredfirstplyfailureload.Moisture
absorptionoffsetsthisdetrimentalthermaleffectatbothmicroandmacrolevels
3Metals:Usuallyarisesfromheattreatmentormechanicalworking
RESIN
A solid, semisolid, or pseudosolid organic material which has an indefinite (often high)
molecularweight,exhibitsatendencytoflowwhensubjectedtostress,usuallyhasasoftening
or melting range, and usually fractures conchoidally. Most resins are polymers. In reinforced
plastics, the material used to bind together the reinforcement material, the matrix. [See also:
POLYMER]
RESINCONTENT
Theamountofresininalaminateexpressedasapercentoftotalweightortotalvolume
RF
Radiofrequency
R.F.
Reservefactor
RGLASS
Ahighstrengthgradeofglassfibre,[Seealso:GLASSFIBRE]
RH
Relativehumidity
RIG
Afixtureortoolthatretainsamaterial,sampleorstructure,e.g.fortestingandprocessing;also
knownasjigorfixture
RML
Recoveredmassloss
RMS
Rootmeansquare
ROSETTA
ESAcometrendevousmission.LaunchedinMarch2004,Rosettawillbethefirstmissioneverto
orbitandlandonacomet.FollowingthedecisionnottolaunchEuropescometchaser,Rosetta,
in January 2003, scientists and engineers in the programme examined several alternative
missionscenarios.Eachwasjudgedonthebasisoftheexpectedscientificreturn,thetechnical
risksrelatedtousingtheRosettadesigninthenewmission.InMay2003,Rosettawasprovided
withanewtarget(http://www.esa.int/science/rosetta)
RT
Roomtemperature
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RULEOFMIXTURES
Linear volume fraction relation between the composite and the corresponding constituent
properties; also known as Law of Mixtures e.g. For modulus of a composite Ec, the rule of
mixturesequationis:
Ec E f V f EmVm
where:
Ef=modulusofthefibre
Vf=volumefractionoffibreinthecomposite
Em=modulusofthematrix
Vm=volumefractionofthematrix
S
SANDWICH
1 Construction: An assembly composed of a lightweight core material, such as honeycomb,
foamedplastic,andsoforth,towhichtworelativelythin,dense,highstrengthorhighstiffness
facesorskinsareadhered,[Seealso:FACESHEET]
2Panel:Asandwichconstructionofaspecifieddimensions
NOTE: Thehoneycombandfaceskinscanbemadeofcompositematerialormetalalloy.
SATELLITE
Anunmannedspacecraftgenerallyorientedtoscientific,telecommunication,earthobservation
missions,GlossaryRef.[Ref1]
SCOTCHLITE
Aproprietarybrandofglassmicroballoons,manufacturedandsuppliedby3M
SD
Standarddeviation;astatisticallyderivedquantity
SECONDARYBONDING
Aprocesswherebymanufacturedcomponentpartsarejoinedbyanadhesive;canbeappliedto
compositepartsthathavealreadybeencuredormetalpartsorcombinationsthereof
NOTE: Thisisdifferentfromcocuring,[Seealso:COCURING].
SERVICECONDITIONS
The combination of mechanical loading and environmental effects experienced by a material,
componentorstructureinoperationoveritsintendedlife
SERVICELIFE
interval beginning with the last item inspection or flaw screening proof test after
manufacturing,andendingwithcompletionofitsspecifiedlife
[ECSSEST32]
SGLASS
A magnesiaaluminasilicate glass, especially designed to provide filaments with very high
tensilestrength
SHEARMODULUSRATIO
Ratio of the shear modulus of the core material to that of the face sheet in a sandwich
construction
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SHELFLIFE
1statedtimeperiodinwhichthemanufacturerguaranteesthepropertiesorcharacteristicsofa
productforthestatedstorageconditions,[ECSSQ7071]
2 Period of time during which a material can be processed to produce final properties with
consistentlystableparameters,[ECSSQST7022]
SHELFLIFE(LIMITED)
Aperiodoftime,usuallystatedbythemanufacturerorsupplier,thatwhenelapsedmeansthat
amaterialcannolongerbeprocessedtoproduceconsistentlystablefinalproperties,[Seealso:
SHELFLIFE]
SHOPLIFE
The shop life of a prepreg is that period following removal from the specified storage
conditions and attaining shopfloor temperature for which the prepreg remains workable in
termsoftack,andflowandcurecharacteristics
SHURLOK
Manufacturerandsupplierofstandardtypesofinsertsandacommonlyusedpottingresin
SI
Theinternationalsystemofunits,publishedbytheInternationalStandardsOrganisation(ISO)
SILEX
Semiconductor laser intersatellite link experiment. The ESAdeveloped SILEX terminal on
boardtheArtemissatellitehasenabledittoreceivepicturedatafromtheFrenchSpot4satellite
vialaser
SKIN
Asheetofmaterialappliedtooutsidesurfaceofacoreinordertomakeasandwichpanel;also
knownasfacesheetandfaceskin
SMH
Structuralmaterialshandbook;ECSSEHB3220
SNCURVE
Stresspernumberofcyclestofailure;agraphusedtodisplayfatiguetestingresults
SPACECRAFT
A space system which could be either manned or unmanned and could have any type of
mission objectives, i.e. telecommunications, transportation, earth observation, interplanetary
exploration,GlossaryRef.[Ref1]
SPACEPROVENMATERIALORMECHANICALPART
Onewhosepropertiesarewellunderstoodandthatisproducedbymeansofastableprocess,
usuallyconfirmedbyahistoryofcontinuousorfrequentproductionruns.Itmustbecompliant
witharecognisedsetofspecifications.Itwillhavebeenusedinspaceapplications,orwillhave
successfullycompletedanappropriateevaluationprocess
SPECIFICGRAVITY(SG)
A dimensionless quantity also known as Relative Density. Ratio between the density of a
materialandthatofwaterunderstandardconditions
SPECIFICSTIFFNESS
Themeasureofthestiffnessofamaterialwithrespecttoitsdensity
SPECIFICSTRENGTH
Themeasureofthestrengthofamaterialwithrespecttoitsdensity
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SPOOLINSERT
Throughthethicknessinsert
SPOT
AseriesofEarthobservationsatellitesprovidingdataformapping,disastermanagementand
controllingtheenvironment
SPOT5
TheCNESSPOT5satellitewassuccessfullyplacedintoSunsynchronousorbitinMay2002by
an Ariane 4 launcher. This, the fifth SPOT satellite to be launched, ensures the continuity of
SPOTEarthobservationdataandprovidesevenbetterhighresolutionimages
STACKINGORDERorSEQUENCE
Ply ordering in a laminate. Stacking sequence does not affect the inplane properties of a
symmetric laminate. Only the ply number and angles are important. But stacking sequence
becomes critical for the flexural properties, and the interlaminar stresses for any laminate,
symmetricornot;alsoknownaslayup
STANDARDORESTABLISHEDPROCESS
Onethatiswelldocumented,hasaprevioushistoryofuse,iswellunderstoodandforwhich
standard inspection procedures exist. Such a process would generally be covered by ECSS
specificationsorotherinternationalornationaldocuments
STATICFATIGUE
Failureofapartundercontinuedstaticload;analogoustocreeprupturefailureinmetaltesting,
butoftentheresultofageingacceleratedbystress
STIFFNESS
Ratiobetweentheappliedstressandtheresultingstrain.Youngsmodulusisthestiffnessofa
material subjected to uniaxial stress; shear modulus to shear stress. For composite materials,
stiffness and other properties are dependent on the orientation of the material. [See:
MODULUS]
STORAGELIFE
Thelengthoftimethatamaterialcanbekeptunderpredeterminedconditionsandnotdegrade,
e.g. Prepreg: usually 18 C for thermosetting resin systems, with subsequent factory floor
operationsatroomtemperature,[Seealso:SHELFLIFE]
STRAINGAUGE
Widely used device for point measurement of strain. Usually thin film metals which, when
strained,changeinelectricalresistance
NOTE: Requirecalibrationandtemperaturecompensation.
STRENGTHRATIOorSTRENGTH/STRESSRATIO
Measure related to MARGIN OF SAFETY. Failure occurs when the ratio is unity; safety is
assuredforexamplebyafactorof2iftheratiois2.Theratioisparticularlyeasytoobtainifthe
quadraticfailurecriterionisused
STRENGTH
Maximum stress that a material can sustain. Like the stiffness of a composite material, this is
highly dependent on the direction as well as the sign of the applied stress; e.g. axial tensile,
transversecompressive,andothers
STRESSAMPLITUDE(R)
Fatiguetest:therangeofstressesinducedinalaminatewhenacyclicloadisapplied,[Seealso:
R]
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STRESS
Intensityofforceswithinabody.Thenormalcomponentsinducelengthorvolumechange;the
shear component, shape change. The numerical value of each component changes as the
reference coordinate system rotates. For every stress state there exists a principal direction, a
uniquedirectionwhenthenormalcomponentsreachmaximumandminimum,andtheshear
componentvanishes
STRESSSTRAINCURVE
A graphical representation of a materials response to increasing load. Often used to depict
relationshipsbetweenstress(load)andstrain(elongation),e.g.stiffness,strength(s)andstrainto
failure
STRESSSTRAINRELATION
Alinearrelationisusuallyassumedforcalculatingstressfromstrain,orstrainfromstress.For
multidirectional laminates, it can be generalised to include inplane stressstrain, and flexural
stressstrainrelations.Allanisotropicrelationsaresimpleextensionsoftheisotropicrelation
STRUCTURALCOMPONENT
Amajorsectionofthestructure(e.g.wing,body,fin,horizontalstabiliser)thatcanbetestedas
acompleteunittoqualifythestructure
STRUCTURALFAILURE
[See:FAILURE(STRUCTURAL)]
STRUCTURALSUBCOMPONENT
A major threedimensional structure that can provide complete structural representation of a
sectionofthefullstructure(e.g.stubbox,sectionofspar,wingpanel,wingrib,bodypanelor
frames)
STRUCTURE
Allitemsandassembliesdesignedtosustainloadsorpressures,providestiffnessandstability,
orprovidesupportorcontainment
STYCAST
Aproprietarytypeofpottingresin,producedbyEmersonandCumin
SUBASSEMBLY
Asubdivisionofanassemblyconsistingoftwoormoreitems
NOTE: VerificationleveltypicalofUSstandard,GlossaryRef.[Ref1].
SUBSYSTEM
1Afunctionalsubdivisionofapayloadconsistingoftwoormoreitems
2 A set of functionally related equipment, connected to each other, that performs a single
categoryoffunctions,e.g.structure,power,attitudecontrol,thermalcontrol,GlossaryRef.[Ref
1]
SWARF
Wastematerial,usuallymetallic,producedduringmachiningprocesses
SYMMETRICLAMINATE
Possessing midplane symmetry. This is the most common construction, because the curing
stresses are also symmetric. The laminate does not twist when the temperature and moisture
content change. An unsymmetrical laminate on the other hand twists on cooling down and
untwistsafterabsorbingmoisture
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SYNTACTIC
1General:Highlyordered
2Apottingcompoundcontainingafillermadeofhollowglassmicrospheresthat,whencured,
hasafoamlikestructure,[Seealso:ADHESIVE(SYNTACTIC)]
SYSTEM
Thecompositeofelements,skillsandtechniquescapableofperformingtheoperationalroles.A
system includes all operational equipment, related facilities, materials, software, services and
personnelrequiredforitsoperation,e.g.launchsystem,onorbitsystem,GlossaryRef.[Ref1]
T
T
Toxichazardindex
TAB
Amaterial,usuallyfixedtoeachendofatestspecimen,whichenablesloadtobetransferredto
thetestspecimenwithoutcausingdamagetothetestspecimen;compositetestspecimensoften
havelightalloyorglassfibrebasedcompositetabsadhesivelybondedtothetestspecimen
TACK
Stickinessofaprepregorfilmadhesive;animportanthandlingcharacteristic
TAN
TransallNorm;aspecification
TEST
A verification method wherein requirements are verified by measurement of performance
relativetofunctional,electrical,mechanicalandthermalparameters.Thesemeasurementscan
require the use of special equipment, instrumentation and simulation techniques, Glossary
Ref.[Ref1]
TESTPROCEDURE
AdocumentwhichprovidesdetailedstepbystepinstructionstotheTestteamsforconducting
thetestactivitiesinagreementwiththeTestSpecificationrequirements,GlossaryRef.[Ref1]
TESTSPECIFICATION
AdocumentpreparedforeachmajortestactivitydescribedintheVerificationPlantasksheets
withtheobjectivetodetailthetestrequirements,Ref.[Ref1]
Tg
Glass transition temperature; the temperature at which a material changes from a glassy to
ductilestate,givingasteepincreaseinfreevolume
THERMALCONDUCTIVITY
Ability of material to conduct heat; the physical constant for quantity of heat that passes
throughaunitcubeofasubstanceinunittimewhenthedifferenceintemperatureoftwofaces
is1degree
THERMALCYCLING
The repeated change of temperature experienced by a material, component or structure; the
maximumandminimumtemperaturesarenormallythoseassociatedwithorbitingtheEarth
THERMALEXPANSION
[See:COEFFICIENTOFTHERMALEXPANSION]
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THERMALLOAD(STRESS)
The structural load (or stress) arising from temperature gradients and differential thermal
expansionbetweenstructuralelements,assemblies,subassembliesoritems
THERMALSHOCK
Suddenandrapidchangeintemperature,usuallyoveralargetemperaturerange
THERMALSOAK
Aperiodoftimethatamaterial,componentorstructureisexposedtoanelevatedtemperature,
e.g.structuresunderneaththermalprotectionsystems
THERMOCOUPLE
Deviceformeasuringtemperatureconsistingoftwodissimilarconductorsjoinedattheirends
which,whenheated,developacharacteristicEMF.Thetemperatureisindicativeofthatofthe
junctionofthepairinthethermocouple,i.e.apointmeasurementdevice.
NOTE: Calibrationandcompensationarerequired.
THERMOPLASTIC
Organicmaterial,thestiffnessofwhichcanbereversiblychangedbytemperaturechange.One
unique property of this material is its large strain capability, e.g. PEEK. On the other hand,
processingrequireshighertemperaturesandpressuresthanthoseforthermosettingplastics
THERMOSETTING
Organic material that can be converted to a solid body by crosslinking, accelerated by heat,
catalyst, ultraviolet light, and others. This is the most popular type of material for the matrix
phaseofcompositematerials,adhesivesandpottingresins,[Seealso:EPOXY]
THROUGHTHETHICKNESSINSERT
Aninsertwhichpassesthroughtheentiresandwichpanelthickness,alsoknownastransverse,
doublesided,spoolorthruspool
TITANIUM(Ti)
Metallicelement,meltingpoint1670C,density4540kgm3.Uses:alloyingadditions,classof
aluminide.Matrixalloyforcomposites,structuralmaterialsforaerospaceusesgenerallywhere
operational temperatures exceed those possible with aluminium. Manufacture of structural
shapes with superplastic forming/diffusion bonding technique, [See also: SPF/DB]. Extremely
difficulttocast.Sensitivetopresenceofhydrogenandoxygen
Tm
Meltingtemperatureatwhichthematerialchangesfromthesolidstatetothemoltenstate,in
C
TML
Totalmassloss.[Seealso:OFFGASSING,OUTGASSING]
TOTALMASSLOSS(TML)
totalmasslossofmaterialoutgassedfromaspecimenthatismaintainedataspecificconstant
temperatureandoperatingpressureforaspecifiedtime
NOTE: TMLiscalculatedfromthemassofthespecimenasmeasuredbeforeandafterthetest
andisexpressedasapercentageoftheinitialspecimenmass.
[ECSSQST7002]
TOUGHNESS
Theenergyrequiredtobreakamaterial,equaltotheareaunderthestressstraincurve
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TOXIC
Substances causing serious, acute or chronic effects, even death, when inhaled, swallowed or
absorbedthroughtheskin
[ECSSQ7071]
TOXICHAZARDINDEX(T)
ratiooftheprojectedconcentrationofeachoffgassedproducttoitsSMACvalueandsumming
theratiosforalloffgassedproductswithoutseparationintotoxicologicalcategories
NOTE FurtherdetailsonthecalculationofthisTvaluecanalsobeobtainedinNASASTD
6001.
[ECSSQST7029]
TOXICITY
[See:TOXIC]
TRACEABILITY
The ability to trace the history, application, use and location of an item through the use of
recordedidentificationnumbers
TRANSITIONTEMPERATURE
Thetemperatureatwhichthepropertiesofamaterialchange.[Seealso:GLASSTRANSITION
TEMPERATURE]
TRANSVERSEISOTROPY
Materialsymmetrythatpossessesanisotropicplane;e.g.aunidirectionalcomposite
TYPE(INSERT)
The various types of inserts can be grouped by the means that they are embedded into a
sandwichpanel:
(A)forsimultaneousbondingduringsandwichproduction,alsoknownascocure;
(B) for an existing sandwich using either a thermosetting resin (usual potting process of
standard inserts) or for nonstandards inserts by an equivalent bonding process, e.g. carbon
fibretubeinserts;
(C)formechanicalclampingorscrewingintoanexistingsandwich.
TYPEA(INSERT)
Usedforsimultaneousbondingduringsandwichstructureproduction
TYPEB(INSERT)
Used for an existing sandwich structure; embedded with a thermosetting potting compound
(pottingofstandardinserts),orbyanequivalentbondingprocedure(nonstandardsinserts)
TYPEC(INSERT)
Usedformechanicalclampingorscrewingintoanexistingsandwichstructure
U
UD
Unidirectional
UHM
Ultrahighmodulus;arangeofcarbonfibres
ULTIMATELOAD
[See:LOADS]
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ULTIMATESTRENGTH
the maximum load or stress that a structure or material can withstand without incurring
ruptureorcollapse
NOTE It is implied that the condition of stress represents uniaxial tension, uniaxial
compression,orpureshear.
[ECSSEST32]
ULTIMATETENSILESTRENGTH(UTS)
Highest stress sustained by a material before catastrophic failure. The ultimate or final stress
sustainedbyaspecimeninatensiontest;thestressatmomentofrupture
NOTE: UTSsometimesdenotesultimatetensilestress.
ULTRAHIGHMODULUSCARBONFIBRES(UHM)
Arangeofcarbonfibresinwhichthetensilemodulusexceeds395GPa,typically
ULTRAVIOLET(UV)
Zone of invisible radiation beyond the violet end of the spectrum of visible radiation. Since
ultravioletwavelengthsareshorterthanthevisible,theirphotonshavemoreenergy,enoughto
initiatesomechemicalreactionsandtodegrademostplastics
UNAVIA
Italianstandardsorganisation(newsystem)
UNDERCURING
Anincorrectprocessinwhichthereisinsufficienttimeortemperaturetoenablefullandproper
curingofanadhesiveorresin
UNI
Italianstandardsorganisation(oldsystem)
UNIDIRECTIONALCOMPOSITE
Acompositehavingonlyparallelfibres
UNSYMMETRICLAMINATE
Alaminatewithoutmidplanesymmetry
USA
UnitedStatesofAmerica;alsodenotedasUS
UTS
UltimateTensileStrengthorStress;[See:ULTIMATETENSILESTRENGTH]
UV
[See:ULTRAVIOLET]
V
VANTICO
Formerly CibaGeigy, UK. Manufacturer and supplier of Araldite range of epoxybased
adhesivesandpottingresins
VCM
VolatileCondensableMaterial
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VERIFICATION
The verification is a process oriented to demonstrate that the system design meets the
applicable requirements and is capable of sustaining its operational role along the project life
cycle,Ref.[Ref1]
VERYHIGHSTRENGTHCARBONFIBRES(VHS)
Arangeofcarbonfibresinwhichthetensilestrengthexceeds3500MPa,typically
Vf
Volumefractionofreinforcementfibreswithinacompositematerial,expressedasapercentage
VHS
Veryhighstrengthcarbonfibres
VISCOSITY
1measureofthefluidityofaliquid,incomparisonwiththatofastandardoil,basedonthe
timeofoutflowthroughacertainorificeunderspecifiedconditions,[ECSSQ7071]
2Thepropertyofresistancetoflowexhibitedwithinthebodyofamaterial,expressedinterms
ofrelationshipbetweenappliedshearingstressandresultingrateofstraininshear
VOID
Air or gas trapped in a material during cure, e.g. air or gas bubbles present in the mass of
pottingaftercure
NOTE: Indicatestheneedforproperventingduringthepottingprocess.
VOIDCONTENT
Volumepercentageofvoids,e.g.calculatedfromthemeasureddensityofacuredmaterialand
thetheoreticaldensityofthestartingmaterial
NOTE: Implies that voids are uniformly distributed throughout the body, which is not
alwaysthecase.
VOLATILECONTENT
Ameasureofthemasslossfromasamplesubjectedtoprescribedtestconditions.Thevolatile
loss is an indication of the solvent content of the material, which can result in highlevels of
voids remaining after cure. Occurs due to the vaporisation of the usually lowboilingpoint
solventwithintheresinconstituentduringcure.
VOLATILES
Materials in a sizing or a resin formulation capable of being driven off as a vapour at room
temperatureorslightlyabove
VOLUMEFRACTION
Fractionofaconstituentmaterialbasedonitsvolume;ameasureofthequantityofonephasein
acompositematerial,usuallythereinforcementfibrecontent,e.g.denotedasVfandexpressed
asapercentage
W
WAISTED
Atypeoftestspecimenorcouponwherethegaugelengthisnotparallelfortheentirelength
WARP
1 The yarn running lengthwise in a woven fabric; a group of yarns in long lengths and
approximately parallel, put on beams or warp reels for further textile processing, including
weaving
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2Achangeinshapeordimensionofacuredlaminatefromitsoriginalmouldedshape
WATERABSORPTION
Ratiooftheweightofwaterabsorbedbyamaterialuponimmersiontotheweightofthedry
material.[Seealso:MOISTUREABSORPTION]
WATERVAPOURREGAINED(WVR)
Massofthewatervapourregainedbythespecimenaftertheoptionalreconditioningstep.
NOTE: WVRiscalculatedfromthedifferencesinthespecimenmassdeterminedafterthetest
for TML and CVCM and again after exposure to atmospheric conditions and 65 % relative
humidityatroomtemperature(223)C.
[ECSSQST7002]
WEAVE
Theparticularmannerinwhichafabricisformedbyinterlacingyarnsandusuallyassigneda
stylenumber
WEFT
Thetransversethreadsorfibresinawovenfabric;fibresrunningperpendiculartothewarp.
NOTE: Alsocalledfill,filler,filleryarn,woof
WERKSTOFFLEISTUNGSBLATT
Germanstandardsorganisation
WETTING
Flowandadhesionofaliquidtoasolidsurface,characterisedbysmooth,evenedgesandlow
contactangle
WITNESSSAMPLE
A sample made of identical materials to that used in a composite laminate that undergoes
exactly the same processing as the laminate. The objective is to ensure that all the
manufacturing processes applied, e.g. layup and cure, are correct. Testing and inspection of
witnesssamplesprovideconfidencethatthepropertiesoftheassemblymeetthosestipulatedin
thedesign;alsoknownasREFERENCESAMPLEforinserts
WOVENFABRICS
Fabricsproducedbyinterlacingstrandsmoreorlessatrightangles
WRINKLE
1 A surface imperfection in laminated plastics that has the appearance of a crease in one or
moreoutersheetsofthepaper,fabric,orotherbasewhichhasbeenpressedin
2Sandwichpanels:deformationofthefaceskins;apotentialfailuremode
WROUGHTMETALPRODUCT
Metallic stock material, e.g. in the form of sheet and strip, plate, bar, which is produced by
methods involving large amounts of plastic deformation (such as forging, rolling, extrusion)
thatresultsinamaterialwithawroughtmicrostructure,oftenwithsomelevelofanisotropy
Wt%
Weightpercent
WVR
WaterVapourRegained
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X
XMM
Xraymultimirrortelescope
Y
YIELDSTRENGTH
maximumloadorstressthatastructureormaterialcanwithstandwithoutincurringaspecified
permanentdeformationoryield
NOTE Theyieldisusuallydeterminedbymeasuringthedepartureoftheactualstressstrain
diagramfromanextensionoftheinitialstraightproportion.Thespecifiedvalueisoftentaken
asaunitstrainof0,002.
[ECSSEST32]
YIELDSTRESS(YS)
Stressatwhichpermanentdeformationcommencesinamaterial.Thelimitofreversibleelastic
behaviour,[Seealso:PROOFSTRESS]
YOUNGSMODULUS
Theratioofamaterialssimpletensilestress,withinelasticlimits,totheresultingstrainparallel
tothedirectionofthetensilestress
Z
notermsorabbreviations
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References called in this clause

[Ref1] AleniaSpazio,Italy
ReviewandImprovementsofESAAIVGuidelines:TF/DM/9352(Aug.1984)
ESA/ESTECContractNo.AOP/OL/RB/324147.
ESAPSS0180Issue1Draft(Sept.1994)
[Ref2] G.F.Dieter
MechanicalMetallurgy.
McGrawHill.ISBN007016891,1976
[Ref3] D.R.Lide,Editorinchief
HandbookofChemistryandPhysics
72ndEdition,CRCPressInc(1992).ISBN0849305659
[Ref4] M.H.Weik
FibreOpticsStandardDictionary
Chapman&Hall.3rdEdition(1997).ISBN0412122413
ECSSP001,ECSSGlossaryofterms
ECSSEST32,SpaceengineeringStructuralgeneralrequirements
ECSSEST3201,SpaceengineeringFracturecontrol
ECSSEST3208,SpaceengineeringMaterials
ECSSQST7002,SpaceproductassuranceThermalvacuumoutgassingtestforthe
screeningofspacematerials;
ECSSQST7022,SpaceproductassuranceControloflimitedshelflifematerials
ECSSQST7029,SpaceproductassuranceDeterminationofoffgassingproductsfrom
materialsandassembledarticlestobeusedinamannedspacevehiclecrewcompartment
ECSSQ7071,SpaceproductassuranceDatafortheselectionofspacematerialsand
processes
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4
Insert system
4.1 Insert systems and components
4.1.1 Inserts
An insert is part of a detachable fixation device, which enables the interconnection of honeycomb
sandwich structures; connection between such structures and other structural parts, e.g. frames,
profiles,brackets;mountingofequipment,e.g.boxes,feedlines,cableducts.
The system consists of a removable and a fixed structural element. The removable part is either a
screw or other threaded element adapted to a nutlike part, the insert. This is connected to the
honeycombstructure by using a potting compound; normally a twopart epoxy resin system, [See
also:7.1Pottingcompound].
Figure41showsthecomponentsofastandardtypeofinsertsystem,[Seealso:5.2].
NOTE Nonstandard types of inserts are described in A.3 and carbon fibre
reinforcedplastictubeinsertsinF.6.
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ATypicalstandardtypeinsert
Face sheet
Core
Face sheet
Potting
Honeycomb panel
[See also: 8.1] Structural sandwich concept
BTypicalstandardtypeinsertembeddedinhoneycombpanel
Figure41:Insertsystem:Components
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4.1.2 Insert system components

Theinsertsystemconsistsofthreemaincomponents:
Insert;
Sandwichstructure;
Pottingmaterial.
TheitemsthatformaninsertsystemaregiveninTable41.
Table41:Insertsystem:Generaldefinition
Malethreadedelement
Insert Femalethreadedelement(eitherfixedor [See:Table51]
replaceable)
INSERTSYSTEM
Mechanicalclampingorscrewing Notadvised
Bondingwithresin:
Joining
method simultaneouslyduringsandwichproduction,or
[See:Table51]
integrationintoanexistingsandwich(bypottingor
anequivalentmethod).
Facesheet
Sandwich Bondingcomponent [Seealso:6.1]
Core
NOTE The terms used to describe the different types of inserts vary across
theindustry,e.g.:
Partiallypotted,alsoknownas:blind,borne,singlesided.
Fully potted, also known as: throughthethickness, doublesided,
transverse.
[Seealso:Figure87]
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4.1.3 Loading modes

ThebasictypesofinsertloadingaresummarisedinFigure42,[Seealso:Clause10]

P
Q
Tension
Shear
Pull-out
M T
Bending
Torque
Rotation
NOTE Insertwithflangesillustrated,butloadingmodesapplytoalltypesof
inserts,[See:5.1].
[SeeFigure88forthenotationforforcesactingonaninsert]
Figure42:Insertsystem:Summaryofloadingmodes
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5
Insert
5.1 General
Insertsareusuallydescribedbytheir:
Type,e.g.groupedbythemeansinwhichtheyareembeddedintoasandwichstructure,[See:
5.2].
Size,[See:5.3].
Material,[See:5.4].
Surfaceprotection,[See:5.5].
5.2 Types
5.2.1 General
There are three types of insert which are distinguished by the method of integration into the
honeycombsandwichstructure;asshowninTable51.Theseare:
GroupAforsimultaneousbondingduringsandwichproduction;
GroupBforanexistingsandwichusingathermosettingresin,e.g.:
usualpottingprocessofstandardinserts.
anequivalentbondingprocedurefornonstandardsinserts.
GroupCformechanicalclampingorscrewingintoanexistingsandwich.
5.2.2 Group A
Theseinsertsareusedonlyinratherthinsandwichstructures,i.e.lowcoreheight,andcanbeapplied
onlyincaseswherenoparticularlockingdemandsexist.Moreover,itisratherdifficulttopositionthe
insertexactlyatthepointatwhichitisneededforconnectionpurposes.Forthisreason,theinserthas
a large diameter to enable the drilling of a bore hole and thread cutting to provide a margin of
between3mmand6mmformisalignment.
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Table51:Typesofinserts
Floating Nut
Diameter Potting Torque Thread
Type Shape Material Exchange Standards Comments
(mm) Considerations Locking Locking
Capability
Type A: Bonding during sandwich manufacture
None or The bore hole is drilled after
Full bonded
1 17 to 30 Al square e.g. Locktite No - sandwich bonding.
with core filler
shape Only for small core height.
Type B: Potting (or equivalent non-standard procedure)

NAS 1832
Al Al insert can be used with St
Partially or Planes or Deformation NSA 5135
2 11 to 22 (St) No or Ti screws.
fully potted riffles of tread PA 3825
(Ti) Most common type.
ENN 3GG/386
Al
Partially or Planes or Deformation
3 11 to 22 (St) No - Rarely used
fully potted riffles of tread
(Ti)
NAS 1832
Fully potted Planes or TAN 16489 Available with and without
4 11 to 14 Al e.g. Locktite No
only riffles PAN 3827 thread.
NSA 5071
St Partially or Planes or ERNO No. R

5 6 to 14 e.g. Locktite No Rarely used.
Ti fully potted riffles 000/095.000
St Partially or Planes or Only for very low loads.

6 3 to 6 e.g. Locktite No -
Ti fully potted riffles Rarely used.
Partially or Planes or
7 19 to 70 Al e.g. Locktite No - For high loads
fully potted riffles
NAS 1835
Al: Extended and heavy type for
Partially or Planes or Deformation PAN 3829
8 19 to 25 Insert Yes applying floating nuts and
fully potted riffles of thread ENN 379
Ti: Nut exchanging capacity.
NSA 5072
Carbon fibre
9 7 to 20
CFRP /
Al
tube bonded N/A
e.g. Locktite,
helicoils.
No No
Carbon fibre tube inserts,
[See also: A.3 and F.6]
into core
[See also 10.3]

10 - - - - - - -
[Ref. [5-2]]
Type C: Mechanically clamped or screwed

Al
Adhesive Deformation Low pull-out strength, if no
11 14 to 22 (St) - No TAN 16485
bonding of thread connection with core.
(Ti)
Al
Adhesive
14 to 22 (St) - - No - -
bonding
(Ti)
Key: St:steel;Ti:titanium;CFRP:carbonfibrereinforcedplastic
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5.2.3 Group B
Inserts potted by means of curing epoxy resin are the most important group. The main part of this
handbookisconcernedexclusivelywithinsertsofthistype.
Nonstandard alternatives, in which the normal potting is replaced by an equivalent bonding
procedure,aredescribedinAnnexAandAnnexF,[See:A.3andF.6].
A normal potted insert, incorporated in honeycombsandwich structures by potting, has the basic
shapeshowninFigure51.
Figure51:Typicalinsert
Ahollowcylindricalbodywithflangedendsisthestandardconfiguration.Boththediscsandflanges
provide a formlocking connection with the resin and prevent applied loads from being transferred
onlybyadhesionshearforcesbetweenresinandinsert.
Theupperflangeispiercedbytwoholes,onefortheinjectionofthepottingresinandoneforventing
purposes.
The cylindrical section and the lower flange have a riffled surface, or the lower flange has flats on
opposite sides. Both provisions increase the shearload capability when the insert is subjected to
torsion.
Athincircularsheetinthelowerflangeprotectsthethreadfromresincontaminationduringpotting.
Arecessintheupperpartofthecylindricalbodypermitsthreaddeformationbycompression.Thisis
toensureselflockingofthematedscrew.
[Seealso:10.3forflangedinserts]
5.2.4 Group C
Themechanicallyfastenedinsertshavesignificantdisadvantages:
Nodirectconnectionwiththesandwichcorewhichcauseslowloadcarryingcapability;
Anindividualadaptedsizeforeachcoreheight;
Torquecanbetransferredbyadhesivebondingonly.
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5.2.5 Potting methods

ThefourdifferentmethodsofpottinginsertsingeneralusearedescribedinTable52.
NOTE The potting dimensions should be justified if other techniques are
used.
Table52:Pottingmethods
Potting Potting Expected
Device Comments
method level(1) filling
Feasiblebutimpracticablemethod.A
resinreservoirisneededaboveeach
full verygood
inserttocompletefillingduetoresin
Resinfunnel shrinkage.
Casting
apparatus
Nolongerinuse.
partial bad Sandwichplatehastobeturnedover
beforecuring.
Compressedair full good(2) Veryeconomicalmethodwhenalarge
cartridges(Semco
partial good numberofinsertsarefitted.
cartridges)
Usualforasmallnumberofinserts,e.g.
Injection
Manualinjection repair.
full good(2)
(bysmallmedical Injectionmethodsenablehandlingof
partial good
squirter) sandwichplateimmediatelyafter
potting.
Usualwheninsertsarepottedduring
Foaming no full good
sandwichmanufactureprocess.
Notadvisableforstandardpotting,i.e.
Paste full fillingofhoneycombcells.
spatula bad
application partial PreferredmethodforCFRPtubeinserts,
[Seealso:A.3;F.6].
NOTE(1) Seealso:Figure87forschematicoffullandpartialpotting.
NOTE(2) 100%fillingisnotpossiblebecauseasmallamountofairalwaysremainstrappedatthetopof
corecells.
5.2.6 Injection
Theinjectionmethodisthemostfrequentlyusedbecauseofitsadvantageswhenalargenumberof
insertsarefitted.
NOTE Except for data in Annexes, the data given in this handbook for
standardinsertsarebasedupontestresultsfromspecimensprepared
bytheinjectionmethodinaccordancewiththestatedmanufacturing
procedure,[See:23.3].
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5.3 Sizes
5.3.1 General
There are a wide variety of sizes, shapes and dimensions available because inserts were developed
separatelyinvariouscountriesbydifferentcompanies.
Theproductscanbegroupedas:
Commerciallyavailable,whicharestandardspecifieditems,[Seealso:A.2];
Nonstandard, which are designed and manufactured inhouse for a particular project
application,[Seealso:A.3]:
basedonconventionalinsertdesigns,wheredimensionsormaterialsusedaredifferent,
[Seealso:F.1forcasestudies];
novel insert designs, e.g. carbon fibre tube inserts, [See also: A.3; F.6 for an example of
theirusewithintheRosettaLanderproject].
5.3.2 Standards
Many inserts have been qualified to meet company standards, projectrelated standards or, after
approvalbynationalairworthinessauthorities,nationalstandards.
AlistofsomestandardsisgiveninTable53.
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Table53:Listofinsertstandards
1832
1833
NationalAerospaceStandard NAS 1835
1836
1837
65187
65188
65189
DeutschesInstitutfrNormung DIN 65190
65191
65192
65193
16487
16488
TransallNorm TAN
16489
16490
3825
3826
PanaviaStandard PAN 3827
3828
3829
DeutscheAirbusNorm DAN 214
5345
NormalisationSudAviation NSA
5074
366
377
ERNONorm ENN 379
386
398
5.3.3 Strength
Themostimportantparametersrelatedtostrengthare:
Insertoveralldiameterdi;
Insertoverallheighthi
Consequently, within this handbook, the insert loadcarrying capabilities are based on these two
parameters.
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5.3.4 Standardised diameters

ThestandardiseddiametersaregiveninFigure52,whichshowsthatcertaindiametersarepreferred.
Itindicatesthat:
Diameters that follow a geometrical progression of the type (a.qn) where the constants are a =
8,96andq=1,25;
Advisablestandardsetofdiameters,whichbestfitsthepresentlystandardiseddiameters.
NOTE Testprogr.denotesdiametersinvestigatedin[Ref.[51]].
Key:(*)SeealsoTable51
Figure52:Standardisedinsertdiameter
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5.3.5 Standardised heights

ThestandardisedinsertheightsinFigure53showconsiderablescatterandnopreferredheightscan
beidentified.
Key:(*)SeealsoTable51
Figure53:Standardisedinsertheight
Whenstandardisedinsertheightsareplottedasafunctionofstandardisedinsertdiameters,asshown
inFigure54,thedashedlinesdenoteexamplesoflineardependencies.
Anadvisedsetofinsertheightswasderivedonthebasisofthestraightlinethatconnectsthecrossing
ofpreferreddiameterswithheightsinwholemillimetres.
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Figure54Preferredsetofinsertheights
5.4 Materials
5.4.1 General
The majority of standard commerciallyavailable inserts are made from certain grades of metals or
combinationsthereof,thesebeing:
AluminiumAlloys
TitaniumAlloys
Steels,bothcarbonsteelandstainlessalloys.
[Seealso:ECSSQ7071]
Nonstandardinsertscanbemadefromthesameordifferentgradesofmetalsor,morerecently,from
carbonfibrereinforcedplastics,[Seealso:A.3].
AsummaryofinsertsusedinspaceapplicationsisgiveninAnnexAfor:
commercialproducts,[See:TableA1]
nonstandarditems,[See:TableA2].
[Seealso:AnnexFforcasestudies]
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5.4.2 Aluminium alloys

Usually inserts are made of aluminium alloy AA 2024 (DIN AlCuMg2), solution heat treated and
naturallyorartificiallyaged,thushavingtheconditionT85.
SomecomparablematerialdesignationsaregiveninTable54,Ref.[51].
NOTE Chemicalcompositionsofequivalentalloysarenotalwaysidentical.
[Seealso:Table55forsurfaceprotection]
Table54:Inserts:Aluminiumalloyequivalents
Country EquivalentGrade(1) StandardsOrganisation
Europe AW2024 CEN
3.1354T851 WerkstoffLeistungsblatt
Germany
AlCuMg2 DIN
3L65
U.K. BS../CommonFiles/GlossaryB.pdf
2024
AU4G1 AIR9050/C
France
2024 AFNOR
PAC4,5GM UNAVIA81102
Italy
9002/4(3583) UNI(oldsystem)
QQA225/6T8511 Federalspecification
U.S.A. 2024T8511 MILHDBK5
2024 ASTM
Japan 2024 JIS
Russia 1160 CIS
Key:(1)Chemicalcompositionsofequivalentalloysarenotalwaysidentical.
5.4.3 Titanium alloys

TitaniumalloyTiAl6V4(solutiontreatedandaged)isusedforapplicationswhereimprovedstrength
orspeciallockingpropertiesareneeded,[Seealso:Table55forsurfaceprotection].
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5.4.4 Steels
5.4.4.1 Carbon steels

Steel is sometimes used, e.g. carbon steel AISI 1137 (as referred in Fed. Std. 66) in heattreated and
waterquenched conditions, inserts made from carbon steels are always cadmium plated, [See also:
Table55forsurfaceprotection].
NOTE AccordingtoECSSQ7071,theuseofcadmiumplatinginspacecraft
structuresisnotallowed,duetosublimationproblemsthatcanarise
inthermalvacuum.
5.4.4.2 Stainless steels

Carbon steels are replaced by stainless steels of the austenitic type, e.g. AISI 303 or 1.4305 to DIN
17007.
[Seealso:Table55forsurfaceprotection]
5.4.5 Material selection

Thematerialsthattheinsertsaremadefrom,thematerialsandprocessesusedtoembedthemandthe
sandwichpanelsthemselvesconformtotheECSSstandards,[See:ECSSEST3208;ECSSQ7071].
Iftheinsertispottedwithanepoxyresin,thereisnoadvantageinusingamaterialthathasahigher
temperature resistance than aluminium, i.e. the resin fails at a lower temperature than the onset of
damagetotheinsert.
Itisalsounreasonabletoselectaninsertmaterialstrongerthanaluminium,becausethestrengthofthe
systemislimitedbythestrengthoftheepoxy.
Inserts with changeable floating nuts make it possible to use a higherstrength material for the nut
withinthealuminiumhousing.
Thethreadwithintheborecanbeclosedonthebottomsideofthelowerflangebyathin,flatshimor
cupmadeofaluminiumalloyAlMgSiCu,i.e.AA6061inasoftannealedtemper.
5.5 Surface protection
5.5.1 General
All inserts need protection to prevent corrosion. Some typical insert materials and their surface
protectionaregiveninTable55.
AsummaryofinsertsusedinspaceapplicationsisgiveninAnnexAforbothcommercialproducts,
[See:TableA1],andnonstandarditems,[See:TableA2].
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5.5.2 Aluminium alloy

The housings made from aluminium alloy 2024 (AlCuMg2) are treated by a specified anodising
process,e.g.LN9368,CodeNo.2100orMILA8625C.
Galvanic treatment in a sulphuricacidbath results in a 10 m to 15 m thick aluminium oxide layer,
whichishardandelectricallynonconductive.Thispreservestheinsertfromcorrosiveattackandgives
a suitable bonding surface. For insert systems with floating and removable nuts, the housing, plug
andnutaretreatedinthesamemanner.
CoversclosingtheboreholearechromatedinaccordancewithMILC5541,ClassIA.Whenacupis
appliedasaclosure,theinnerandoutersurfacesarechromated.
NOTE AccordingtoECSSQ7071,theuseofcadmiumplatinginspacecraft
structuresisnotallowed,duetosublimationproblemsthatcanarise
inthermalvacuum.
Table55:Typicalinsertmaterialsandsurfaceprotection
Someapplicable Appliedsurface
Materialdesignation
specifications protection
3.1354T8511Werkstoff
Leistungsblatt
2024(AlCuMg2) 2024T8511
Aluminiumalloys
heattreatedandaged QQA225/6 Anodised,e.g.LN9368

(naturallyorartificially): Code2102MILA8625C.
81102UNAVIA
ConditionT85
AU4GI
AIR9050
AA606
AlMgSiCu
3.3214LN Chromated
softannealedtemper
81105UNAVIA
Titaniumalloy
3.7164.7WerkstoffLeistungsblatt
Ti6AI4V Normallynotnecessary.
TiAl6V4
MILHDBK5 Anodisedforspecial
solutiontreatedandaged
COMP.TA6V cases.
AIR9183
Carbonsteel AISI1137 Cadmiumplated(1)

Steels
AISI303
ASTMA582
Stainlesssteel PassivatedLN9368
1.4305DIN
303BS
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5.5.2.1 Stainless steel
Insertsofstainlesssteelarepassivatedtoaspecifiedstandard,e.g.LN9368,CodeNo.1200.
5.5.2.2 Titanium alloys

Titanium parts, if any, are used without any treatment because they automatically develop a
protectiveoxidelayeraftermachining.
Inordertoincreaseprotectionagainstcorrosion,anadditionalcoatingcanbecreatedusingaspecified
anodisingtreatment,e.g.LN9368,CodeNo.2500.
5.6 References
5.6.1 General
[51] R.Hussey&J.WilsonRJTechnicalConsultants
LightAlloysDirectoryandDatabook,
Chapman&Hall,ISBN0412804107(1998)
[52] N.LavalSonacaSA,Belgium
Insertswithflanges
WorkingGroupcontribution(2004)
[53] J.BlockDLR,Germany
[54] MILHDBK5
MetallicMaterialsandElementsforAerospaceVehicleStructures
5.6.2 ECSS standards

[See:ECSSwebsite:www.ecss.nl]
ECSSEST3208,SpaceengineeringMaterials
ECSSQST70,SpaceproductassuranceMaterials,mechanicalparts
andprocesses
ECSSQ7071,SpaceproductassuranceDatafortheselectionofspace
materialsandprocesses
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6
Sandwich panels
6.1 Sandwich properties

Asandwichconsistsof,[Seealso:8.1]:
FaceSheets(topandbottom);
Core;
Adhesivefilm(forbonding).
6.1.1 Insert load-bearing capability

The contribution of the sandwich parts to the loadbearing capability of an insert is shown in Table
61.
Table61:Effectofsandwichcomponentsoninsertloadbearingcapability
Contributionofsandwichcomponenttoinsertloadbearing
Loadtype capability
Core Facesheet Core/facebond
Tension High Medium Verylow(1)
Compression High Medium Low
Shear Low High Verylow(1)
Bending High Medium Low
Torsion High Low Low
NOTE(1)Contributionincaseofnonmetallicfacesheetscanneedreconsideration.
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6.1.2 Sandwich dimensions

TheprincipaldimensionsofasandwichareshowninFigure61
Where:
f1,f2 =thicknessoffacingsheets,fiff1=f2
c =coreheight
Figure61:Sandwichandcore:designation
6.2 Face sheet properties

The characteristics of face sheets are dictated by the properties of the materials used, e.g. metal or
composite.
Forcompositefacesheets,thelaminateconstructiondeterminesthedirectionalproperties;asshown
inFigure62.
6.2.1 Tensile and compressive loading
6.2.1.1 Strength
The strength values of the face sheets do not usually influence the tensile or compressive load
carryingcapabilityofaninsert.
6.2.1.2 Stiffness
The capability of an insert under tensile and compressive loading is influenced by the bending
stiffness,B,ofthefacesheets.
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Figure62:Facesheetproperties:Isotropic,anisotropicandquasiisotropic
characteristics
6.2.1.3 Isotropic face sheets

The higher the bending stiffness, B, of the face sheets compared with the shear stiffness of core, the
highertheloadcontributionofthefacesheets.
Forisotropicfacesheets:
3
E f
B 12 (1f 2 ) [6.21]
f
Thustherelevantpropertiesofthefacesheetsare:
f facesheetthickness
Ef Youngsmodulusoffacesheets
f Poissonsratiooffacesheets
fy yieldstrengthoffacesheets
For an analytical determination of the insert loadcapability, these values should be applied in the
equationsdevelopedinAnnexC.
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6.2.1.4 Anisotropic face sheets
Thecouplingandflexuralstiffnessisusedinthecalculationoftheloadcontributionforanisotropic
facesheets.
Acloseapproximationcanbemaderegardingtheslightinfluenceofthefacesheet(about10%to20%)
attypicalfacesheettocorecombinations.
Efand f2inEqn.[6.21]arereplacedby(ExEy)and(xy)respectively,wherethesevaluesarethe
resultsoftheinplanelaminatetheory.
Theconversion,showninEqn.[6.21],enablestheinsertcapabilitydiagramstobeused.
Thesediagramsweregeneratedforsandwichstructureswithdifferentaluminiumfacesheets,butalso
appliedtosandwichstructureswithanisotropicfacesheets.
E x E y 1 Al
2
f Al
f an
4
E Al 1 x y
[6.22]
where:
fAl facesheetthicknessaluminium
fan facesheetthicknessanisotropicmaterial
Ex Emodulusxdirection
Ey Emodulusydirection
Al Poissonsratioaluminium
x Poissonsratioxdirectionanisotropic
y Poissonsratioydirectionanisotropic
6.2.2 Shear loading
6.2.2.1 Isotropic face sheets

Forinplaneshearloadsonisotropicfacesheets,theyieldstrengthoftheupperfacesheetisrelevant
totheinsertloadcapability,[See:6.6].
The failure mode is a compressive buckling of the isotropic face sheet, [See also: 6.6 for core tensile
strength].
6.2.2.2 Anisotropic face sheets

Aninplaneshearloadedanisotropicfacesheet,e.g.CFRP,canfailbydifferentmodes,asshownin
Figure63.
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a)Tensilefailure b)Shearoutfailure

c)Dimplingfailure d)Bearingfailure
Figure63:Possiblefailuresmodes:Anisotropicfacesheetsundershearloading
Table 62 shows the shearload capabilities of tested CFRP face sheets, manufactured from two
materialsoftenusedinspacecraft.
Where the material or stacking sequences of the composite face sheets deviate, the shearload
capabilitiescanonlybeagrossindicationforthedesign.Inthiscase,adetailedinvestigationofthe
pinloadedshearcapabilityoftheselectedcompositehastobeperformed.
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Table62:FailuremodeandshearloadcapabilityoftestedCFRPfacesheets

Fibre E0basis 0max.
orientation test basistest Pmax. Failure Tension
0 dins/w(2)
() E0 theory(1) test(N) modes Compression
theory(1)
outer / inner (N/mm2) (N/mm2)
812 2653 dimpling T
0/90 75.047
790 2760 dimpling C
812 2253 dimpling T
90/0 75.047
790 2160 dimpling C
151 2660 bearing T
45/45 13.086
914CT300
228 2381 dimpling C

645 4653 bearing T
45/0/45 57.714 0.25
Laminate
602 4163 bearing C

22.5/22.5/ 319 4531 bearing T
37.610
67.5 380 4315 bearing C
568 3870 bearing T
60/0/60 52.631
589 3813 bearing C
216 3605 bearing T
30/30/90 27.344
293 3858 bearing C
545 1825 tensile T
914CHM
0/90 95.542
410 2128 dimpling C
0.25
80 1931 T
45/45 12.518 tensile
118 2069 C
914CT300
bearing/
151 2234 T
tensile
45/45 13.086 0.16
bearing/
228 1849 C
tensile
NOTE(1)Propertiesshownwithgreybackgroundweredeterminedbylaminatetheory.
NOTE(2)Insertdiameter/Specimenwidth.
6.2.3 Other loads

Thefacesheetpropertiesareunlikelytohaveasignificanteffectunderotherloadingconditions.
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6.3 Core properties
6.3.1 Types of cores

This handbook is primarily concerned with hexagonal honeycomb cores, although the analytical
determination of the insert load capability, as described in Annex C, is also valid for other types of
core,i.e.tubular,corrugatedandfoamcores.
6.3.2 Hexagonal core

Therelevantdimensionsofthehexagonalcoreare:
Cellsize,Sc
Foilthickness,t0
[Seealso:Figure61]
6.3.2.1 Core anisotropy

Twoprincipaldirectionscharacteriseanyhexagonalcore:
Ldirection,coincidingwiththedirectionofthedoubledfoils;
Wdirection,perpendiculartotheLdirection.
As a result of the core anisotropy, the shear strength and the shear modulus in the Ldirection are
approximatelytwicethatoftheWdirection.
6.3.2.2 Effect on insert strength

Theanisotropicbehaviourhasonlyasmallinfluenceontheinsertstrengthcapability,owingto:
Deviationsinthenominalcoredensity(10%)causedby:
deviationinthenominalfoilthickness;
deviation in the geometricallyexact hexagonal cell forms, caused by the expansion
process.
prebuckling properties of the cell walls caused by the hole piercing process on perforated
cores.
6.3.2.3 Mechanical properties

The mechanical properties of cores vary very widely, as shown in Figure 64. Consequently, a
distinctionismadebetween:
Guaranteedcorestrengthrelatedtominimuminsertloadcarryingcapabilitiescombinedwith
minimumpottingsize;
Typicalcorestrengthrelatedtotypicalinsertloadcarryingcapabilitiescombinedwithtypical
pottingsize.
[Seealso:6.6]
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Figure64:Corestrength:Deviation(%)ofactualstrengthfromguaranteedvalues
Thecorepropertiesaremoreimportantforinsertssubjectedtonormallyactingtensileorcompression
loads.Thesepropertiesarethe:
Shearmodulus,[See:6.4];
Shearstrength,[See:6.5];
Tensilestrength,perpendiculartothesandwichplane,[See:6.6];
Compressivestrength,perpendiculartothesandwichplane,[See:6.7].
Table63givesthemechanicalpropertiesofcommontypesofaluminiumcores.Mechanicalproperties
forsomecommontypesofnonmetalliccoresareshowninTable64.
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Table63:Mechanicalpropertiesofcommonaluminiumalloyhexagonaltypecores
NOTE(1)Designation:cellsizecorealloyfoilthickness
NOTE(2)Basisofinsertcapabilityplots,[See:AnnexB];P=90%values;Nottestedvaluesfromsuppliersdatasheets
NOTE(3)TTensile;CCompressive
NOTE(4)guar.guaranteed;typ.typical;min.minimum;av.average
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Table64:Mechanicalpropertiesofcommonnonmetallichexagonaltypecores
NOTE(1)Designation:materialcellsizedensity NOTE(4)guar.guaranteed;typ.typical;min.minimum;av.average
NOTE(2)Basisofinsertcapabilityplots,[See:AnnexB] NOTE(5)Notavailable
NOTE(3)TTensile;CCompressive NOTE(6)Nylonfibre/phenolresin
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6.4 Core shear modulus

Theshearmodulusofthecoreinfluencesthewayinwhichtheloadtransmittedthroughtheinsertis
distributedbetweenfacesheetsandcore.
Thegreaterthecorestiffnessis,thelowertheloadcontributionofthefacesheets.
6.4.1 Data sources

Valuesofcoreshearmodulusarenotspecifiedinstandards,suchasMILC7438F.Valuesarequoted
onlyindatasheetspreparedbycoresuppliers,takingintoaccountbothcoredirectionsWandL.These
figuresaretoohighincomparisonwithinserttestresultsandforthisreasontheycannotbeapplied
fortheanalyticaldeterminationofthestaticstrengthoftheinsert.
Frommeasurements,theshearmodulusvarieswiththeloadingandtendstodecreaseasaresultof
nonlinearity,i.e.shearbucklingofsinglefoilsoccursathalftheexpectedvalue.
Consequently,aneffectivecoreshearmodulus,Gc,thatreflectstherealsituationis:

GW
Gc 3
[6.41]
Where:
GW shearmodulusinWdirection.
[See: Table 63 for GC values for common types of aluminium cores; Table 64 for GC values for
commontypesofnonmetalliccores].
6.5 Core shear strength

Wheninsertsaresubjectedtotensileorcompressiveloads,theloadcarryingcapabilityisdetermined
bytheabilityofthecoretotaketheaxiallyinducedloadtransmittedfromtheinsertviathepotting
compound.Thiscanonlybeperformedbyshearforces.
When loaded in tension or compression, the insert system fails by a shear rupture of the core foils
surroundingtheinsert.
Thecircularstrengthisappliedbecausebothfoildirectionsparticipateinthetransmissionoftheshear
force.
SincethenumberofsinglefoilsintheLdirectionis72%greaterthanintheWdirection,theeffective
coreshearstrength,whichisrelevantfortheinsertloadcapabilityisgivenby:
c crit 1.36 w crit [6.51]
Thisappliesforguaranteedaswellasfortypicalshearstrengthvalues.
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6.5.1 Data sources

Usuallytheguaranteedminimumshearstrengthvalues, wcrit.min shouldbeused.Thevalueslistedin
Table63andTable64aretakenfromMILC7438Fandsuppliersdatasheets.
The typical values in Table 63 and Table 64 are from datasheets previously published by the core
suppliers.
Atypicalvalueistheexpectedaveragevaluestatedbythesupplier.
6.6 Core tensile strength

The core underneath partially potted inserts loaded in tension can fail by tensile rupture, [See also:
10.1].
6.6.1 Data sources

Thetensilestrengthofthecoreperpendiculartothesandwichplaneisnotspecifiedinthestandards
orinthesuppliersdatasheets.
6.6.2 Aluminium core

Thetensilestrengthofthealuminiumcoreisthereforedefinedby:
0 crit t 0 crit t c
0 [6.61]
Where:
0 critt tensilestrengthofcorematerial:
270N/mm2forAA5052H38(fromMILHDBK5),or
330N/mm2forAA5056H38.
c coredensity,e.g.32kg/m2for3/165052.0007core.
0 densityofcorematerial,e.g.2800kg/m2foraluminium.
ThetypicalvaluesccritttyplistedinTable63arebasedonthetypicalcoredensityctyp.
Theminimumvaluesccrittmintakeintoaccountthemaximumallowablescatterofcoredensityvalues
of10%.
c crit t min 0.9 0 crit t c
0 [6.62]
6.6.3 Non-metallic cores

Wheretypicaltensilestrengthsofnonmetalliccorematerialswerenotavailable,ccritttypwasassumed
tobeequaltoccritctyp.
Theminimumvaluesccrittminwascalculatedby:
c crit t min 0.9 0 crit c typ [6.63]
Table64includestensilestrengthsofNomex and GFRP determined by this method.

NOTE Thesetensilestrengthvaluesareconsideredtobeveryconservative.
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6.7 Core compressive strength

Thecoreunderneathpartiallypottedinsertsloadedincompressioncanfailbycompressiverupture,
[See:7.5].
Thecompressivestrengthccritcofthecoreperpendiculartothesandwichplaneisgivenas:
ccritcmin minimumcompressionstrength:
o metalliccores:MILC7438F
o nonmetalliccores:suppliersdata.
ccritctyp typicalcompressionstrengthofcore,takenfromcoresuppliersdata.
6.8 Core to face sheet bond

Failureofthebondbetweenthecoreandfacesheetisnotexperiencedininserttests.
The load transferred from the insert to the face sheets, which are usually thin in spacecraft
applications,issolowthatitiseasilytransmittedbythebond.
NOTE The foot of a bracket connection needs a minimum diameter at least
equivalenttothepottingdiameter2bp.
[See:10.4]References
[61] MILHDBK5MetallicMaterialsandElementsforAerospaceVehicle
Structures
[62] MILC7438FCoreMaterial,Aluminum,ForSandwichConstruction
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7
Embedding of inserts
7.1 Potting compounds
7.1.1 Commercial products

Commerciallyavailableinsertpottingmaterialsareusually2partepoxyresinsystems,[See:ECSSQ
7071].Theirinherentcharacteristicsareusuallymodifiedbyadditionsofmicroballoons,e.g.formass
reduction;viscositycontrol;toaidprocessing.
Table71summarisessomepottingcompoundsusedinspaceapplications,Ref.[[71],[73],[74]].
NOTE The component parts of potting compounds (resin, hardener,
accelerators)arelimitedshelflifematerialssotheirusablelife,storage
and working conditions are controlled, e.g. workshop environment
andpotlife,[See:ECSSQST7022]
Othertypesofadhesivesaresometimesusedduringtheintegrationofinsertsintosandwichpanels,
including:
Filmadhesivesforbondinginsertflangesontosandwichpanelexternalsurfaces,e.g.BSL312
UL,[See:F.5];LoctiteHysol9321,[See:F.7];
Foamingadhesivesforcocuredsandwichpanelswithinserts,e.g.Cytec/Cyanamid:FM4101
(150C);FM37(120C),Ref.[71].
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Table71:Example:Insertpottingcompoundsforspaceapplications
Cure Tensile Compressive Shear Tensile Temp.
Supplier: Density
temp. strength strength strength modulus use
Source[]
R R crit R R crit ER
Productcode C C
kg/m3 N/mm2 N/mm2 N/mm2 N/mm2
Emerson & Cuming: 0.6 to MBB-ERNO [3]
14 36 10 2300 <100
Lekutherm X227 0.7 [See: 25.1; 25.3]
Altropol: CASA [1]; Patria [4]
Neukadur EP 270 + [7]; Astrium UK [7]
RT/24h
3M Scotchlite 0.64 14 36 10 2300 <100 with T3 hardener
+ 60/2h
H20/1000 micro-
ballons
Vantico: [2]; Sonaca [7];
Araldite 2011 (AW Case study: F.2; F.3
106/HV953U)
Vantico: Daimler-Benz Aero.
Araldite 2004 [1]; Sonaca [7]
RT
(Araldite AV138M/ [See: ECSS-Q-70-71]
HV 998)
3M Scotchweld [2]; Sonaca [7]; Case
EC2216 study: F.3; F.10
Emerson & Cuming: CASA [1]; Patria [4];
Stycast 1090/9 Kongsberg [6];
RT 73 (average)
Astrium UK [7]; See
also: IATP E.2
180 Alcatel Espace [1]
Emerson & Cuming: CASA [1]; Alenia-
Stycast 1090 SI: RT Spazio [1]; Astrium
UK [7]
Shur-lok: SLE 3010 CASA [1]; [2];
LVC Contraves [1, 2, 5];
RT
Case study:F.4; F.5;
F.7; F.9; F.10; F.11
Scheufler: DLR [7]; [8]; Case
RT/18h
L160 / H163 + glass study F.6; A.3
0.58 17 43 13 to 15 2000 <90
micro-ballons +
90/12h
Aerosil
Cytec/Cyanamid: FM Contraves [1]; Sonaca
150 (foam adhesive)
410-1 [7] for co-cured inserts
Others: [See: Suppliers websites for product information] [1]
Altropol: - - - - - - DASA-RI [1]
Neukadur EPX227/
RT
Durosehlt3 + 3M
microballons
Emerson & Cuming - - - - - - Alenia-Spazio [1]
(Possehl):
Lekutherm +
microballons
Silmid: AY103; - - - - - - Westlands [1]
RT/18h
AV121; HY951; BJO
60/1h
0930
3M RT - - - - - - BAe Airbus [1]
Loctite-Hysol RT - - - - - - BAe Airbus [1]
Vantico RT - - - - - - BAe Airbus [1]
Source [6] IATP2InsertAllowableTestProgramNo.2KongsbergGruppenAS,Test
[1] InsertTechnologyIndustrySurvey(1995) ReportNo.02TR68040906(Oct.1997)
[2] MatraMarconiSpaceContributiontoESAInsertDesignHandbook; [7] ECSSinsertdesignhandbookworkinggroupsurvey(2004)
MMSRef.NT/102/BG/355013.96(Dec.1996) [8] StudyonCarbonFibreTubeInsertsJ.Block,R.Schtze,T.Brander,K.
[3] FromESAInsertDesignHandbook(1987) Marjoniemi,L.Syvnen,M.Lambert:DLRBraunschweig/HelsinkiUniversity.
[4] Privatecommunication(Feb.2002) Technology/Patria;ESTECContractNo.16822/02/NL/PA,(2004)
[5] Privatecommunication(Feb.2002)
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7.1.2 Modification of properties

Mostresinsystemsareadaptedforpottingofinsertsbytheadditionofother materialsthatmodify
theproperties.Suchmodificationscanaffecttheoverallmechanicalandthermalperformancebutalso
theprocessingcharacteristics.
Theviscosityisusuallymonitoredtoensurecompatibilitywiththeprocessmethodusedtoapplythe
pottingcompound,e.g.injection,[Seealso:23.3;25.3].
7.1.2.1 Lekutherm X227

The potting material, applied in the manufacturing procedure [See: 23.3] is a liquid twocomponent
epoxy resin of reduced weight and simultaneously improved viscosity. This is achieved by the
additionofglassmicroballoons.
Acharacteristicpropertyofthisresinisthatitcanonlybeappliedbinjectionwithanairpressurised
gun.Providedthatthecorrectviscosityismaintained,itdoesnotflowafterinjection.
[SeeTable71]:forbasicRTpropertiesofLekuthermX227;25.3formixingandcureconditions]
NOTE Neukadur EP 270, which is widely used forinsert potting, isamore
recent variant of the Lekutherm X227 epoxy system. Some variation
within properties can therefore be expected between the two resin
systems.
7.2 Potting and equivalent dimensions
7.2.1 Insert load capability

Unliketheinsertdimensions,thepottingdimensionshaveadecisiveinfluenceontheloadcapability
oftheinsert.
Therelevantdimensions,showninFigure71,arethe:
pottingradius,[Seealso:7.2.2Increasinginserttensilecapability]:
effectivepottingradius,bp,[See:7.3].
realpottingradius,bR,[See:7.4].
pottingheight,hp,[See:7.5].
NOTE Equivalent potting dimensions relate to carbonfibre tube inserts,
[See:7.2.1.2TypeBinsert].
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Figure71:Pottinggeometry
7.2.1.1 Type A insert

The potting dimensions of the, seldom used, insert implemented during sandwich manufacturing
(TypeA)shouldbeestablishedindividually,[See:Table51].
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7.2.1.2 Type B insert
ThesedimensionsarevalidfortheTypeBinsert,[See:Table51].
Forcarbonfibretubeinserts,[See:Table51,TypeB9],thepottingdimensions,asdepictedinFigure
71,arereplacedbyequivalentparameters,[See:A.3andF.6fordetails].
7.2.2 Increasing insert tensile capability
7.2.2.1 General
Thecapabilityofaninsertcanbeimprovedbyincreasingthepottingradius,[Ref.[73]].Inpractice,
thiscanbeachievedbyopeningeachcellwithintheborehole.
7.2.2.2 Example
Table72showstheeffectofincreasingthepottingradiusforapartiallypottedinsert,[Ref.[73]].
Insert(single):
ShurlokSL601M615.9S;
diameter17.4mm,height15mm.
Sandwichpanel:
facesheets:aluminiumAZ5GUT6(7075T6),1mmthick.
core:nida440AG5,heightc=40mm.
Potting:SLE3010;RTcure.
Table72:Example:Effectofincreasedpottingradiusoninserttensilecapability
Borehole Averagevalue(N) Minimumvalue(N) No.ofsamples
Normal 7895 6240 4
Improved(1) 8850 7180 5
NOTE(1)AdditionalcellsopenedcomparedwithNormalborehole,[Ref.[73]].
7.3 Effective potting radius, or equivalent dimension

The effectivepotting radius bp isananalytical dimension describing the radial influencezone of the
potting,[See:Figure71].
bpisrelevantfortheloadparticipationofthecorearoundandunderneaththepotting,[Seealso:12.1;
AnnexC).
bptakesintoaccountthatthedoublecellwallsadjacentto thepotting,whicharemuchstiffer
andstrongerthanthesinglecellwallsandwhichgenerallydonotfail,canbeconsideredasan
integralpartofthepotting.
bp is defined as the average distance of the nearest single cell walls surrounding the potting
fromthecentreoftheinsert.
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1
bp
n bn
[7.31]
Theeffectivepottingradius,bpdependson:
Insertradius,bi;
Sizeofcorecell,Sc;
Locationofinsertcentrewithinthehexagonalcell.
NOTE1 Theequationsprovidedhereassumeclassicalinsertpotting.
NOTE2 For carbonfibre tube inserts and other nonstandard insert designs,
the equations remain valid when an equivalent definition for bp is
used,[See:A.3andF.6fordetails].
7.3.1 Minimum value

Foreachcombinationofinsertradiusandcellsize,theeffectivepottingradiusbpattainsaminimum
valueforacertainpositionoftheinsertcentrewithinthehexagonalcell.Thisminimumisgivenby
theformulas,[Ref.[72]]:
Perforatedcore:
b p min 0.93192 bi 0.874 S c 0.66151 [7.32]
Nonperforatedcore:
b p min 0.9bi 0.7 S c [7.33]
7.3.2 Average value

Theaverageortypicalvalueofbpisgivenby:
Perforatedcore:
b p typ 1.002064 bi 0.940375 S c 0.7113 [7.34]
Nonperforatedcore:
b p typ bi 0.8 S c [7.35]
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7.3.3 Relationship of minimum and average values

Nonperforated core Figure 72 shows the effective potting radius for nonperforated core (Eqn.
[7.33])and(Eqn.[7.35])plottedasafunctionoftheinsertdiameter.
[Seealso:Table122forperforated,aluminiumcore;Table123fornonperforated,nonmetalliccore]
Figure72:Effectivepottingradiusasafunctionofinsertdiameter
NOTE Improveddatausing(Eqn.[7.34])and(Eqn.[7.35])
[See also: Table 122 for perforated aluminium core, Table 123 for
nonperforated,nonmetalliccore].
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7.4 Real potting radius, or equivalent dimension

The real potting radius bR is the radius of the circle the area of which is identical to the real cross
sectionalareaFRofthepotting:
F N F
b R

R
PC

C
[7.41]
Where:
NPC numberofcorecellsfilledinwithpottingresin
FC crosssectionalareaofonecorecell:
Fc 0.95 0.75 SC cos

2
[7.42]
Where:
0.95reductionforimperfecthexagonalshapeofcell;
SC nominalsizeofcorecell;
30forhexagonalhoneycomb;
FC 8.4mm2ifSC=3.2mm;
FC 19.0mm+ifSC=4.8mm.
Like the effective potting radius bp [See: 7.3], the real potting radius bR depends on bi, SC and the
positionoftheinsertcentrewithrespecttothehexagonalcell.bRisrelevanttothetensilefailureofthe
potting.
7.4.1 Minimum value

TheminimumrealpottingradiusbRcanbedescribedby,[Ref.[72]]:
bR bi 0.35 SC [7.43]
7.4.2 Average value

TheaverageortypicalvalueofbRisgivenby:
bR typ bi 0.5 SC [7.44]
NOTE1 Theequationsprovidedhereassumenormalinsertpotting.
NOTE2 For carbonfibre tube inserts and other nonstandard insert designs,
the equations remain valid when an equivalent definition for the
minimumrealpottingradius,bR,isused,(See:A.3andF.6fordetails).
7.4.3 Relationship between minimum and average values

Figure73showsminimumandaveragevaluesofrealpottingradiusbRforthetwomostfrequently
usedcellsizesof3.2mm(1/8)and4.8mm(3/16).
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Figure73:Realpottingradiusasafunctionofinsertdiameter
7.5 Potting height

The potting height hp is the average depth down to which the core cells concerned are filled with
pottingresin,[See:Figure74
7.5.1 Full potting

Themaximumpossiblepottingheightisidenticaltothecoreheight,c.Thisisfundamentallythecase
iftheinsertheightisintherangebetweencoreheightc,and(c 7 mm):
hp c for c hi c 7 mm [7.51]
Thiscaseiscalledfullpotting.
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7.5.2 Partial potting

Forgreatercoreheight(chi7mm),thepottingheightisgenerallysmallerthanthecoreheight.
Thiscaseiscalledpartialpotting.
7.5.3 Minimum value

Theminimumpottingheightnecessaryforpartialpottingdependsontheinsertheight,hi:
hp min hi 7 mm [7.52]
Thevalueof7mmresultsfromthe:
Boreholeshouldbe3mmto4mmdeeperthantheinsertheight;
Core,underneaththeinsert,hasatleasttobeconnectedbythepottingresinoveradepthof3
mm.
hp min, which is independent of core height, should be used for the derivation of permitted design
minima.
7.5.4 Average value

Theaveragepottingheight,usedforthederivationoftypicalpermissibledesignvalues,dependson
thecoreheightcandthesizeofthecorecellsSC:

h p typ h p min A tanh chp min hp min [7.53]
With:A=2.5mmforSC=3.2mm,and:A=5.0mmforSC=4.8mm.
Where:tanh()isthehyperbolictangent.
7.5.5 Relationship of minimum and average values

Therelationshipbetweenpottingheight(hp,hpmin,hptyp)andcoreheightcforthefrequentlyusedinsert
height,i.e.hi=9mm,isshowninFigure74.
7.5.5.1 Full potting

Aslongasthecoreheightislessthanorequaltotheminimumnecessarypottingheight,i.e.hchi+7
mm,thepottingisconsideredasfullpottingwherethepottingheightisequaltocoreheight.
7.5.5.2 Partial potting

Forpartialpotting,i.e.inthiscase(hchi+7=16mm),theminimumandtypicalvaluesdiverge;as
showninFigure74.
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Figure74:Pottingheightasafunctionofthehoneycombcoreheight
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7.6 Potting mass

Anestimationofthepottingmassisusedtodeterminetheoverallstructuralmass.
7.6.1 Effect of core and insert characteristics

Figure75showsthattheweightofpottingdependsonthe:
Coreheight:
Cellsize;
Insertdiameter.
Thevaluesarebasedonaninsertheightof9mmandadiameterof14mm,fullypotteduptoacore
heightof16mm,andpartiallypottedatgreatercoreheights.
7.6.1.1 Other insert heights

The values in Figure 75 were not corrected by the weight coefficients from Figure 76 for insert
heightsotherthan9mm.
Figure75:Meanweightofpottingmassesversuscoreheightandinsertdiameter
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Figure76:Correctioncoefficientforweightofinsertheights
7.6.1.2 Partial and full potting

TwocasescanbedistinguishedinFigure76:
Partialpotting,and
Fullpotting,i.e.theinsertheightisthesameasthecoreheight.
Theweightdatacontainsthemassofresinonly.
NOTE Insertmassisdeterminedfromstandards.[Seealso:AnnexA].
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7.6.2 Total mass of insert system

Thetotalmassofaninsertsystemisdeterminedby:
Pottingmass,[See:Figure75andFigure76];
Massofinsertelements;
NOTE Insertmassisdeterminedfromstandards.
Reducedby:
massoffacesheethole,givenby:
f bi
2
[7.61]
massofremovedcore(negligible).
7.7 References
7.7.1 General
[71] ERATechnologyLtd./RJTechnicalConsultants
InsertTechnologyforSpaceApplications
EuropeanIndustrialSurvey1995
[72] StandardisationofDesignAnalysisandTestingofInsertsinStructural
Elements.
Finalreport.ESTECContractNo.3442/77/NL/PPRider1
[73] MatraMarconiSpaceContributiontoESAInsertDesignHandbook;
MMSRef.NT/102/BG/355013.96(Dec.1996)
[74] J.Block,R.Schtze,T.Brander,K.Marjoniemi,L.Syvnen,M.Lambert:
DLRBraunschweig/HelsinkiUniv.Technology/Patria
StudyonCarbonFibreTubeInserts,
ESTECContractNo.16822/02/NL/PA,(2004)

ECSSQ70series Spaceproductassurance
ECSSQ7071 SpaceproductassuranceDatafortheselectionof
spacematerialsandprocesses
ECSSQST7022 SpaceproductassuranceControloflimitedshelf
lifematerials
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8
Mechanics of sandwich structures
8.1 Structural sandwich concept

TheAmericanSocietyforTestingandMaterials(ASTM)definesasandwichstructureas:
A structural sandwich is a special form of a laminated composite comprising of a
combinationofdifferentmaterialsthatarebondedtogethersoastoutilisetheproperties
ofeachseparatecomponenttothestructuraladvantageofthewholeassembly.
Although this definition is not very specific, it covers the type of structural sandwich panels most
oftenappearinginmodernstructuralapplications.Suchsandwichpanels,asshowninFigure81,can
beintheformofbeams,platesorshellsallofwhichhavethreemainconstituents:
Anupperfacesheet;
Alowerfacesheet;
Acorematerial.
Figure81:Schematicofstructuralsandwichpanelsubjectedtobothinplaneand
outofplaneexternalloading
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A sandwich assembly consists of two thin, stiff and strong face sheets separated by a thick, light,
compliant and weaker core material, [See: Figure 81]. The face sheets are adhesively bonded to the
coretoenableloadtransferbetweenthecomponents.
Inastructuralsandwich,thefacesheetsacttogethertoformanefficientstresscouplecounteracting
the external bending load, whereas the core resists shear and stabilises the face sheets against
buckling.
Theadvantagesgivenbysuchadesignconceptarenumerous,including:
Highstiffnesstoweightratio;
Highstrengthtoweightratio;
Integrationoffunctions,suchasthermalandacousticinsulation;
Highenergyabsorptioncapability;
Fewdesigndetails.
However,giventhelistofadvantages,currentlythemostimportantdrawbacksare:
Complicatedqualitycontrol;
Loadingandjoiningdifficulties,includingtheuseofinserts;
Lackofknowledgeconcerningtheeffectofdamage.
8.1.1 Properties of constituent materials
8.1.1.1 General
Thedesignofastructuralsandwichpanelisanintegratedprocessofsizingandmaterialsselection,
anditisthetaskofthedesignertoutiliseeachmaterialcomponenttoitslimit.
8.1.1.2 Face sheets

Thepropertiesofprimaryinterestforthefacesheets,alsoknownasskins,are:
Highstiffness;
Hightensileandcompressivestrengths;
Impactresistance;
Environmentalresistance,e.g.thermal,chemicalUV;
Surfacefinish.
CommonlyusedfacesheetmaterialsforspacecraftapplicationsarealuminiumalloysandCFRP.
8.1.1.3 Core
Thecorematerialisjustasimportantasthefacesheetmaterial,eventhoughitdoesnotappearsoat
first.Usuallyitisthematerialcomponentthatthedesignengineerhastheleastknowledgeof.
Thepropertiesofprimaryinterestforthecorecanbesummarisedas:
Lowdensity;
Highstiffnessandstrengthperpendiculartofacesheets;
Highshearstiffnessandshearstrength;
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Thermalconductivity(loworhighdependentontheactualapplication);
Dielectricproperties,e.g.forantennaapplications.
Commonly used core materials for spacecraft applications are aluminium, Nomex and GFRP
honeycombs,andmorerarelypolymericcellularfoams,suchasPVCorpolyurethanefoams.
8.1.2 Fundamentals of classical antiplane sandwich theory

Thefundamentalsofsandwichtheory,i.e.themathematicaldescriptionofthemechanicalbehaviour
of sandwichstructures, can be foundin textbooks; suchas[Ref.[81], [82], [83], [84]]. However, a
briefreviewofthesimplestpossiblesandwichtheoryispresented.
Thesimplesttheoriesofsandwichbeams,platesandshellsareinmanyrespectssimilartotheclassical
engineering theories of beams, plates and shells with the exception that the transverse shear
deformations should be accounted for. Furthermore, sandwich theories account for the fact that
different load types are carried by different parts of the structures. For simplicity, only sandwich
beams are treated here, but all the basics also extend to sandwich plates and shells. The sign
conventions for the beam displacements w and u, the bending moment M and the transverse shear
forceQareshowninFigure82.
Figure82:Signconventionsforsandwichbeamelement
Consider a sandwich beam subjected to arbitrary external support and loading conditions, and
assumethatthefacesheetsareidentical,i.e.f1=f2=f.
For such a sandwich beam, it is recognised that two deflection parts contribute to the overall
deflectionpattern;asshowninFigure83:
Deflectionsduetobendingmoments:bendingwb
Deflectionsduetotransverseforces:shearingws
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Figure83:Deformedsandwichbeamelement:deflectioncontributionsfromboth
bendingandshearing
For a sandwich beam with thin face sheets (compared with the core thickness), the two deflection
partsmaybesuperimposedas(partialdeflectionsapproach):
w wb ws [8.11]
Thebendingdisplacementwbiscalculatedaccordingtoclassicalbeamtheory:
d 2w M
2

dx D [8.12]
M
wb dxdx C1 x C 2
D
Where:
C1andC2areintegrationconstantstobedeterminedfromtheboundaryconditions
oftheproblem;
Distheflexuralrigidityofthesandwichbeam.
ForsandwichbeamswithidenticalfacesheetstheflexuralrigidityDcanbeexpressedas:
f 3 f (c f ) 2 c3
D b E f E c [8.13]
6 2 12
Where:
b widthofthesandwichbeam
Ef elasticmoduliofthefacematerial.
Ec elasticmoduliofthecorematerial.
For sandwich beams with thin face sheets and low stiffness core material Eqn. [8.13] can
approximatedby:
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bf (c f ) 2
D Ef ForfcandEfEc
2
TheexpressiongivenforDinEqn.[8.14]correspondstoEc 0,whichin[Ref.[82]]isreferredtoas
anantiplanecore(theinplanestiffnessofthecorematerialisnegligible).
TheshearingdeflectionwscorrespondingtooverallshearingofthesandwichbeamisshowninFigure
84,whereitisassumedthattheshearingdeformationonlyoccursinthecore,i.e.Gf=,andthatthis
deformationislinear(assumingconstantcoreshearingstrainandstressoverthecorethickness).
NOTE Shearingdeformationofsandwichbeamelement(ws dws/dx).
Figure84Shearingdeformationofsandwichbeamelement
AsshowninFigure84,theshearinganglecanbe dividedintoatransverse, and an in-plane part,

0. The in-plane shearing angle 0 can be expressed as:
uupper ulower
0 [8.15]
c
Where:
uuppe in-plane displacements of the upper face sheet.

ulower in-plane displacements of the lower face sheet.
FromFigure84,thegeometricalrelationfoundis:
dws c
( 0 )
c f
[8.16]
dx
Theshearingstraininthecorematerialisconstant, andisassociatedwith ashearingstress cthatis
alsoconstantthroughthedepthofthecore.
Thetransverseshearingstrainisdefinedas:
c Q
[8.17]
Gc Gc ( c f )
InsertingEqn.[8.17]intoEqn.[8.16]gives:
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dws Q c
0
dx S (c f )
[8.18]
M 0 cx
ws C3
S (c f )
Where:
C3 anintegrationconstant.
S thesandwichbeamshearingstiffness,whichisdefined by:
(c f ) 2
S Gc [8.19]
c
Eqn.[8.19]togetherwithEqn.[8.12],constitutesthecompletedisplacementsolutiontothesandwich
beamproblem.
Consequentlytherearefourconstants(C1,C2,C3, 0),whicharedeterminedfromthestatementofthe
boundaryconditions.
Thestressesinthesandwichbeam,i.e.thenormalstressesinthefacesheets(thefacesheetshearing
stresses are usually ignored) and the normal and shearing stresses in core material can be
approximatedintheform(validforEc<<Efandf<<c):
c c
Mz 2 f z2
xf E f where
D c c
z ( f )
2 2
[8.110]
Mz c c
xc Ec where z
D 2 2

Q
c
b(c f )
Usuallytheinplanecorenormalstressxcisofinsignificantmagnitudeandisthereforeignored,i.e.:
Ec=0xc0forantiplanecore.
8.1.2.1 Application
Theprinciplesappliedinthederivationspresentedprovideaverysimpletheory,whichnevertheless
includesthemainfeaturesofthemechanicsofsandwichbeams.Thusthetheoryaccountsfor:
The face sheets carry the bending moment loading and the core carries the transverse shear
loading.
Bothbendingandshearingcontributessignificantlytothedeformations.
The derived theory is valid for sandwich beams, but the same principles also apply for a sandwich
plateandshelltheories.
In the derivations it was assumed that the thickness of the face sheets was thin compared with the
corethickness,butthetheorycanbeextendedtosandwichpanelswiththickfacesheets.
Thiscomplicatesthetheoryasthebendingstiffnessofthefacesheetsthemselvescannotbeignoredin
thecaseofthickfacesheets.
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However,sandwich panelsfor spacecraftapplications are usually characterised by having very thin
face sheets compared with the core thickness, and the simple sandwich theory presented herein
providesaccurateresultswithrespecttopredictionofgloballoadresponsecharacteristics.
8.2 Structural failure modes

Sandwich panels fail when they are subjected to some type of overloading conditions. Sandwich
panelscanfailinmanydifferentways,whereeachfailuremodegivesaconstraintontheloadbearing
capacityoftheconsideredsandwich.
Whichfailuremodebecomesactiveinagivensituationdependsonthegeometry,materialdataand
external load conditions. Hence the geometry, material data and external load conditions also
determinestheperformancelimitsofasandwichstructure.
AsummaryofthemostimportantfailuremodesforsandwichpanelsisshowninFigure85
(A)Faceyielding/fracture.
(B)Coreshear.
(C)Shearcrimping.
(D)Generalbuckling.
(E1)and(E2)Facewrinkling(localbuckling).
(F)Facedimpling(intercellbuckling)
(G)Localindentation(localbendingoffacesheet).
Figure85:Failuremodes:HoneycombcoresandwichpanelsThefailuremodescanbe
groupedas,[See:Figure85]:
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Global:(A)to(D)areassociatedwiththegloballoadresponsecharacteristicsofthesandwich
panel.
Local:(E)to(G)areassociatedwithlocalloadresponsecharacteristics,orjustlocaleffects.
NOTE Theconceptoflocaleffectsinthiscontextreferstoscenarioswhere
thefacesheetstendtobendabouttheirownmidsurfacesratherthan
aboutthemidsurfaceofthesandwichpanel.
8.2.1 Global failure modes

Globalfailuremodescan,inprinciple,beaccountedforusingthesimpleclassicalantiplanetypeof
sandwichtheory;[See:8.1].
NOTE Detailsaregivenin[Ref.[81],[82],[83],[84]].
8.2.2 Local failure modes

Local failure mode types, however, cannot be accounted for using a classical antiplane type of
sandwichtheory,asthesefailuremodesareassociatedwithlocalbendingeffects.
Where load introduction through hard points, such as inserts, in sandwich structures is of real
interest, the local bending phenomena,asshownby failure mode (G) playan important role;[See:
Figure85].
NOTE A summary and discussion of global and local failure modes of
structuralsandwichpanelsisgiveninECSSEHB3220.
8.3 Load introduction aspects and discontinuities
8.3.1 General
Asimplesandwichtheorywhichincludesthemostimportantaspectsofthemechanicsofsandwich
panels(atleastwithrespecttopredictionofgloballoadresponsecharacteristics)isoutlinedin8.1.
Thepossibleorlikelyfailuremodesarediscussedin8.2.
Thecausesoflocalbendingeffectsaredescribedfurtherhere.
Thesimpleclassicalantiplanetypeoftheory,[See:8.1],isbasedontheassumptionthatthedistancec
+ f between the middle surfaces of the face sheets remains unchanged during deformation, [See:
Figure 82 Thus, it is implicitly assumed, that the transverse stiffness of the core material (Ec in the
thicknessdirection)isinfinitelylarge.Obviously,thisisnottrue,andinregionsofloadintroduction
as well as in regions where material and geometric discontinuities are present, the assumption of
constantsandwichpanelthicknessdoesnothold.
Insuchregionsthefacesheetstendtoactasbeamsorplatesbendingabouttheirownmiddlesurface,
andsignificanttransversenormalandshearstressconcentrationsarepresentintheinterfacesbetween
thefacesheetsandthecorematerial.
The simplest possible case of local bending in a sandwich beam is given in Figure 86, [Ref. [84]],
whichshowsasandwichbeamunder3pointbending.
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Figure86:Schematicoflocalbendingeffectsinsandwichbeamsubjectedto3
pointbending
Itshowsthatthesandwichbeamrespondstotheloadintwoways:
Global load response, which can be accounted for using the simple classical antiplane
sandwichbeamtheory,anda
Local bending response, which cannot be accounted for using simple classical antiplane
sandwichbeamtheory.
8.3.2 Local bending response

The local bending response is characterised by a wavy harmonic nature and a very steep decay
awayfromthepointorareaofloadapplication,e.g.supports,geometrychange,materialchangeor
otherdiscontinuousphenomena.
Thelocalbendingcausestheinducementofseverestressconcentrations,andfailuremodescanbe
thecauseofstructuralfailureare:
Shearfailureofthecore;
Crushingofthecore(indentationfailure);
Delaminationininterfacesbetweencoreandfacesheets;
Tensileorcompressivefailureofthefacesheets;
DelaminationoftheloadedfacesheetforsandwichpanelswithlaminatedFRPfaces.
The type of local bending effects, as shown in Figure 86, is characteristic for the local effects
generallyseeninstructuralsandwichpanels.Thus,thesamelocaleffectsareactiveinonewayorthe
otherincaseswhere:
Sandwichpanelssubjectedtolocalisedexternalloading;
Sandwichpanelswithlocalisedsupportconditions;
Sandwich panels with face sheets with thickness dropoffs, e.g. tapered FRP faces; debonds,
discontinuouschangeofcoreproperties;
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Joints between adjoining structural sandwich panels or sandwich panels and monolithic
structuralcomponents,e.g.Tjoints,cornerjoints;
Sandwichpanelswithinsertsandmechanicalfasteners.
8.3.3 Antiplane-type theory

The design formulas derived from the classical antiplane type of sandwich theory cannot provide
anymeaningfulanswersinareasofloadintroduction,ormaterialandgeometricdiscontinuities.Thus,
itusualpracticetoadoptothermethodsofanalysis,ifsuchlocalisedphenomenaarepresent.Which
kindoftheoryisnecessary,inordertoincludesuchlocalisedphenomenaintheanalysis,dependson
theactualproblemaddressed.
8.3.4 Finite element analysis

Obviously,detailedfiniteelementanalysis,basedontheuseofseverallayersofsolidelementsforthe
core material and the use of plate or shell elements (or several layers of solid elements) for the face
sheets,are able to provide accurate predictions(except for problems with stress singularities) of the
local response characteristics in areas where local bending phenomena cannot be ignored. This,
however, is a very costly solution, and the required modelling efforts alone make this option
unattractiveformostpurposes.
8.3.5 Elastic foundation model

Localisedloadintroductionproblems,[See:Figure85],canbeanalysedsatisfactoryinsimplecasesby
consideringtheloadedfacesheetsasbeamsorplatesonanelasticfoundation(thecorematerial).
Theelasticfoundationmodelcanprovideagoodestimateofthestressesinducedbylocalbending.
Superpositionofthelocalbendingstresseswiththeglobalstresses,predictedbyclassicalantiplane
theory,provideanaccuratepredictionofthestressstateinthehighlystressedregions.
NOTE Theimplementationofthisapproximatemethodcanbefoundin[Ref.
[84]].
8.3.6 Transverse flexibility

For the more general cases of local bending, i.e. cases where local bending effects influence the
elastic response of the face sheets as well as the core, more sophisticated mechanical models are
needed.
Thekeypointisforthetheorytoincludethetransverseflexibilityofthecorematerial,i.e.toaccount
forthefactthatthethicknessofthesandwichpaneldoesnotremainconstantduringdeformation,and
thatthetwofacesheetscandeflectdifferently.
8.3.7 Higher-order sandwich beam theory

Including the transverse flexibility of the core is important when addressing loadintroduction
problems, support problems, and problems involving material and geometric discontinuities in
sandwichbeams,[Ref.[86],[87],[88]].
This was done by formulating a higherorder sandwich beam theory, which includes separate
descriptions of each face sheet and separate description of the core material. The core material is
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modelled as a special type of transversely isotropic solid where only the outofplane stiffness is
accountedfor.Theprinciplesbehindthishigherordersandwichbeamtheoryhasbeenadaptedand
extended, [Ref. [89], [810]], with the purpose of analysing sandwich plates with inserts (potted
insertsofthethroughthethicknessandfullypottedtypes).
Unfortunately,thehigherordertheoriesaremuchmorecomplexthanthesimpleclassicalantiplane
theoriesinamathematicalsense.Itisnotpossibletoderivesimpledesignformulaefromthehigher
order theories because they cannot be solved in closed form. Their solutions can only be achieved
usinganumericalapproach.
The higherorder theories can, however, account for the local bending effects leading to structural
failureofsandwichpanelsinquantitativeterms.
[See:8.5foradiscussionofthesedesigntheories]
8.4 Sandwich plates with potted inserts

Thehandbookfocusesoninsertspottedbymeansofacuringepoxyresin,themostimportantgroup
ofinserts[See:Figure87].
Informationonnonstandarddesigns,whereclassicalpottingisreplacedbyanalternativeprocedure,
arealsodiscussed,[See:A.3andF.6].
8.4.1 Classification of potted insert types

Figure87showsthethreedifferenttypesofpottedinserts.Theirstaticloadcarryingcapabilitycanbe
rankedas:
Throughthethickness highest
Fullypotted
Partiallypotted lowest
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Figure87:Schematicofpottedinserttypesforsandwichpanelsusedfor
spacecraftapplications
8.4.2 Load transfer

Ofthethreedifferenttypesofpottedinserts,theloadtransfermechanismsassociatedwiththrough
thethicknessinsertsarethesimplest,eventhoughthewordsimpleinthiscontextismisleading.
Thebasicsoftheloadtransferinsandwichpanelsthroughthethicknessinsertsareconsideredanda
fewimportantfeaturessummarised.
NOTE Acompletedescriptionofthemechanicalresponseofsandwichplates
with throughthethickness inserts is beyond the scope of this
handbook.
8.4.3 External load cases

Details about the mathematical modelling using a higherorder sandwich plate theory, as well as
detailedresultsobtainedforthevariousaxisymmetricandnonaxisymmetricloadcases,asshownin
Figure88,aregivenin[Ref.[89],[810]].
[Seealso:8.5forasummaryofusinghigherordertheoryversusclassicalantiplanetheory]
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Figure88:Modeldefinitionofsandwichplatewiththroughthethicknessinsert
Inthemodellingofasandwichplatewithaninsert,itisassumedthattheinteractionbetweenadjacent
inserts, as well as the interaction between the considered insert and the plate boundaries or other
sourcesoflocaldisturbances,canbeignored.
Figure88definestheconstituentparts,thegeometryaswellasthepossibleexternalloadcases.The
sharp separation between the potting and the honeycomb core, [See: Figure 88] is a strong
idealisation,asthepottingtohoneycombintersectionisnotdefinedpreciselyinageometricalsense,
[Seealso:FigureD1].
Theboundaryconditionsimposedintheanalysisare:
r = bi: the throughthe thickness insert is considered as an infinitely rigid body to which the
facesheetsandthepottingmaterialarerigidlyconnected(clampingconditions);
r=bp:continuityofsolutionacrosspottingtohoneycombintersection;
r = a: it is assumed that the face sheets as well as the honeycomb midsurface are simply
supported,enablingshearstresstransferinbothfacesheetsandcore.
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8.4.4 Example
8.4.4.1 Symmetric sandwich plate with insert subjected to out-of-plane load

This applies to an insert subjected to outofplane load investigated with higherorder theory. Some
results are presented for the case of a circular sandwich plate with a throughthethickness insert,
[Seealso:8.5;AnnexD;FigureD1].
Itisassumed,thattheinsertissubjectedtoanoutofplaneloadP(axisymmetricloadcase),andthat
thetwofacesheetsofthesandwichareidentical.
NOTE A numerical solution is used because the boundary value problem
constitutedbythegoverningequations,definedbytheadoptedhigh
ordersandwichplatetheory[Seealso:8.5]thatcanbeclassifiedasa
third order shear deformation plate theory, and the prescribed
boundaryconditions,cannotbesolvedinclosedformforthecaseof
a circular plate with an insert subjected to various externalloadings,
[Ref.[815],[816],[817]].
Thegeometry,materialandexternalloaddataare:
Geometry:bi=10mm;bp=30mm;a=150mm;c=10mm;andf1=f2=1mm.
Topfacesheet:quasiisotropicFRPlaminate,Ef1=40GPa,f1=0.3.
Bottomfacesheet,sameastopfacesheet,i.e.Ef2=Ef1;f2 = f1.
Pottingcompound:bulkepoxy,Ep=2.5GPa;Gp=0.93GPa.
Honeycomb core: honeycomb 3/1650560.0007; Properties: Eh =310MPa; Gh (GW + GL)/2 =
138MPa.
Insert:throughthethickness;hi=f1+c+f2=12mm.
Externalload:compressiveoutofplaneload;P=1kN
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0
-0.05
-0.1
-0.15
-0.2
w1, wc, w2, mm
-0.25
-0.3
w1, wc, w2
-0.35
-0.4
-0.45
-0.5
0 25 50 75 100 125 150
r, mm
NOTE Outofplanedisplacements(coremidsurface):w1,w2,wc.
Load:Compressive(outofplane)P=1kN
Theory:Numericalhigherorder
Figure89:Example:Lateraldisplacementsofasymmetricsandwichplatewith
insertsubjectedtocompressiveoutofplaneload
Figure 89 shows the outofplane (lateral) deflections of the face sheets (w1, w2), and the core
midsurface,wc.InFigure89,Figure810andFigure811,rbp=30mmcorrespondstothepotting
region,whereasr>30mmcorrespondstothehoneycombregion.
Fromtheresults,[See:Figure89],theoutofplane(lateral)deflectionsofthetwofacesheetsandthe
corematerialmidsurfacesarealmostidentical.
As expected due to the symmetry of the sandwich plate considered, the outofplane (lateral)
displacementsofthetwofacesheetsw1,w2areidentical.
Themidsurface,outofplane(lateral)displacementofthecorematerialwc(pottingandhoneycomb),
however, is slightly different from w1, w2 close to the inserttopotting and pottingtohoneycomb
interfaces(difficulttoseeonthefigure),wherethecorechangesabruptly.Thedifferencebetweenthe
outofplane (lateral) face sheet and core displacements, encountered at these locations, causes the
inducementoftransversenormalstresses(c)inthepottingandthehoneycombcore.
Figure 810 shows the stress distribution in the core material. The values of the transverse normal
stress c aregivenattheinterfacebetweenthetopfacesheetandthecore (c top) andattheinterface
betweenthebottomfaceandthecore (c bottom).
Accordingtothehigherordersandwichplatetheory,c varieslinearlyoverthecorethickness.
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Figure 810 also shows the distribution of the transverse core shear stress component c, which is
assumedtobeconstantovertheheightofthecorematerial.
Consideringthe cdistribution,thepresenceoftransversenormalstressesisalocalphenomenon,as
significantc ccontributionsareonlypresentcloseto r = bi = 10 mm(i.e.closetotheinsert)andclose
to r = bp = 30 mm(i.e.closetothepottingtohoneycombintersection).Also, c top and c bottom areof
oppositesigns,i.e.whenoneiscompressivetheotheristensileandviceversa.
1.2
1
rz
0.8
0.6
c bottom
0.4
Core stress, MPa
0.2
-0.2
-0.4
-0.6
c top
-0.8
0 25 50 75 100 125 150
r, mm
NOTE Corestresscomponents:rz = c , ctop, cbottom
Figure810:Example:Corestresscomponentsofsymmetricsandwichplatewith
insertsubjectedtooutofplanecompressiveforce
Consideringtheshearstressdistributioninthecorematerial,theoveralltendencyisthat c decreases
with increasing r-values. The overall tendency of decreasing c-values with increasing r is a
consequence of the fact that the total transverse shear stress resultant Pr total = Pr1 + Pr2 + cc is
inverselyproportionalto r (verticalequilibrium,P=2 r Pr total), andthatthemainpartofPiscarried
bythecorematerial, i.e. by c.
Figure 810 also shows that the abrupt change of core stiffness at the pottingto honeycomb
intersectiononlycausesminorfluctuationsofthec -distribution.
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Pertainingtothecombinedinfluenceofthetransversenormalandtheshearstresscomponentsonthe
pottingandhoneycombmaterials,themechanicalpropertiesofthetwomaterialsareverydifferent.
Thus, the stiffness and strength properties of the honeycomb material are usually an order of
magnitudelowerthanthoseofthepotting.
From Figure 810, the magnitude of the peak stresses in the potting and honeycomb regions are of
about the same magnitude, so a weak spot is located at the position of the pottingtohoneycomb
intersection(atr=bp)aswellasashortdistanceintothehoneycombmaterial.
Itisconcludedthatthestressconcentrationsinthepottingregion(closesttotheinsert)arenotlikely
tocauseafailure,exceptforthepossibilityoffailureduetoweakbondsbetweentheinsertandthe
potting as well as between the face sheets and the potting. However, the stress concentrations
encountered at the pottingtohoneycomb intersection and immediately after that, can provoke a
prematurefailure.
Theactivefailuremechanismsarelikelytobeoneoutofthree:
Honeycomb topsurface: Tensile ctop-stresses can cause a failure in the (weak) bond between
thetopfacesheetandthehoneycomb.
Pottingtohoneycomb intersection: Shear c-stresses can cause a shear rupture of the core
surroundingthepottingmaterial.
Honeycomb bottomsurface: Compressive cbottom-stresses can cause a compression failure

(buckling)ofthehoneycombcells.
Inpractice,coreshearruptureisthecauseofstructuralfailureinmostcases,i.e.failureatthepotting
tohoneycombintersection,Ref.[[811],[812]].
Figure811showsthedistributionoftheradialbendingmomentresultantsMr1,Mr2;whereMr1and
Mr2areidentical(duetothesymmetry)andthattheyattaintheirpeakvaluesattheinserttopotting
intersection(r=bi=10mm).Thelocationofthepeakbendingmomentresultantsisduetotherestrictive
boundaryconditionsimposedbytheinsert(clamping).Anotherlocalpeakisseenaroundthepotting
tohoneycomb intersection at r=bp but the decay of Mr1, Mr2 is seen to be complete a short distance
awayfromr=bp.
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0.5
-0.5
Mr1, Mr2, Nmm/mm
-1 M ,M
r1 r2
-1.5
-2
-2.5
-3
-3.5
0 25 50 75 100 125 150
r, mm
NOTE Radialbendingmomentresultants:Mr1,Mr2
Figure811:Example:Radialbendingmomentresultantsinfacesheetsof
symmetricsandwichplatewithinsertsubjectedtooutofplanecompressiveforce
These results demonstrate that complicated loadtransfer mechanisms are active in sandwich plates
withinserts.Thisisespeciallypronouncedintheregionsclosetotheinsertandclosetothepottingto
honeycomb interface, i.e. in regions where significant changes of geometry and stiffness properties
takeplace.
Away from the locations of discontinuous change of geometry or material properties, the core
materialcarriestheloadinpureshearandnolocalstressconcentrationsarepresent.Intheseregions
classicalantiplanesandwichplatetheoryiscapableofdescribingthestressstateaccurately,[Seealso:
8.5forabriefsummaryofusinghigherordertheoryversusclassicalantiplanetheory].
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8.4.5 Purpose of the potting compound
8.4.5.1 General
The actual purpose or function of the potting compound in the inserttosandwich plate system has
tworoles.
8.4.5.2 Primary function

The potting material provides the connection between the insert and the honeycomb material to
ensurethatapropershearloadtransfercanbeaccomplishedbetweentheinsertandthehoneycomb
material.Thisconnectingfunctionisobtainedwhenthepottingcompoundisinjectedandflowsinto
thoseofthehoneycombcellsthathavebeenleftopenduringmachining(inpreparationoftheholefor
theinsert).
8.4.5.3 Secondary function

Thepottingmaterialparticipatesintheoverallloadtransfer,andislessobviouslyrecognisedthanthe
simpleconnectingprimaryfunctionmentioned.Thus,thepottingcompoundplaysasignificantrole
intheloadtransferininsertsandwichplatesystemssubjectedtoespeciallytransverseloadtypes,i.e.
PandMloadcases,[See:Figure88].Thisisbecausethepresenceofapottingcompound,whichis
usually5to10timesstifferthanthehoneycombcorematerial,causesaconsiderablereliefofthepeak
bending and shear stresses in the face sheets (located adjacent to the insert). This stressrelieving
function is achieved because the relatively stiff potting compound acts as an attractor on the
transverseshearstressesinthesandwichplate.
8.4.6 Design guidelines

Anumberofsimpleguidelinesforthedesignofsandwichplateswithpottedinsertaregiven,based
ontheresultsofextensiveparametricstudies,Ref.[[89],[810]].
8.4.6.1 Structural
Make the radial extension of the potting compound denoted by bpbi, [See: Figure 88] as large as
possible.bpbiisofcourseverydifficulttocontrolinpractice,asthepottingradiusbpisdeterminedby
the flow of potting material into those of the honeycomb cells that have been left open during
machining,i.e. bpbi is determined by the manufacturing process.However, from a purely structural
pointofview,bpbiofatleast0.5bi,ensuresamaximumreliefofthefacesheetbendingandshearstress
concentrations, while, at the same time, the full shear stress transfer capability of the potting
compoundisutilised.
8.4.6.2 Stiffness
Ifpossible,theratioofthepottingstiffnesstothehoneycombstiffness,Ep/Eh,ischosensothatEp/Eh3
to 4. This ensures a good compromise between the peak stress level in the face sheets and in the
pottingandhoneycombmaterials.WhereEp/Eh3to4,thepeakbendingandshearstressesintheface
sheets are raised, while the transverse normal and shear stresses in the potting and honeycomb
materialsaredecreased.TheoppositeisseenforEp/Eh3to4.
The choice of potting stiffness properties invariably ends up being a tradeoff between having the
mostseverestressconcentrationsinthefacesheetsorinthepottingandhoneycombmaterials.
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8.4.6.3 Bending and shear
Thecapabilityofthefacesheetstoresistthepeakbendingandshearstressesadjacenttotheinsert,can
beimprovedconsiderablybyreinforcingthefacesheetsinthezoneswhereinsertsaremounted.Such
reinforcements,whichareusuallyusedforlaminatedFRPfacesheets,canbemadebyaddingextra
plies(suchasUDormultidirectionalprepregs)ontheoutersurfacesofthefacesheets.Thishasthe
effect of increasing the bending stiffness of the face sheets locally, thus causing a raise of the total
shearloadtransferthroughthefacesheets.Thiscausesadecreaseofthepeakstressesinthepotting
andhoneycombmaterials.
8.4.6.4 Bending moment

Load application through groups of inserts can avoid external bending moment loading, i.e. the M
loadcase,[See:Figure88].Thisconvertsthebendingmomentloadingtotransverseshearloads(out
ofplaneloads).
8.4.6.5 Elongation
Potting and adhesive materials with long elongation to failure properties are needed to counter
unavoidablesignificantstressconcentrationsinthepottingmaterialandinthebondlinesbetweenthe
honeycombcoreandfacesheets.
8.4.6.6 Severe loads

Ifsevereexternalloadsareintroducedintosandwichpanels,usethroughthethicknessratherthan
fullyorpartiallypottedinserts.
8.5 Remarks
8.5.1 General
The introduction to the mechanics of sandwich structures, [Ref. [814]] has provided an overall
impression of the structural behaviour of sandwich structures, [See: 8.1], [See also: 8.4 for potted
inserts].
8.5.2 Antiplane theories

Classical antiplane sandwich theories are very useful for predicting global load response
characteristics,butthattheyareinadequateforexplainingthecomplicatedloadtransfermechanisms
presentaroundpointsorareasofloadapplication,support,geometricandmaterialdiscontinuitiesas
wellasinserts.
Toobtainanaccuratedescriptionofthestructuralresponseassociatedwithsuchlocalisedeffects,it
is necessary to include the transverse flexibility of the core material in the modelling. This can be
donebyrefinedfiniteelementmodellingorbyadoptingahigherordersandwichtheory.
Theobviousconclusionisthatclassicalantiplanesandwichtheorycannotbeusedforpredictingthe
loadbearingcapabilityofsandwichplateswithinsertssubjectedtoarbitraryexternalloads.Thereis,
however,oneveryimportantexceptionfromthis.
In the case of sandwich plates with inserts subjected to outofplane tensile or compressive loading,
[See:Figure88]theactivefailuremechanismisnearlyalwaysshearruptureofthehoneycombcoreat
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the intersection between the potting and the honeycomb. The peak shear stress in the honeycomb
material is located exactly at the pottingtohoneycomb intersection, and this stress component is
predictedaccuratelybyclassicalantiplanesandwichtheory.
In other words, for the outofplane load case classical antiplane and higherorder theories yield
almost exactly the same results with respect to the predicted shear stress distribution in the potting
andhoneycombmaterials,[See:Figure810forshearstressdistribution].Thus,itispossibletopredict
the loadbearing capability of sandwich plates with inserts subjected to outofplane loading using
simpledesignformulasderivedfromclassicalantiplanesandwichtheory.
[See also: Annex D for design formulae; Annex B for design graphs (derived on the basis of these
simpleexpressions)]
8.5.3 Higher-order theories

For the more complicated load cases, i.e. cases of sandwich panels with inserts subjected to non
axisymmetricortwistingloads,[See:Figure88]classicalantiplanesandwichtheorycannotbeused
forpredictingthe:
Loadresponse,or
Loadbearingcapability.
Inthesecases,amorerefinedmodellingmethodshouldbeused.Thiscanbedonewiththehigher
ordersandwichplatetheorydevelopedandadaptedforthepurposesofanalysingsandwichplates
withhardpointsintheformofinserts,[Ref.[89],[810],[815]to[822]].
NOTE1 Whenthemathematicalhighordersandwichplatetheory,classified
asathirdordersheardeformationtheory,cannotbeapplieddirectly,
a numerical solution can be consideredinstead, [See: 8.4.4 Example].
A general numerical solver, based on a technique known as multi
segment method of integration or multiple point shooting method
can be applied to the problem of inserts in sandwich panels in cases
wheretheboundaryconditionspreventaclosedformapproach,[Ref.
[815]to[823],inc].
NOTE2 The results in Figure 89, Figure 810 and Figure 811 were derived
usingthisapproach,[Seealso:8.4].
8.5.4 ESAComp
ESAComp is a software package for the design and analysis of composite laminates and structural
elementsfordesignengineersandstressanalysts,availablefromComponeeringInc.,Finland,[Ref.[8
13],[824]].
Addition of modules for the analysis of sandwich plates with throughthethickness, fully potted
andpartiallypottedinsertsundergeneralloadconditions,basedonthehigherordersandwichplate
theoryarefeasible.
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8.6 References
8.6.1 General
[81] Plantema,F.J.
SandwichConstruction
JohnWiley&Sons,NewYork,USA,1966.
[82] Allen,H.G.
AnalysisandDesignofStructuralSandwichPanels,PergamonPress,
Oxford,UK,1969.
[83] Stamm,K.andWitte,H.
Sandwichkonstruktionen(inGerman),SpringerVerlag,Wien,Austria,
1974.
[84] Zenkert,D.
AnIntroductiontoSandwichConstruction:Clause12:LocalisedLoads.
EMASPublishing,WestMidlands,UK,1995.
[85] StructuralMaterialsHandbook,Vol.1,ESAPSS03203,(1994):Clause
26Sandwichstructures;[Seealso:ECSSstandards]
[86] Frostig,Y.andBaruch,M.
BendingofSandwichBeamswithTransverselyFlexibleCore,AIAA
Journal28,pp.523531,1990.
[87] Frostig,Y.
OnStressConcentrationintheBendingofSandwichBeamswith
Transversely FlexibleCore,CompositeStructures24,pp.161169,
1993.
[88] Frostig,Y.andShenhar,Y.
HighOrderBendingofSandwichBeamswithaTransverselyFlexible
Core&UnsymmetricalLaminatedCompositeSkins,Composites
Engineering5,pp.405414,1995.
[89] Thomsen,O.T.
AnalysisofSandwichPlateswithThroughtheThicknessInsertsUsinga
HigherOrderSandwichPlateTheory,ESA/ESTECReportEWP1807,
1994.
[810] Thomsen,O.T.
AnalysisofSandwichPlateswithFullyPottedInsertsUsingaHigher
OrderSandwichPlateTheory,ESA/ESTECReportEWP1827,1995.
[811] W.Hertel,W.PaulandD.WagnerERNORaumfahrttechnikGmbH,
StructuresDept.,Bremen,D.
StandardisationProgrammeforDesignandTestingofInserts,ESACR
(P)1498,ESAContractNo.3442/77/NL/PP,1981.
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[812] W.Pauland D.WagnerERNORaumfahrttechnikGmbH,
StandardisationProgrammeforDesignandTestingofInserts,RiderII,
ESACR(P)1665,ESAContractNo.3442/77/NL/PP,1981.
[813] Saarela,O;Palanter,M;Hberle,J;Klein,M.
ESACOMP:APowerfulToolfortheAnalysisandDesignofComposite
Materials,ProceedingsoftheInternationalSymposiumonAdvanced
MaterialsforLightweightStructures,ESTEC,Noordwijk,March1994,
ESAWPP070,pp.161169.
[814] O.T.ThomsenCompConsult
WorkOrderNo.6ESTECContractNo.10.983/94/NL/PP(1996)
[815] O.T.ThomsenAalborgUniversity,DK
Privatecommunication(July2004)
[816] O.T.Thomsen
SandwichPlateswithThroughtheThicknessandFullyPottedInserts:
EvaluationofDifferencesinStructuralBehaviour
CompositeStructures,Vol.40,No.2,pp.159174.(1998)
[817] O.T.Thomsen&W.Rits
AnalysisandDesignofSandwichPlateswithInserts:AHighOrder
SandwichPlateTheoryApproach
CompositesPartB,Vol.29B,pp.795807(1998)
[818] O.T.Thomsen&W.Rits
AnalysisofSandwichPanelswithInsertsUsingaHigherOrder
SandwichPlateTheory.
Proceedingsofthe10thInternationalConferenceonCompositeMaterials
(ICCM10,Eds.K.StreetandA.Poursartip),Vancouver,Canada,Vol.5,
pp.3542.(1995)
[819] O.T.Thomsen
SandwichPlateswithInsertsModelling,AnalysisandDesign
ProceedingsoftheESAConferenceonSpacecraftStructures,Materials
andMechanicalTesting
ESTEC,Noordwijk,TheNetherlands,pp.619626(1996)
[820] O.T.Thomsen
LoadIntroductionAspectsinSandwichPanelswithHardPoints.
ProceedingsoftheFirstInternationalConferenceonCompositeScience
andTechnologyICCST/1(Eds.A.AdaliandV.E.Verijenko),Durban,
SouthAfrica,pp.539544(1996)
[821] O.T.Thomsen
HigherOrderEffectsinSandwichPlateswithInserts.
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ProceedingsoftheXIXthInternationalCongressonTheoreticaland
AppliedMechanics,Kyoto,Japan(1996)
[822] O.T.Thomsen
SandwichPlateswithThroughtheThicknessorFullyPottedInserts:
DifferencesinStructuralBehaviourandProperties.
EuropeanMechanicsColloquium(EuroMech360):Mechanicsof
SandwichStructures,Sainttienne,France,pp.407414.(1997)
[823] J.Stoer,R.Bulirsh
AnIntroductiontoNumericalAnalysis,
SpringerVerlag,NewYork,1980.
[824] M.Palanter:ComponeeringInc,Finland:
Privatecommunication(June2004)

ECSSEHB3220 Structuralmaterialshandbook
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9
Design aspects
9.1 Design parameters

An insert is part of detachable fixation device. It enables the junction of honeycomb structures, the
connectionwithotherstructuralparts,suchasframes,profilesandbrackets,aswellasthemounting
ofequipment,e.g.boxes,feedlinesandcableducts.
An insert system consists of a removable and a fixed structural element. The removable part being
eitherascreworanotherthreadedelement.Thisisattachedtothefixedpart,theinsertandusually
connected to the honeycomb by potting compound. A standard insert system is composed of three
components,[Seealso:Clause5;A.3;F.6fornonstandardinsertsystems]:
Insert,
Sandwichstructure,
Pottingcompound,orequivalent.
Designersdecidingtouseinsertsfacealargenumberofoptionsandnonstandardisedparametersto
considerthatrelateto:
Geometry;
Material;
Loads;
Failuremodes;
Specialconditions.
Table91summarisesthebasicinsertdesignparameters.
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Table91:Summaryofthebasicinsertdesignparameters
SPECIAL
GEOMETRY MATERIAL LOADS FAILUREMODE
CONDITIONS
Face sheet
Face sheet Mechanical loads Strength and stability Reliability
thickness
aluminium Short term and long design
GFRP term manufacture
CFRP control
testing
Life and residual
Core Core Static loads
strength
height foam tensile
cell size honeycomb: shear:
foil thickness Al 5052 + symmetric
perforated
Al 5056 + antisymmetric
GFRP torsion
bending moment
Nomex
magnitude of load
direction of load
Insert Insert Dynamic loads Failure of core
diameter aluminium shock shear
height steel vibration normal
titanium quasistatic buckling
cyclic
Potting Potting Conditions Failure of face sheets
diameter Classical: glass amplitude tensile
height bubble + epoxy exceedances shear out
configuration Other, [See: sequence dimpling
A.3; F.6 direction bearing
Insert-to-edge
Preload Failure of insert
distance
thermal fracture on insert flange
environment fracture on thread or
mounting stress screw
Insert-to-insert
Thermal Failure of potting
distance
same normal quasistatic resin fracture on basic
load dynamic plane
opposite shear fracture on
normal load cylinder
Physical load
radiation
vacuum
humidity

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There is no standardised method to handle joints realised by inserts. In general, some of the
parameters are already available, e.g. global stiffness, thermal or moisture stability or functionality
aspects.
An insert joint is designed for the existing structure. However, a designer has a possibility to make
localchangestotheglobalstructuretoobtainabetterjointusinganinsert.
Figure91illustratesthevariousdesignalternativesandparameters.
Figure91:Basicaspectsofinsertdesign,analysisandtesting
9.1.1 Metal face sheets

Insertsinhoneycombsandwichpanelswithmetallicfacesheetsarecommonlydesignedtakinginto
accounttwoindependentaspects:
The panel parametersareselected based on the global requirements, e.g. globalload carrying
capability,aminimumstiffness,thermalstability,massoptimisation,humanfactors(inmanned
modules/spacecraftforexample,thefacesheetshouldbethickenoughtoavoiddamagecoming
fromonboardhumanactivities).
Theinsertdesignisthenperformedquiteindependentlybyselectingthenumberofinsertsand
their dimensions able to carry the required loads following the design guidelines and data
withinthishandbook.
[Seealso:11.1]
9.1.2 Composite face sheets

ForCFRPfacesheetsitneedstoberecognisedthatthenumberofparametersisfarhigherthanforthe
commonmetalfacesheet,e.g.aluminiumalloy,wherethefacesheetthicknessistheonlyparameter.
Therearemanyoptionsoffibretypes,plythickness,fibreorientation,numberofpliesanddifferent
laminatestackingsequencestobeconsideredforcompositefacesheets.Bydefinition,theselectionof
an insert design for CFRP sandwich panels cannot be as simple as for panels having far less
anisotropicmetalfacesheets,[Seealso:ECSSEHB3220].
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AfurtherconsequenceofsandwichpanelwithCFRPfacesheetsrelatestothedesignprocedure.Itis
not possible to select inserts independently of the panel design. The panel global capability is
significantlyinfluencedbytheholecuttoincorporatetheinsert.Inparallelaretheinsertloadcarrying
capabilitiesunderinplaneloadingwhicharereducedbytheglobalmembranestressappliedtothe
panelfacesheet.
Consequentlythedesignerisconfrontedwiththeinteractionofglobalandlocalrequirements.
9.2 Main load directions

Aninsertcancarryoutofplane,inplane,momentandtorsionloadsbothinstaticanddynamiccases,
asshowninFigure92.
Inaddition,thegeometricaldimensionsandenvironmentconditions,e.g.thermal,moisture,radiation
andvacuum,shouldallbeconsidered
Figure92:Insertloadcases
9.2.1 Out-of-plane load

An outofplane load can be either tension or compression. It is good design practise to carry the
bendingmomentsbytheoutofplaneforceonpairsofinserts,asshowninFigure93.
Figure93:Insertoutofplaneload
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9.2.2 In-plane load

Aninplaneloadcanbeeithertensionorcompression.Agooddesignpractiseisthattorsionalloads
arecarriedbyinplaneloadsonseveralinserts;asshowninFigure94.
C om p r es sion T en sion
Tor sion
Figure94:Insertinplaneload
9.3 References
9.3.1 General
[91] L.Sylvnenetal:PatriaFinaviacompOy,Finland
AnalysismodelsforinsertdesignrulesinsandwichpanelswithCFRP
facings
Patriareport:GS1PFCRP0002(January2003)
ESTECContractNo.14076/99

ECSSE30series SpaceengineeringMechanical
ECSSEHB3221 Adhesivebondinghandbook
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10
Design considerations
10.1 Insert arrangement

Designconstraintsgovernthewayinwhichinsertsareincorporatedintoasandwichstructure.
Figure101showsseveralofexamplesofinsertarrangements.
NOTE Insertswithalateralaxishaveverylowloadcarryingcapabilities,so
areavoided,[See:Figure101C].
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Single insert without edge

A [See:12.1]
influence
B Singleinsertnearedges [See:18.1;18.2]
C Insertaxisparalleltofacings
Adjacent inserts axially

D [See:19.1]
loadedinthesamedirection
Adjacent inserts axially

E loaded in opposite [See:19.2]
directions
Adjacent inserts in line

F (profile junction [See:19.3]
arrangement)
Adjacent inserts in group

G (bracket junction [See:19.5]
arrangement)
Figure101:TypicalinsertarrangementsLoad capability
Variousinsertarrangementsaredescribedinmoredetail:
CaseA:Singleinsertwithoutedgeinfluences,[See:12.1].
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CaseB:Singleinsertnearedge,[See:17.1;17.2]
CaseC:Insertaxisparalleltofacesheets.
NOTE Tobeavoidedduetotheverylowloadcarryingcapability.
CaseD:Adjacentinsertsaxialloading(samedirection),[See:19.1].
CaseE:Adjacentinsertsaxialloading(oppositedirection),[See:19.2].
CaseF:Adjacentinsertsinline(profilejunction),[See:19.1].
CaseG:Adjacentinsertsingroup(bracketjunction),[See:19.1].
10.2 Load conditions
10.2.1 General
Aninserttransfersfivebasictypesofload,whichcanactsinglyorcombined.Theseare:
Tensile, where the load is normal to the plane of the sandwich away from the surface, [See:
12.1];
NOTE Alsoknownaspullout.
Compressive,wheretheloadisnormaltotheplaneofthesandwichtowardsthesurface,[See:
13.1];
Shear,wheretheloadisintheplaneofthefacesheet,[See:14.1];
Bending,[See:15.1];
NOTE Alsoknownasrotation.
Torsion,[See:16.1].
NOTE Alsoknownastorqueout.
TheloadconditionsaresummarisedinFigure102.
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Loadcapability
Load normal to plane of the

sandwichawayfromthesurface
a [See:12.1]
Tensileload
alsoknownaspullout
Load normal to plane of the

b sandwichtowardsthesurface [See:13.1]
Compressiveload
Loadintheplaneofthefacing
c [See:14.1]
Shearload
Bendingload
d [See:15.1]
alsoknownasrotation
Torsionalload
e alsoknownas [See:16.1]
torqueout
Figure102:Insertloadconditions
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10.2.1.1 Tensile, compression and shear
Adesigngivespreferencetoloadingsintheinsertaxisortransversetoit,i.e.tensile,compressiveor
shearloading;[See:Figure102a,bandc].
Whenaloadactsinadirectionthatformsanacuteanglewiththeinsertaxis,thisloadcanberesolved
into two rectangularlyacting components, thus producing tension and shear or compression and
shear.
10.2.1.2 Bending
Bending loads should be avoided because of the low bending strength and stiffness of an insert
system.
10.2.1.3 Torsion
Torsionalloadsonsingleinsertsarerestrictedtoscrewingandlockingtorquesonly.
[Seealso:10.6forgeneralguidanceoninsertselection]
10.2.2 Design guide
10.2.2.1 Metallic face sheets

Forsandwichpanelswithmetalfacesheets,aninsertisusuallyloadedviaacleat,bracketorawasher
having a footprint size larger than the potting dimension. The preload of the screw connecting the
brackettotheinsertisselectedtobesufficientlyhighinordertopreventgapping,[101].
Figure103showssomeexamplesthatareinlinewiththegeneraldesignrules.
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Figure103:Sandwichpanelwithmetallicfacesheets:Generaldesignrules
Thegeneraldesignrulesensurethat,[101]:
Compressiveloadsaretransmittedviathefacesheetintheareaofthepotting.Thebracketor
footneedstohaveatleastthemaximumextensionofthepotting;[See:Figure103a].
The insert flange remains parallel to the face sheet such that under inplane loads it cannot
movebelowthefacesheet;showninFigure104b.
Loadsinplaneofthefacesheetareusuallytransmittedbybearingpressurebetweentheouter
insertflangeandthefacesheet;showninFigure104a.
Theborderofthefacesheetaroundtheinsertiswellsupportedtoaccommodateahighbearing
stress,createdinsidebythepottingandoutsidebythebracketorfoot.
Underasufficientpreloadoftheinsertboltminororsecondarybendingmomentsarecorrectly
reacted;asshowninFigure105a.
Major moments in plane of face sheets are introduced by a couple of inserts. Moment
introductiontoaninsert,asshowninFigure104b,shouldbeavoided.
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Figure104:Insertdesignunderinplaneload
Support of insert by an
a adequate diameter of
the counterpart
Introduction of bending
b to the insert (to be
avoided)
Figure105:Insertdesignloadedbymoments
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Formetallicfacesheets,theinsertsareinstalledsuchthattheirflangesareflush,i.e.inplanewiththe
outer plane of the face sheet in order to maintain the advantages summarised by the design; [See:
10.2.2Designguideformetallicfacesheets].Thetoleranceofinstallationissuchthattheflangecanbe
below the outer plane of face sheet by 0.03 mm but never exceeding the face sheet, i.e. protruding
insertsshouldbeavoided,[101].
An insert potted in accordance with this tolerance does not loose a significant part of its preload
whenitisexposedtoelevatedtemperature.
If an insert flange is protruding slightly out of the face sheet due to inadequate manufacturing
tolerances,itcanbemachinedsothatitbecomesflush.Thispracticeissometimesappliedsuccessfully
withaluminiumfacesheet.
10.2.2.2 CFRP face sheets

ForasandwichpanelwiththinCFRPfacesheets,machiningcanbeseenasproblematical,althougha
thorough finishing of the protruding parts of the inserts is considered necessary in order to avoid
damagingthesurfaceply.Themachiningprocessneedstobecarefullyinvestigatedandreflectedin
thedefinitionofthemanufacturingprocedure,[101].
ForthinfacesheetsmadeofCFRPwithaflushmountedinsert,anotherproblemneedstobeavoided
under loads inplane in the face sheet. If the outer insert flange has even a small chamfer, possibly
nonintentional, the load transfer is reduced by bearing stress. The insert tends to undercutthe face
sheet;asshowninFigure106,[101].
Figure106:CFRPfacesheets:Effectofsmallchamferoninsertflangeonload
transfertofacesheet
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10.3 Mounting modes
10.3.1 General
Positioning of inserts with respect to the surface of the sandwich panel depends upon mounting
needs,[Seealso:10.6forselectionofinserts;10.2forloadconditions].
10.3.2 Flush-mounted insert

Generally, a flushmounted insert is necessary, i.e. the upper surface of the insert is level, or flush,
withthefacesheetsurface;asshowninFigure107A.
10.3.3 Recessed insert

Itispracticallyimpossibletosetaninsertaccuratelyintheflushmountedposition,i.e.x=0,soasmall
negative tolerance ofup to 0.03 mm is acceptable, [See:Figure 107 B].Thisis the normal mode of
mountinganditalsoensures:
Good heat transfer from mounted electronic boxes (or other heatdeveloping equipment) into
thefacesheet,and
Minimisessecondarybendingeffects.
Incaseswherethefootoftheequipmentislargerthantheinsertdiameter,whenthetighteningtorque
isappliedtothebolt,theinserttendstobeextractedfromthepanelbyacorkscreweffect.Additional
stressesarealsocreatedatthepaneltoinsertinterface,[Seealso:Protrudinginsert].
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A Flushmountedinsert
Recessedinsert
B
0mm<x<0.03mm
Protrudinginsert
C
withbondedflange
Figure107:Insertmountingmodes
10.3.4 Protruding insert

Aninsertcanbepositionedsuchthattheflange(s)protrudesbeyondthesandwichpanelsurface.This
isalsoknownasproudoroverflush.Thispositioningisusedto,[101]:
guarantee a welldefined contact area between the assembled parts, so controlling the load
transferpath;
limitthecontactbetweenmountedequipmentandthesandwichpanel,e.g.forthermalreasons;
enablesflatnessoveragroupofinserts.
avoidsadditionalstressesandcorkscreweffectseenwithrecessedinsertswhentheequipment
footislargerthantheinsertdiameter,[See:Recessedinsert].
Thelimitedthermalcontactareacanbeaproblemwhenthefootoftheequipmentislargerthanthe
insertdiameter.Ifafullthermalcontactareaisneeded,afillerwithaholethesamediameterasthe
insertflangecanbeplacedbetweenthefootandthepanel.
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10.3.5 Bonded flange

Aprotrudinginsertcanhaveacircularflangeendthatisadhesivelybondedtotheexternalsurfaceof
thesandwichfacesheet,[See:Figure107C].Theflangeenables[102]:
Improvedinplaneshearcapability;
Increased contact area and inertia, so improved stress distribution between two assembled
structures;
Improvedmechanicalperformance,e.g.shear,pullout,torqueandbending(rotation).
NOTE Sandwich panels with metal face sheets exhibit higher properties,
where failure occurs in the bonding, than those with composite face
sheets,wherethefailureoccursinthefirstCFRPply.
Machiningoftheflangesurfacetoimprovethestressdistributionwiththeequipmentfoot,e.g.
individualflatnessandbetweengroups,friction.
Closetolerancesondrilling.
This type of insert is increasingly used for structural loadintroduction points in metallic and
compositesandwichpanelsinspace,e.g.SPOT5,[Seealso:F.7].
The main disadvantages of inserts with bonded flanges are the increased mass and manufacturing
costs,alongwithdifficultiesinrepairinganywhicharemisplacedorpoorlyinstalled,[102].
10.4 Junction of components
10.4.1 General
To achieve a satisfactory junction of components, the brackets should exhibit a sufficiently large
contactareaattheconnectingpoint.
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10.4.2 Minimum value

TheminimumdimensionD,showninFigure108Modea,isequaltothepottingdiameter,whichis
approximatelytheinsertdiameter,di,plus8mm,[See:Figure72]
NOTE InFigure108,Modesbandcshouldbeavoided.
Contact area greater than the

a
potted area
Contact area smaller than the

insert flange area
b
Incorrect design
Shimming plate smaller than the

potted area
c
Incorrect design
Figure108:Connections
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10.5 Adequate insert design
10.5.1 Insert arrangement

Aselectionprocedureforthemostappropriateinsertarrangementisnotpresentedinthishandbook.
Thisremainstheprovinceofcreativedesignerswhoseaimincludesoptimisingthe:
Insertswithrespecttosandwichconfiguration;
Numberofinserts;
Theirpattern;
Addedmass;
Relatedmanufacturingproblems;
Qualityassuranceprovisions.
Within the constraints provided here, designers select the insert configuration that meets a set of
prioritiseddemands.
[Seealso:Clause11]
10.5.2 Typical spacecraft design

Within this handbook detailed information is provided on all aspects of typical spacecraft design,
especiallythe:
Standardisationofinsertgeometriesandmaterials,[See:4.1];
Sandwichpanelcharacterisation,[See:6.1;8.1];
Pottinggeometry,[See:7.1];
Pottingprocess,[See:23.3;25.1];
Staticstrengthofinserts:
tensile,[See:12.1];
compressive,[See:13.1];
shear,[See:14.1];
bending,[See:15.1];
torsion,[See:16.1];
stiffness,[See:20.1
Fatiguelifeofinserts,[See:21.1];
Manufacturingprocedures,[See:23.1];
Testprocedures,[See:27.1;29.1;H.1fortestfixtures];
Qualityassurance,[26.1;27.1;28.1].
NOTE The information is presented in a format that is easily accessible to
designers,withouttheneedforextensiveanalyticalwork.
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10.5.3 Examples
Someexamplesoftheuseofinsertsinspaceapplicationsareprovidedfrom:
IATPinsertallowabletestprogramme,[See:E.1];
CasestudiesofsomeEuropeanprojects,[See:F.1];
Jigsandfixturesappropriatefortestinginserts,[See:H.1].
10.6 Selection of inserts
10.6.1 General
The terms used to describe the standard forms of inserts varies across the industry, [See also: Table
51;Figure87].e.g.:
Partiallypotted,alsoknownasblind,borneorsinglesided.
Fullypotted,alsoknownasblindorborne.
Throughthethickness,alsoknownastransverseordoublesided.
Nonstandardformsofinsertscanbevariationsorcombinationsofthestandardtypes,[See:A.3].
10.6.1.1 Partially potted

These are used where the loads to be transferred, per fixing point, are limited to inplane and
transverse forces. This is often the case where the item to be attached to the sandwich panel has a
numberoffixingpointsjoinedbyastiffstructuralpart,e.g.themajorityofelectronicequipment;feet
ofASAP4struts.
Aglobalbendingmomentisresolvedtopureforcesateachfixingpoint;asshowninFigure109.
Partiallypottedinsertsalsoprovidemasssavingcomparedwithfullypottedinserts,[101].
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Figu
re109:Selectionofinserts:Partiallypotted
10.6.1.2 Fully potted

Sometypesofpartiallypottedinsertscanbefullypotted,[See:Table51].Ingeneral,theirstaticload
bearing capability is better than partially potted inserts, but inferior to throughthethickness types,
[Seealso:8.4].
10.6.1.3 Through-the-thickness
Theseareusedwhenlocalbendingmomentsareappliedtosingleinserts.Thisenablesthebendingto
be transferred directly to the sandwich panel face sheets, as shown in Figure 1010.These forces are
thencounteredbytheinplaneforcesineachfacesheet.
Throughthethickness inserts are also used where a bolted connection to each side of the sandwich
panelisnecessary,e.g.ASAP5,[101]

Figure1010:Selectionofinserts:Throughthethickness
10.6.2 Sufficient static strength

The static strength of an insert is considered successfully verified if its loadcarrying capability is
greaterthanthedesignloads,i.e.limitloads,multipliedbyasafetyfactor,j:
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pallowable pult plimit jn [10.61]
10.6.3 Safety factor

Ifnotdefinedinaprogramspecification,asafetyfactor,jof1.5isappliedtoavoidfailure,[Seealso:
12.4].
10.6.3.1 Example
ThemechanicalpartsoftheEMATVCargoCarrierconsideredadditionalsafetyfactors(SFadd),which
wereappliedto,[102]:
Bonding,structuralinserts(axial):Ultimate:
Tested:1.0
Nottested:1.2
Equipmentinsertsinhoneycomb:Ultimate:
Tested:1.1
Nottested:3.0
Where:
Fy Flim SFadd J E [10.62]
Fu Flim SFadd J R [10.63]
10.7 Minimum and average insert capability
10.7.1 Minimum
TheminimuminsertcapabilitiesPSS min,[Seealso:12.5]arerelatedtotheminimumvaluesof:
pottinggeometry:bp min, hp min

corestrengthofmetalliccores:
ccritmin;ccrittmin;ccritcmin
corestrengthofnonmetalliccores:
ccritguar;ccrittguar;ccritcguar
10.7.1.1 Permissible minimum values

ThePSS minvaluesareapplicablewithoutfurtherinvestigations,providedthatthe:
corepropertiesareinaccordancewith:
MILC7438;
nationalprocurementspecifications.
manufacturingisinaccordancewith:
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manufacturingspecification,[See:23.1;24.1;25.1];
qualityassurancespecification,[See:26.1;27.1;28.1].
If the minimum material data and potting dimension apply, the probability of exceeding the given
minimumloadcapabilityis99%withaconfidencelevelof95%.
10.7.2 Average
TheaverageinsertcapabilitiesPSS av[See:12.7;AnnexB],arerelatedtotheaverageortypicalvalues,
respectively,of:
Pottinggeometry:bp typ,hp typ

Aluminiumcorestrength:
ccritav,ccrittav,ccritcav
Nonmetalliccorestrength:
ccrittyp,ccritttyp,ccritctyp
10.7.2.1 Permissible average values

Seventypercentoftheaveragecapabilityvaluesareapplicablewithoutfurtherinvestigationprovided
thatthe:
Corepropertiesmeet,atleast,thetypicaloraveragevaluesgiveninTable63;
Manufacturingmeetsthe:
manufacturingspecification,[See:23.1;24.1;25.1
qualityassurancespecification,[See:26.1;27.1;28.1]
Loadtransferismaintainedby:
asetofinsertsclosetogetherwithdifferentloads;
thepotentialofredistribution.
NOTE Underthesecircumstances,areducedfactorofsafetycanbejustified,
[Seealso:9.04].
10.8 Pre-design
The design methods detailed within this handbook have been successfully applied to numerous
applications. Some different or simplified hypotheses that have been suggested for predesign are
summarisedhere.Allinformationpresentedistakenfrom[101].
NOTE1 Whatever the analysis method used to determine insert capability,
validation tests are necessary for critical cases, i.e. where safety
marginsobtainedbyanalysisaretoolow.
NOTE2 Guaranteedloadcapabilityvaluesare:
highlydependantonmanufacturingprocessesandtheircontrol;
reliantuponadequatequalityassuranceprocedures.
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10.8.1 Load path for in-plane forces
10.8.1.1 General
Ithasbeenconsidered,andconfirmedbyexaminationoftherupturemode,thatthistypeofloadis
transferredbybearinginthefacesheet.Theallowableforceisthengivenby:
Fall bearingall t [10.81]
Where:
bearing all allowablebearingstressoffacesheetmaterial;
t thicknessofcontactareabetweeninsertandfacesheet;
diameterofcontactareabetweeninsertandfacesheet.
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10.8.1.2 Through-the-thickness insert

Forathroughthethicknessinsertsubjectedtoabendingmoment,itcanbeassumedthatthemoment
istakenbybearingofbothfacesheets.Theinsertisthenconsideredasasimplysupportedbeam,as
showninFigure1011.
Figure1011:Predesign:Throughthethicknessinsertunderbending
Thisanalysisapproachcorrelateswellwithtestresults,butitassumesthattheinsertandboreholeare
ofthecorrectdimensions,i.e.theboreholeismachinedpreciselyfortheinsertused.Iftheboreholeis
toolarge,thentheallowableforceisseverelyreduced.
[Seealso:23.10fordefects]
10.8.1.3 Inserts with an upper flange

Bondingoftheflangetothesandwichpanelskinincreasestheshearloadcapability,by:
Fadd all S bonding [10.82]
where:
all allowableshearstressofbonding,e.g.10MPa,typically;
Sbonding areaofbonding.
10.8.1.4 Inserts near an edge

Afacesheetshearoutfailuremodecanoccurwhereinserts(flangedornot)arepositionedcloseto
theedgeofapanel,asshowninFigure1012.
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Figure1012:Predesign:Facesheetshearoutfailuremode
Theloadcapacitycanbedeterminedby:
Fall 2 d t all [10.83]
where:
d distancefromthepaneledge;
t facesheetthickness;
all allowableshearstressoffacesheetmaterial.
10.8.2 Load path for transverse forces

Thestrengthwhensubmittedtotransverseforcecanbeassumedtobelimitedtotheshearbucklingof
thehoneycombcoreatthecoretopottinginterface.Thisappliesto:
throughthethicknessinserts;
partiallypottedinserts,wheretheinsertheightislargecomparedwiththecoreheight.
Theallowabletensionorcompressionforceisgivenby:
Fall all h D [10.84]
where: D diameterofpotting,[See:Figure1013].
h coreheight;
all allowableshearstrengthofhoneycomb.
NOTE1 Forpartiallypottedinsertswithalowheightcomparedwiththecore
height,thecalculationisnotvalid.
NOTE2 A pessimistic assessment can be obtained by substituting the
heightoftheinsertforthecoreheight(h)inEqn.[10.84].
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Figure1013:Predesign:Throughthethicknessinsertundertransverseforce
10.8.3 Transverse and in-plane load interaction

Given the assumptions made for each load case, loads are transmitted to different loadbearing
components,i.e.:
Inplaneloadsaretransmittedtofacesheets;
Transverseloadsaretransmittedtothehoneycombcore.
Therefore,anyinteractioncanbeconsiderednegligibleforpredesigncalculations.
10.8.4 Proximity and edge effects

Usingthedesignmethoddetailedinthishandbookproducesreductionfactorsthatareknowntobe
veryconservativecomparedwithtestresults.
10.9 Failure modes
10.9.1 General
Failurecanoccurinthesandwichstructurewithinsertsinmanydifferentwaysanddependson,e.g.:
Designparameters;
Loadcases;
Conditions;
Manufacturing.
Generally, the failure occurs in the core by shear stresses under outofplane loads and in the face
sheetunderinplaneloads,[101].
Failure modes are listed in Table 101.Failure occurring in the insert, fasteners and other attachable
devicesisnotconsidered.
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Table101:Failuremodesofinsertjoint
Failure
Failuretype Loadcase(1)
component
Shearfailure Outofplane(T,C)
Core
Tensionfailureunderneathpotting Outofplane(T)

Compressionfailureunderneathpotting Outofplane(C)
Tensilefailureunderneathinsert Outofplane(T)
Potting
Inserttearout Outofplane(T)
Adhesionfailurebetweeninsertandpotting Outofplane(T)
Adhesion
Adhesionfailurebetweencoreandfacesheet Outofplane(T)
Tensionfailure Inplane
Bearingfailure Inplane
Facesheet Dimplingfailure Inplane
Wrinklingfailure Inplane
Shearoutfailure Inplane
Insert Lowerflange,thread,fastener,screw Notconsidered
Key:T=Tension;C=Compression
10.9.2 Failures under out-of-plane loads
10.9.2.1 General
An outofplane load can be either tension or compression. It is good design practise to carry the
bendingmomentsbytheoutofplaneforceonpairsofinserts,asshowninFigure1014,[101].
TheloadistransferredthroughtheinsertsandwichsystemasshowninFigure1015.
Figure1014:Failuremodes:Momentload
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Figure1015:Failuremodes:Loadtransferinoutofplanecase
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10.9.2.2 Study of several cases
10.9.2.2.1 Overview
TheseveralcasesareshowninFigure1016andexplainedintheclauses10.9.2.2.2to10.9.2.2.5.
Figure1016:Failuremodes:Insertasafunctionofcoreheight
10.9.2.2.2 Case A - fully potted or through-the-thickness

Under outofplane tension load rupture occurs, in general, in the core by shear (tension load is
carriedbycoreshear).
10.9.2.2.3 Case B - partially potted, thin core

In the case of low core heights, a partially potted insert acts like a fully potted insert (Case A). The
loadcarryingcapabilityofthecoreinshearisweakerthantheloadcarryingcapabilityofthecoreor
thepottingintension.
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10.9.2.2.4 Case C - partially potted
Thecrosssectionareaofthesinglecellfoilsundershearstressdependsonthecoreheight.Whenthe
crosssection area is large enough, the load carrying capability of the core in shear exceeds the load
carryingcapabilityofthecoreintensionandtheruptureoccursinthecoreunderneaththepotting.
10.9.2.2.5 Case D - partially potted

ThesituationissimilartothatofcaseC,buttheloadcarryingcapabilityofthepottingcompoundin
tension is weaker than the core. Depending on the combination of the core, insert and potting
compound, this failure can occur before core tension failure. Usually this kind of failure occurs ina
combinationofheavyandthickcoreswithasmallinsert.
10.9.2.3 Adhesion failure

Adhesionfailuresbetweentheinsertandthepotting,betweenthecoreandthefacesheetortearout
failures(pottingrupturearoundtheinsert)arerareinspaceapplication.Failuresareusuallydueto
deviationinthemanufacturingprocess.
10.9.2.4 Potting diameter

Failure mode is also very strongly dependent on the potting diameter. The larger the potting
diameter,themorefoilsundershearandthebetterloadcarryingcapability.
Pottingdiameterisaverycomplicatedquantity.Thesizeofarealpottingshapecanbedifferentfor
pottingswiththesameamountoffilledcellsduetothepositionoftheinsertcentrerespectivetothe
hexagonalcell.
The best correlation of insert outofplane loadcarrying capability and potting diameter can be by
examiningthedamagedcellwalls,whicharenaturallysinglefoilscellwalls.Itcannotbeconcluded
thatagreatnumberoffilledcorecellsgivesbetterloadcarryingcapability.Thecriticalparameteris
the number of failing single cell walls. The clarification descriptions and different potting shape
comparisontofailedcellwallsareshowninFigure1017andFigure1018(basedontestdata).
Filled cell
Insert
NPC = 16
NPC = 16 Number of failing single cell wall = 26
Number of failing single cell wall = 24
Figure1017:Failuremodes:Noncorrelationbetweennumberofthefilledcells
andnumberofthefailingcellwalls
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Crossedcellwall
NPC = 17
Number of failing single cell wall = 24
Figure1018:Failuremodes:Unsymmetricalpottingandcrossedcell
It can be concluded that it is impossible to consider in advance how much bigger the real potting
shape is and semiempirical formulae for potting radius are used in the analysis of the insert load
carryingcapability,[101].
10.9.2.5 Failures in potting compound

Thethreetypesoffailuresinthepottingcompoundare:
Inserttearout;
Adhesionbetweeninsertandpottingcompound;
Tensionfailureofthepottingcompound.
The potting compound should have sufficientstrength, so that it is not the weakest link. Stresses in
thepottingbodyareusuallysolowthatitisnottheweakestlinkininsertdesign.
Consequently,failuresinthepottingcompoundareavoidedprovidingthatthepottingprocessiswell
definedandmonitored.Themostcriticalparametersinthepottingprocessare:
Perforationofthecorematerialforventingduringthepottingprocess,
NOTE Adifferenttypeofpottingprocessisusedfornonperforatedcores.
Suitablepottingcompoundviscosityinterval;
Distanceh1=(boreholedepthinsertheight);
Ambienttemperature;
Bendingofcellwallsinthebore.
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10.9.3 Failures under in-plane loads
10.9.3.1 General
Aninplaneloadcanbeeithertensionorcompression.Agooddesignpractiseisthattorsionloadsare
carriedbyinplaneloadsonseveralinserts.TheloadsareshowninFigure1019,[101].
10.9.3.2 Metallic face sheets

In the case of a metallic material under inplane load, the face sheet fails by compressive buckling
aroundtheinsert.Therefore,thecapabilityoftheinsertislimitedbytheyieldstrengthsyoftheface
sheetmaterial.Thevaluesofyieldstrengthformetallicmaterialsareusuallygiveninsuppliersdata
sheets.Althoughotherfailuremodesarepossible,itisthissituationthatappliestothemostcommon
caseshavingaluminiumfacesheets.
Tension
Compression
Torsion
Figure1019:Failuremodes:Inplaneandtorsionloads
10.9.3.3 Composite face sheets

CFRPlaminates exhibit a fairly linear relationship of loading and stress up to their failure. Their
excellentperformanceisaccompaniedbyabrittlefailuremode.Afailurecanbeinitiatedfromvery
local,highlystressedareas.Thefailuremechanismhasnoprimaryorsecondarystress;theyallhave
thesamerelevance.Theverificationoftheelementisseenasoneprocess,[101].
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ForCFRPfacesheetsunderinplaneloads,thefailuremodestobeconsideredareillustratedinFigure
1020:
Tensilefailure(tension);
Shearoutfailure(tension);
Dimplingfailure(compression);
Bearingfailure(tensionorcompression);
Wrinkling.
(a) Ten si le (b) S h ea r
(c) Dim p lin g (d ) Bear in g
Figure1020:Failuremodes:CFRPfacesheets
A tensile failure occurs in a large panel with a sufficientlylargeedge distance. A localfailure starts
fromtheedgeofthehole;asshowninFigure1020(a).
Ashearoutfailureoccurswhentheedgedistancefromtheholeissmall.Thefailurelinecanbeatany
angledependingonthelayupofthefacesheetlaminate.
Undercompressionloading,afacesheetcanbuckleordimpleintothespacesbetweenthehoneycomb
corewalls.Thustheedgeandfrontareclamped.Dimplingofthefacesheetsdoesnotleadtofailure
unlesstheamplitudeofthedimplesbecomeslargeandcausesthedimplesorbucklestogrowacross
thecellwalls,whichresultsinaglobalfailureknownaswrinkling,[Seealso:8.2].
A bearing failure occurs in cases in which both the edge distance and the panel width are large in
comparisonwith the insert diameter.Such damage islocalised.The failure is usually notassociated
withacatastrophicfailureofacompositestructure.Theinitiationofsuchafailurecanbecausedby
compressivebearingatthebaseoftheinserthole.Assumingasinusoidalstressdistribution,themost
susceptibleareaislocatedinfrontofthecentralpointofthehole,[101].
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10.10 References
10.10.1 General
[101] L.Sylvnenetal:PatriaFinaviacompOy,Finland
facings
[102] N.Laval:SonacaS.A.,Belgium
Insertswithflanges
WorkingGroupcontribution(September2003)
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11
Design flow chart
11.1 Introduction
In order to achieve anappropriate design using the guidelines providedin this handbook, it isalso
helpfultohavethestepsintheformofaflowchart.Owingtodifferentdesignconstraints,itisquite
oftenthecasethatnostraightforwardprocedureorguidecanbegivenforeverydayuse.Themain
constraintscanbedefinedas:
The sandwich design and the geometry of the joint are frozen, then the appropriate insert
geometryisdefined.
Thesandwichparametersaregivenandthecorrespondingnumberofinsertsandtheirsizeare
selected.
For an optimum design, the sandwich can be designed at the same time as an adequate number of
insertsandtheinsertgeometryaredefined.
In the case where the sandwich is predefined and the loads are given, [See: 11.2]. Where two main
parameters,e.g.geometryandnumberofinserts,canvary,[See:11.3].
11.2 Flow chart: Predefined sandwich and loads

Figure 111summarises the steps taken during the selection of the insert configuration, when the
sandwichandloadsarepredefined,[111].
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1 Input given:
Sandwich parameter
Number of connections to sandwich and distances
Set of load conditions on each connection point, e.g.
include preloads caused by tolerances, deflection,
temperature.
2 Use a load factor of 1.5 initially
3 Determine max. tensile, compression and shear load

increase
load factor
Choose an appropriate mean insert diameter
4
e.g. consider load, space, [See: 5.3; 10]
Determine minimum tensile, compression and shear

5 load for chosen diameter and given sandwich,
conditions, [See: Annex B]
yes
is the
is increase
minimum load no
of insert diameter
sufficiently
possible?
high?
no
yes

Determine insert influences of:
Distance between them, [See also: 10.1, 19]
6 Edge distance, [See also: 18]
Temperature, [See also: 22]
Combined shear and normal load, [See also: 17]
are the
superimposed influencing
factors reasonably covered
by the load factor no
of 1.5?
yes
change to selection
loop 2 or 3
End of initial design
NOTE The next step would be to perform a detailed analysis if high

reliabilityorlifeisstipulated.
Figure111:Flowchart:Predefinedsandwichandloads
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11.3 Flow chart: Variable main parameters

Figure 112 summarises the steps taken during the selection of the insert configuration, when two
mainparameters,e.g.geometryandthenumberofinserts,canvary,[111].
1 Input given:
Sandwich parameter
Support geometry
Set of max. loads on strut, e.g. include preloads
caused by tolerances, deflection, temperature.
2 Use a load factor of 2 initially
Determine max. tensile and compression load

3
normal to sandwich
increase
load factor
4 Determine max. shear load
Choose most appropriate standard insert diameter,

5
[See: 5.3; 10]
Determine minimum tensile, compression and shear

6 load for given sandwich conditions and insert diameter,
[See: Annex B].
7 Define necessary number of inserts from driving load
8 Define the support size and insert distances
is an
appropriate design
of support no
possible?
yes
Determine insert influences

Distance between them, [See also: 10.1, 19]
9 Edge distance, [See also: 18]
Combined shear and normal load, [See also: 17]
Temperature, [See also: 22]
are the
superimposed influencing
factors reasonably covered
by the initial load no
factor of 2?
yes
change to selection

End of initial design
loop 3
NOTE Itcanbenecessarytorepeattheloop.Anadditionalconsiderationof
thedamagetoleranceaspectsisessential.
Figure112:Flowchart:Variablemainparameters
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11.4 References
11.4.1 General
[111] JesusGmezGarcia:EADSAstrium(Bremen),D
DesignGuideline
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12
Tensile strength
12.1 Normal tensile load
12.1.1 General
Thestaticstrengthcapabilitiesofastandard,singlepottedinsertwithoutedgeinfluences,orwithout
interferencefromsurroundinginserts,underoutofplanetensileloadaredescribed.
The design guidelines presented here cover partially and fullypotted inserts. For throughthe
thickness inserts the same procedures can be used if the nonapplicable failure modes are ignored.
Throughthethickness(spool)insertscannotfailbycoreorpottingtensionbeneaththeinsert.
Forthestrengthcapabilityofnonstandardinsertdesigns,[See:A.3;F.6].
12.1.2 Failure modes

ThedecisivefailuremodesaffectingthestaticstrengthcapabilityPSS ofaninsertundertensileloadin
asandwichpanelareshowninFigure121.
Thesefailuremodesaremainlyinfluencedbytheheightofcorecincombinationwiththeheightof
pottinghp.
[Seealso:10.9]
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Figure121:Failuremodesinrelationtothecoreheight
12.1.3 Shear rupture: core surrounding the potting
12.1.3.1 Fully potted insert

Forfullypottedinserts,i.e.hp = c,theinsertfailsbyshearruptureofthecoresurroundingthepotting,
especiallybyshearruptureoftheundoubledcorefoils.Therefore,thelimitingcapabilitypropertyis
thecoreshearstrengthc crit.
[See:6.5;Table63;Table64]
TheinsertcapabilityPcritincreasesquasilinearlywiththecoreheightc.
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12.1.4 Tensile rupture: core underneath the potting
12.1.4.1 Partially potted insert: Metal core

Forpartiallypottedinserts(c>hp),thecoreunderneaththepottingissubjectedtoatensilestress.Inan
aluminiumcore,thistensilestressincreasesforconstanthpwithincreasingcoreheight.However,up
to a certain height of core, the insert still fails by shear rupture of core around the potting, and the
insert capability Pcrit still increases quasilinearly with core height c. This quasilinear behaviour
results from the early shearbuckling of the single core foils, which maintains an approximately
constantshearstressoverthetotalcoreheight.
NOTE Although partially potted, the insert exhibits the same behaviour as
thatofafullypottedinsert.
If(c hp)reachesacertainlimit,thetensilestressunderneaththepottingreachesthetensilestrength
c crit t ofthecore.
[See:6.6;Table63]
For greater core heights, the shear rupture of the core around the potting and tensile rupture of the
coreunderneaththeinsertoccurtogether:theinsertcapabilityisthensimultaneouslylimitedbyc crit
andc crit tandispracticallyindependentoffurtherincreasesincoreheight.
[Seealso:B.1
12.1.4.2 Partially potted insert: Non-metallic core

Innonmetalliccores,e.g.Nomex,GFRP,theinsertcapabilityforconstanthpincreasesonlyslightly
withincreasingcoreheightc.Thereasonwhythisbehaviourdiffersfromthatofaluminiumcoresis
thattherigidnonmetalliccorescannotadequatelydistributestressconcentrationsbymeansoflocal
deformation.
The stress concentration at the lower flange of the partiallypotted insert is considered to be
conservativelyaccountedforbyastressconcentrationfactorforpartialpotting,Ktpp.
[See:C.3]
12.1.4.3 Notes on insert capabilities in non-metallic cores

Thecapabilitiesofinsertsinnonmetalliccoresaredeterminedbyusingmeasuredcorepropertiesin
combination with an analytical model verified primarily with metallic cores. They can be used for
preliminarydesignbutneedtobesubstantiatedbytestingoftheactualconfiguration.
Whereathin,flexible,nonmetalliccorehasstiff,relativelythick,metallicfacesheets,theloadapplied
normaltothepanelcanbecarriedprimarilybythefacesheets.Thestrengthofthefacesheetneedsto
bechecked,inordertoensurethattheloaddistribution,definedbytheanalyticalmodel,isstillvalid.
Theloadinonefacesheetcanbeapproximatedby:
Pf Pss 2 b p c [12.11]
Thecriterionthatthisloadcanbetransmittedbybothfacesheetshasnotbeentakenintoaccountin
thedesigngraphsprovidedinAnnexB,[See:B.2].
NOTE Thistypeofcheckisnotnecessaryforinsertsinmetalliccoresbecausethe
modelhasbeenverifiedbymanyteststhatimplicitlycoveredthispoint.
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12.1.5 Tensile rupture: potting underneath the insert

Likethecoreunderneaththepotting,thepottingunderneaththeinsertissubjectedtoatensilestress
thatincreaseswithincreasingcoreheight.
For a certain core height, this stress can exceed the tensile strength R crit of the potting compound
before the tensile strength c crit t of the core underneath the potting is reached. This is the case for
heavycoresandcanalsooccurforfullypottedinserts.
AfurtherincreaseinthecoreheightresultsinaslightdecreaseintheinsertcapabilitybecausePcritis
thenonlylimitedbyc crit t.
Owingtotherigidityofthepotting,noadvantagecanbetakenfromtheshearstrengthofthecore.
Theshearstressesinthecorearoundthepottingdecreasewithafurtherincreaseofthecoreheightc.
12.1.5.1 Effective stress concentration

Fortheusualtypesofpottingcompound,i.e.asyntacticfoam,tensilestrengthvaluesthatincludethe
effectivestressconcentrationKt,(derivedfrominserttestresults),are:
R crit min =9N/mm2

R crit typ =12N/mm2
ThesevaluesarelowerthanthepottingmaterialstrengthgiveninTable71.Inthiscase,avalueforKt
lessthan1.8isadvisable.
NOTE Ktvaluesfordifferentpottingcompoundsaredeterminedbytesting.
12.2 Basic parameters

The basic parameters for the determination of the capability of potted inserts under tensile load are
summarisedinTable121andarerelatedtothe:
Facesheets:
thickness,f
material:
o EfYoungsmodulus,and
o fPoissonsratio.
Insert,[See:Table122;Table123]
diameterofinsertdi influencingthepottingradiusbp
flangeradiusofinsert bi
heightofinserthiinfluencingthepottingheighthp
Core:
coreheight,c
cellsize,Sc; shearmodulusGc
foilthickness,t0influencingshearstrengthc crit
corematerial tensilestrengthc crit t
[Seealso:12.1forcommentsoninserttypes;AnnexA]
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Table121:Propertiesfordeterminingpottedinsertcapability:Tensileload
Propertiesof MinimumvaluesPSStmin AverageorTypicalvaluesPSStav
components accordingto: accordingto:
Thickness f f
Sheet
Youngs
Ef Ef
modulus
Poissonsratio f f
Figure64 Figure64
Effectiveradius bpmin Table122 bptyp Table122
Table123 Table123
Potting
Figure71 Figure71
Realradius bRmin Table122 bRtyp Table122
Table123 Table123
Height hpmin Figure72 hptyp Figure72
Tensilestrength Rcritmin =9N/mm2 Rcrittyp =12N/mm2
Height c c
Table63 Table63
Shearmodulus Gc Gc
Table64 Table64
Core
Table63 Table63
Shearstrength ccritmin ccrittyp
Table64 Table64
Table63 Table63
Tensilestrength ccritmin ccrittyp
Table64 Table64
Perforatedcore RC =(1.720.0063c0.2641f) RC =(1.2070.00544c0.2088f)
RC(1)
Unperforated
RC =0.91 RC =1
core
NOTE(1)Modelcorrelationcoefficient,[See:12.3].
c=coreheight,formerlyshownashcinPSSIDH.
NOTE(2)[Seealso:AnnexGforlistingofequations]
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Table122:Perforatedcores:Effectiveandrealpottingradiusversusinsert
diameter
Corecellsize,Sc=4.8mm 3/16
Insertdiameter,di 9 11 14 17.5 22 mm
min 7.70 8.63 10.03 11.66 13.75 mm
Pottingradius,bp
typ 8.28 9.28 10.78 12.54 14.79 mm
min 6.18 7.18 8.64 10.43 12.68 mm
Realpottingradius,bR
typ 6.9 7.9 9.4 11.15 13.4 mm
min 6.33 7.26 8.66 10.29 12.39 mm
Pottingradius,bp
typ 6.81 7.81 9.31 11.07 13.32 mm
min 5.62 6.62 8.12 9.87 11.12 mm
typ 6.1 7.1 8.6 10.35 12.6 mm
NOTEPerforatedcores,e.g.aluminium.
bpmin=0.93192bi+0.874Sc0.66151 bRmin=bi+0.35Sc
bptyp=1.002064bi+0.94035Sc0.7113 bRtyp=bi+0.5Sc
bi=0.5di
Table123:Nonperforatedcores:Effectiveandrealpottingradiusversusinsert
diameter
min 7.41 8.31 9.66 11.24 13.26 mm
Pottingradius,bp
typ 8.34 9.34 10.84 12.59 14.84 mm
min 6.18 7.18 8.64 10.43 12.68 mm
typ 6.9 7.9 9.4 11.15 13.4 mm
min 6.29 7.19 8.54 10.12 12.14 mm
Pottingradius,bp
typ 7.06 8.06 9.56 11.31 13.56 mm
min 5.62 6.62 8.12 9.87 12.12 mm
typ 6.1 7.1 8.6 10.35 12.6 mm
NOTENonperforatedcores,e.g.Nomex,GFRP.
bpmin=0.9bi+0.7Sc bRmin=bi+0.35Sc
bptyp=bi+0.8Sc bRtyp=bi+0.5Sc
bi=0.5di
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12.2.1 Out-of-plane loads: Insert strength
12.2.1.1 Sensitivity to parameters

Thesensitivityofeachcomponentinoutofplanecasesarecalculatedusingtheexpression,[121]:
PIp 1 I 1 r b p K ( b p ) a K 1 ( a )
(r ) (
(h c) I r a b p I 1 ( a ) K 1 ( b p ) I 1 ( b p ) K 1 ( a )
[12.21]
K 1 ( r ) a I 1 ( a ) b p I 1 ( b p )
)
a b p I 1 ( a ) K 1 ( b p ) I 1 ( b p ) K 1 ( a )
where:
P appliedoutofplaneload
coreshearstress
f facesheetthickness;assumingfacesheetsaresimilar
f1,f2 individualfacesheetthicknesses
h totalsandwichthickness=c+f1+f2
outerradiusofpanel
bp effectivepottingradius
bR realpottingradius
Ip momentofinertiaofthepanel
f1 f 2 (h c) 2
= [12.22]
4(h c)
Is moment of inertia of the face sheets
3 3
f1 f 2
= [12.23]
12
I = I p + Is
ratio of stiffness between core and face sheets
Gc (h c) I
= [12.24]
E c f1 f 2 I s
Gc shear modulus of the core
Es
E = [12.25]
1 s
2
I1(x), K1(x) Bessel functions, where x = r, a, b

Thevaluesareshownfor,[121]:
coreshearfailureinTable124.
coretensionfailureinTable125.
NOTE Thesensitivityiscalculatedgiven5%deviationforeachcomponent.
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Table124:Outofplanecapability:Effectofcomponentsoncoreshear
Originalvalues +5%values Increase Influence
(N) (N) (N) (%)
bp 11.42 mm 3784 11.99 mm 3974 190 5.02
c 30.00 mm 3784 31.50 mm 3959 175 4.62
ccrit 1.46 MPa 3784 1.53 MPa 3973 189 4.99
f 0.30 mm 3784 0.32 mm 3825 41 1.08
NOTE Example case: Partially potted; D17, 3/160.001P; c = 30 mm, f = 0.3
mm.Failuremode:Coreshear.
Table125:Outofplanecapability:Effectofcomponentsoncoretension
Originalvalues +5%values Increase Influence
(N) (N) (N) (%)
bp 8.64 mm 6258 9.07 mm 6660 402 6.42
c 40.00 mm 6258 42.00 mm 6270 12 0.19
ccritt 8.45 MPa 6258 8.87 MPa 6389 131 2.09
ccrit 1.46 MPa 6258 1.53 MPa 6439 181 2.89
f 0.30 mm 6258 0.32 mm 6329 71 1.13
NOTE Examplecase:Partiallypotted;D14,1/80.001P;c=30mm,f=0.3mm.
Failuremode:Coretension.
Thecontributionsofthedifferentcomponentsfor,[121]:
CoreshearinFigure122
CoretensioninFigure123
Sensitivity of Out-of-plane
Core shear
f
7%
bp
32% Example case:
Partially potted
c crit D17,3/16-0.001P,
32% c = 30mm, f = 0.3mm
Pult = 3784N
Total improvement 595N

c
29%
Figure122:Outofplanecapability:Contributionsofthemaincomponentson
improvedcoreshear
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Sensitivity of Out-of-plane
Core tension
f
9%
Example case:
c crit
Partially potted
23% D14,1/8-0.001P,
c = 40mm, f = 0.3mm
Pult = 6258N
bp
50%
c crit t Total improvement 775N
16% c
2%
Figure123:Outofplanecapability:Contributionsofthemaincomponentson
improvedcoretension
BasedontheresultsinFigure122andFigure123,itcanbeconcludedthatthefacesheetthickness,f,
has very limited influence on outofplane capacity when the failure mode is core shear or core
tension,[121].
12.3 Minimum and average design values
12.3.1 Overview
Twolevelsofinsertcapabilitieshavebeendeterminedandplottedasafunctionofcoreheight:
MinimuminsertcapabilitiesPSS min
AverageinsertcapabilitiesPSS av
[Seealso:13.2;AnnexB]
12.3.2 Minimum insert design values
12.3.2.1 General
Theminimuminsertdesignvaluesarebasedupon:
Minimumstrengthproperties;
Minimumpottingdimensions;
Modelcorrelationcoefficient,RC
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12.3.2.2 Minimum strength properties

Minimumstrengthpropertiesofcoreshearstrengthwithaprobabilitygreaterof90%.
Wherethosedatawereunavailable,minimumguaranteedvalues,providedbythesupplier,areused
andindicatedonthestrengthdesignplots.
12.3.2.3 Minimum potting dimensions

Minimumpottingdimensionswithaprobabilitygreaterthan90%:
Perforatedcores,e.g.aluminium:WherestatisticaldataareavailableEqn.[7.34]isused,[See:
7.3].
Unperforatedcores,e.g.Nomex,GFRP:Eqn.[7.35]isusedtodeterminetheminimumpotting
dimensions,[See:7.3
12.3.2.4 Model correlation coefficient

ModelcorrelationcoefficientRC,withaprobabilitygreaterof90%ofthetestedoranalysedinserts:
Perforatedaluminiumcore:
RC=1.1720.0063c0.2641f [12.31]
Othertypesofcore:
RC=0.91
NOTE c=coreheight,formerlyshownashcinPSSIDH.
12.3.2.5 Design values

The possibility that the three minima with an individual probability of 90% apply together is so
unlikelythattheresultingvaluesareregardedasdesignAvalues(P=99%;CL=95%).
NOTE Theanalyticallydeterminedvaluesofpartiallypottedinsertsinnon
metallic core have not been confirmed by as many tests as those
within a metallic core. Therefore, these values can be used for
preliminarydesignonly.
Iftheminimumcorestrengthfromincominginspectionjustmeetstheguaranteedminimumvalue,
thisisconsideredtobecoveredbythesafetyfactorof1.5(aconservativevalue).
[See:12.4]
12.3.3 Average insert values
12.3.3.1 General
Theaverageinsertvaluesarebasedupon:
Averagestrengthproperties;
Averagepottingdimensions;
Modelcorrelationcoefficient,RC.
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12.3.3.2 Average strength properties

Averagestrengthpropertiesofcoreshearstrengthwithaprobabilitygreaterthan50%.
Where those data were unavailable, the typical values provided by the supplier are used and
indicatedonthestrengthdesignplots.
12.3.3.3 Average potting dimensions

Averagepottingdimensionswithaprobabilitygreaterthan50%:
Perforatedaluminiumcore:wherestatisticaldataareavailable,Eqn.[7.34]isused,[See:7.3].
Nonperforated (Nomex, GFRP) cores: Eqn. [7.35] is used to determine the average potting
dimensions,[See:7.3].
12.3.3.4 Model correlation coefficient

ModelcorrelationcoefficientRCwithaprobabilitygreaterthan50%ofthetestedoranalysedinserts:
Perforatedaluminiumcore:
RC=1.2070.00544c0.2088f [12.32]
Othertypesofcore:
RC=1
NOTE1 c=coreheight,formerlyshownashcinPSSIDH.
NOTE2 Verification of reliability coefficients applies to the sandwich panel
dimensionsinthishandbook.Paneldimensionsexceeding80mmby
0.8mmneedadifferentmethod.
12.4 Safety factors
12.4.1 Load capability

The loadcarrying capabilities provided are determined for perforated aluminium cores in use by
statisticalanalysisongroupsofseveralhundredsamples.
Based upon the variability identified, the given capabilities are considered as in agreement with
designAvalues(P=99%;CL=95%).
Thereforethereisnoneedforanincreasedsafetyfactortoaccountforthehighvariabilitygenerally
experienced if the installation of the insert is performed properly, i.e. in accordance with the
manufacturingprocess.
A safety factor of 1.5 against the minimum A ultimate capabilities provided is therefore possible
providedthattherearenootherrequirementswithintheprogram.
NOTE Within the industry, a safety factor of 2 is often stipulated, probably
arising from similarity with other structures. This can be reduced to
1.5providedthatalltheconditionsmeetthosestated.
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12.4.2 Failure modes

Theinsertcapabilityislimitedtoloadsresultinginlargepermanentdeformations.
Asinitiationofsignificantdeformationbeginsclosetoultimateload,thereis(withasafetyfactorof
1.5 on ultimate capabilities) no reason for a separate verification of a no permanent deformation
requirementwithrespecttofailureoftheinsertduetocorefailure.
NOTE Aseparateverificationcanbenecessaryforenvironmentalfactorsor
otherunusualfailuremodes,e.g.atelevatedtemperatures.
12.5 Permissible tensile loads
12.5.1 General
Standard type partially and fullypotted inserts are covered by the design rules provided here. For
throughthethicknessinsertsthesameprocedurescanbeusedifthenonapplicablefailuremodesare
ignored. Throughthethickness (spool) inserts cannot fail by core or potting tension beneath the
insert.
[Seealso:A.3;F.6fornonstandardinserts]
12.5.2 Insert capability graphs

The permissible tensile or compressive load graphs in Annex B show the capability of inserts to
withstand tensile loading plotted as a function of the core height c with face sheet thickness f. The
differentgraphsrelatetodifferentinsertdiameterdi andtodifferentcoretypes.
[Seealso:B.2]
Theoccasionalcrosses(x)insomeloadcapabilitycurvesdenoteatensileruptureofthepottingwhich
shouldbeavoided,e.g.byincreasingtheinsertheighthi ,[See:12.6].
12.5.3 Design values
12.5.3.1 Minimum values

PSS t min values are regarded as design A values (P = 99%; CL= 95%) for all cases where the usual
incoming inspection is performed and where the inserts are installed in accordance with the
manufacturing and quality assurance procedures, [See: 23.1; 24.1 and 25.1 for manufacturing; 26.1;
27.1and28.1forQA].
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12.5.3.2 Average values
ThePSS t av valuesareachievedinqualitycontroltesting,[See:28.1].
Inaddition,70%oftheaveragecapabilityvaluesareapplicabletodesignwithoutfurtherinvestigation
providedthatthe:
Core properties meet at least the typical or average values listed in Table 63 (metallic) and
Table64(nonmetallic).
Manufacturingconformswithmanufacturingandqualityassuranceprocedures,[See:23.1;24.1
and25.1formanufacturing;26.1;27.1and28.1forQA].
Loadtransferismaintainedbyasetofinsertsclosetogetherwithdifferentloads.Bypotential
loadredistribution,areducedfactorofsafetycanbeconsidered.
12.6 Influence of insert height

NOTE Theinformationgivenhereappliesonlytopottedinserts.
12.6.1 Insert capability graphs

Althoughthecapabilitygraphs,[See:AnnexB]areestablishedforaninsertheight,hi =9mm,theyare
alsoapplicableforotherhi values.
12.6.2 Different insert heights

Amodificationofinsertheight,hi onlyshiftsthebreakofthecurvestowardslowerorhighercvalues,
accordingtotherelationship:
*
C I * C I hi hi [12.61]
Where:
hi basicinsertheight=9mm
hi* newinsertheight
cI cvalueatcurvebreakforbasicinsertheighthi
cI* newcvalueatcurvebreakfornewinsertheighthi*
TheshiftisshownschematicallyinFigure124.
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Figure124:Influenceofinsertheightoninsertcapability
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Theincreaseinhi increasestheinsertcapabilityonlyforthosecaseswherethefailureoccursinthe:
Coreunderneaththepotting,or
Pottingunderneaththeinsert.
Anincreaseinhiisadvisedespeciallyifruptureofthepottingunderneaththeinsertisanticipated.
12.7 Composite face sheet
12.7.1 Effect of anisotropy

The outofplane load carrying capability of insertsandwich panel geometry is nearly totally
dependantonthecoreproperties;basedontestdata,[121].
The calculation procedure which is derived to define the outofplane capability of the insert
sandwich systems with metal face sheets is also valid for insertsandwich systems with face sheets
madefromCFRPorGFRP.
Theexpressionsusedforthecompositefacesheetsare:
Youngsmodulus:
E Ex Ey [12.71]
Poissonsratio:
xy yx [12.72]
12.7.2 Loading by moments

AlthoughCFRPfacesheetsarecomplex,thesituationisgenerallysomewhatsimilartometallicface
sheets,wherebytorsionandbendingmomentsarecarriedbyacoupleofinserts.
[See:15.3,16.3]
[Seealso:10.2]
12.8 References
12.8.1 General
[121] LassiSyvnen,KariMarjoniemi,AriRipatti,MarkkuPyklinen:Patria
FinaviacompOy,Finland
facings
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13
Compressive strength
13.1 Normal compressive load
13.1.1 General
Thegeneralstatementsmadein12.1fornormaltensileloadactingonpottedinsertsarealsovalidfor
compressiveoutofplaneloadwithsomeexceptions,describedhere.
Partially and fullypotted inserts are covered by the design rules presented here. For throughthe
thickness inserts the same procedures can be used if the failure modes which cannot occur are
ignored.Throughthethickness(spool)insertscannotfailbycorecompressionbeneaththeinsert.
Forthestrengthcapabilityofnonstandardinsertdesigns,[See:A.3;F.6].
13.1.2 Partially-potted inserts

Thetensilestrengthc crit tofthecoreunderneaththepottingisreplacedbythecompressivestrength
c crit clistedinTable63(metallic)andTable64(nonmetallic).
13.1.3 Potting strength

Thisdoesnothavealimitinginfluenceontheinsertcapability,becausethecompressivestrengthof
thepotting:
Farexceedsitstensilestrength;
Evenhigherthanthecompressivestrengthofthecore.
13.1.4 Increased face sheet thickness

Whenf>0.6mm,theinsertcapabilityisreducedbecauseafailureofthebondbetweentheupperface
sheetandcorecanoccurneartheinsert.Thisistakenintoaccountbyneglectingtheloadcontribution
oftheupperfacesheet.
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13.1.5 Insert capabilities
13.1.5.1 Minimum
Theminimuminsertcapabilityisgivenby:
PSScmin=RCPcritmin [13.11]
where: RC=0.89
13.1.5.2 Average
Theaverageinsertcapabilityisgivenby:
PSScav=RCPcritav [13.12]
where: RC=1
13.2 Permissible compressive loads

The statements made in 12.5 for permissible tensile loads also apply with respect to permissible
compressiveloads.
Standard partially and fullypotted inserts are covered by the design rules presented here. For
throughthethicknessinsertsthesameprocedurescanbeusedifthenonapplicablefailuremodesare
ignored.Throughthethickness(spool)insertscannotfailbycorecompressionbeneaththeinsert.
13.2.1 Graphs of permissible static insert loads

InAnnexB,thetwodeterminedlevelsofinsertcapabilitiesareplottedasfunctionofthecoreheight.
[See:B.2forkeytoinsertdesigngraphs]

Ingeneral,theguidelinesthatapplyformetallicfacesheetsarealsovalidforCFRPfacesheets,[See:
12.7].
Asdiscussedin10.2,loadingofaninsertisgenerallyperformedviaabracket,boxorwasherhavinga
footprintsizelargerthanthepottingdimension(takingintoaccountanynonregularityofthepotting
area).Thepreloadoftheboltsconnectingthebracketwiththeinsertistobesufficientlyhighinorder
topreventanygapping.
[SeeFigure103,Figure104]
These provisions ensure that all compressive loads are transmitted via the facing in the area of the
potting.
[Seealso10.2]
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Support of the CFRP laminate can be compromised by slight variations in tolerance of the
components,i.e.:
finishing operations performed on protruding inserts after potting can damage thin CFRP
laminates,
slippagebetweenthebracketsandfacing,e.g.undervibrationloads,cancausedamageonthe
surfacesoftheCFRPfacings,
Misalignment or poor fabrication can result in gapping in the contact area, such that the
intendedsupportaroundtheinsertholeisnotachieved.
Oneoptionistouseaprotrudinginsert,asshowninFigure131.Inthiscasetheborderoftheinsert
holeisbondedwithresinduringpotting[Seealso:10.2,10.3].
Figure131:Compressivestrength:Protrudinginsert
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14
Shear strength
14.1 Shear (in-plane) load
14.1.1 Effect of in-plane load

TheshearorinplaneloadQ, appliedtotheinsertisconsideredtoactinthemidplaneoftheupper
facesheet,asshowninFigure141.
The diameter D of the foot of the attached part needs to be at least as large as the typical potting
diameter,i.e.:
D 2bp 2(bt 4 mm) [14.11]
where:
bp pottingradius.
Thisisnecessarytoprovidesufficientclampingoftheinsertandpreventtheinsertfrombeingpushed
undertheupperfacesheet;asshowninFigure141.
Figure141:Shearloadedinserts:Clampingconditions
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14.1.2 Effect of face sheet material
14.1.2.1 Metallic face sheet

The insertsandwich combination fails by compressive buckling of the upper face sheet around the
socketoftheattachedpart.
Therefore,thecapabilityoftheshearloadedinsertislimitedbytheyieldstrengthfyofthefacesheet
material.
[Seealso:6.2;14.3]
14.1.2.2 Non-metallic face sheet

Thefailuremodeofinplane,shearloadedinsertsandwichcombinationswithcompositefacesheets,
e.g.CFRP,candifferfromthatofmetallicfacesheets,[Seealso:14.3].
Thefailuremode,aswellastheoffaxisyieldstrength,dependsonthe:
Materialused;
Numberoflayers;
Stackingsequence.
[Seealso:6.2]
14.1.3 Effect of partial clamping

Asmallportionoftheloadiscarriedbythecoreduetothepartialclampingofthecoreinthevicinity
oftheupperfacesheet.Thispartoftheload,Qc,dependsonthestiffnessofthecorewithrespectto
theloaddirection.
Conservatively,onlythecorestiffnessintheweakerWdirectionisconsidered,[Seealso:6.3;6.5].
Thispartoftheloadcanbegivenbythesemiempiricalformula:
Qc 8bp2 W crit [14.12]
where:
Wcrit shearstrengthofcoreinWdirection.
NOTE Thecriticalshearloadisquasiindependentofthecoreheight,c.
14.2 Permissible shear load

Standard partially and fullypotted inserts are covered by the design rules presented. For through
thethicknessinsertsthesameprocedurescanbeusedforeachfacesheetorskin.
Thetotalcapacityalsodependsuponwhethereachfacesheetisloadedequally,i.e.zeromomenton
panel; or just one, i.e. moment on the panel equals the applied shear load, times the offset to the
neutralaxisofthepanel.Thelatteristhenormalcaseforapartiallypottedinsert.
Incaseswherebothfacesheetsareused,thecorecomponentcanbeusedinadditiontothefacesheet
componentbut,asthederivationofthecorecomponentissemiempirical,testverificationisneededif
itisusedonbothfacesheets.
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Thepermissibleshearload,QSS,whichcanbetheappliedtotheinsertisgivenbythesemiempirical
formula:
QSS 8bp2 W crit 2 f b p fy for bp 11 mm [14.21]
Where:
bp pottingradius,[See:7.3;Table122;Table123
Wcri t shearstrengthofcoreinWdirection,[See:Table63;Table64].
fy yieldstrengthoffacesheets,accordingtostandards,[See:6.6].
f thicknessofupperfacesheet.
[Seealso:14.3forcompositefacesheets]
This expression is limited to values of bp less than 11 mm due to the difficulty of clamping greater
pottingradii,[See:Figure141].
NOTE bp=11mmisusedinEqn.[14.21]forbp>11mm.
14.3.1 Strength
Thesecommentsapplytoinsertsremotefromedgesorotherdisturbances.Theanalysismethodforin
planeloadisbasedontestdata.However,theresultsoftheseanalysesdonotcorrelateverywellwith
thetests,[141].
Thebestcorrelationiswithmetallicfacesheetsandfacesheetswith0/90fibreorientations.
The worst correlation is with face sheets with 45 fibres orientations and HT high tenacity or HM
highmodulusfibres.
ThecorrelationisshowninFigure142andFigure143,[142].
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Figure142:Correlationbetweencalculatedandtestedinplanecapabilitieswith
fibreorientation
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Figure143:Correlationbetweencalculatedandtestedinplanecapabilitieswith
fibrestrength
TheinplaneloadQ,appliedtotheinsertisconsideredtoactinthemidplaneoftheupperfacesheet.
Thediameterofthefootoftheattachedpartshouldbeatleastaslargeasthetypicalpottingdiameter.
Ageneraldesignapproachconsistsoffourprimaryelements,wherethecapabilityofthesandwich
insertsystemisinvestigatedwithrespecttothe:
Globalstressactingasaremotestressintheareaoftheinsert;
Stressconcentrationimposedbytheinsertholeinthepanel;
Inplaneloadsloadingtheholebybearingpressure,then
Radialandcircumferentialstressesimposedbytheloadnormaltothefacesheet.
Inaddition,theeffectofseveralinsertsclosetoeachother,theirrelativedirectionofloadsaswellas
theeffectoftheirdistancefromfreeboundariestakenintoaccountinanapproximatemanner.
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14.3.2 Face sheets

With a throughthethickness insert, with symmetrical loads both face sheets, capabilities can be
determinedusingtheexpression:
QSttt _ symm. 2(2t s bp sy ) [14.31]
where:
ts facesheetthickness,
bp pottingradius,
sy yieldstrengthofthefacesheet.
Foranunsymmetricalloadcase:
QSttt _ unsymm. 2t s b p sy [14.32]
In the partially potted case the core contribution should be taken into consideration by the semi
empiricalexpression:
Qc 8 b p2 Wcrit [14.33]
where:
Qc corecontributionofinplaneloadcarryingcapability.
Wcrit shearstrengthofcoreinWdirection.
Thepermissibleshearloadcarryingcapabilityforapartiallypottedinsertisgivenby:
QS 8 bp2 W crit 2 ts bp sy [14.34]
14.3.3 CFRP face sheets
14.3.3.1 Overview
AtleastfourdifferentfailuremodesofCFRPfacesheetsarepossibleunderinplaneloads,[Seealso:
Figure63]:
Tension;
Shearout;
Dimpling;
Bearing.
NOTE Theanalysisgivenappliestofacesheetswith0/90 fibre directions
only.
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14.3.3.2 Tension (net section)
Thebasicequationtoestablishthemaximuminplaneload,Qtagainstfailureintensionis:
1
Qt ( w bi )t s t ,ult [14.35]
K e'
where,[See:Figure144fornomenclature]:
Ke stressconcentrationfactordependinguponbi/wande/w,[See:Figure145];
w panelwidth;
bi insertdiameter;
ts facesheetthickness;
t,ult ultimatetensilestrengthoffacesheet;
E edge distance.
P
P
w
bi
Figure144:Nomenclature:Ultimateinplaneloadagainstfailureintension
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Figure145:Shearstrength:Stressconcentrationfactor
14.3.3.3 Shear-out
ThebasicequationforthemaximuminplaneloadQtagainstshearoutfailureis:
bi 1
Qs 2t s (e ) s [14.36]
2 cos
Where,[See:Figure146fornomenclature].
angleoffailuredirection;
s inplaneshearstrengthoffacesheet.
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Figure146:Shearstrength:Failureangle
14.3.3.4 Dimpling
The maximum inplane load at which dimpling of the sandwich face sheet occurs, shown in Figure
147,isgivenintheempiricalexpression:
2
2 Es ts
Qd bp t s K D [14.37]
1 s2 Sc
where:
bp typicalpottingradius;
Es Youngsmodulusoffacesheet;
s Poissonsratiooffacesheet;
Sc corecellsize.
KD dimpling coefficient; which depends on the plate geometry, boundary
conditionsandtypeofloading.
TheanalysisoftestdatagaveavalueofKDof2.0.WhereasfromFigure147,itcanbeconcludedthata
constantvalueofKD=2.0isnotsupportedbytestresultsinthewholerangeofts/Sc.
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Figure147:Shearstrength:Criticalstressesforintracellularbuckling(dimpling)
underuniaxialcompression
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14.3.3.5 Bearing
ThebasicequationforthemaximuminplaneloadQtagainstbearingfailureis:
2
Qb K b bi t s comp [14.38]

where:
Kb coefficient which depends on: panel geometry and stress
introduction;
BasedonpreviousteststheKbvalueof2.2waschosen.
Bi insertdiameter;
comp ultimatecompressionstrengthofthefacesheet.
14.3.4 Effect of panel layout
14.3.4.1 Edge influence

Thereducedloadcarryingcapabilityofinsertsunderinplaneloadingthatarelocatedatafreepanel
edgecanbeexpressedby:
*
Qcrit Qcrit EQ [14.39]
where:
Q*crit insertcapabilityundershearload,reducedbyedgeinfluence;
Qcrit initialshearcapabilityofinsert;
EQ edgecoefficientforshearloadedinsert.
Formetallicfacesheets:
e e
EN 0.66 0.06 for e 3bp [14.310]
bp bp
and: EN 1 for e 3bp
where:
e distancebetweeninsertcentreandpaneledge;
bp pottingradiusofinsert.
TheedgecoefficientEQisplottedagainsttherelativeedgedistance,e/bpinFigure148.
Owing to the complicated nature of fibrereinforced composites, it can be concluded that tests are
necessarytoobtainreliabledataforedgecoefficients.
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Figure148:Shearstrength:Influenceofedgedistance
14.3.5 Sensitivity of insert strength in face sheets

Table141givesthesensitivityofeachcomponentininplanecases,accordingto(Eqn.[14.34]),i.e.:
QS 8 b p2 W crit 2 t s b p sy [14.311]
Thesensitivityiscalculatedfora5%deviationofeachcomponent.Thecontributionsofthedifferent
componentsareshowninFigure149.
Table141:Inplanecapability:Effectofcomponentsoncoreshear
Original values +5% values Increase Influence
(N) (N) (N) (%)
bp 11.42 mm 3097 11.99 mm 3311 214 6.91
sy 289.00 mm 3097 303.45 mm 3196 99 3.20
w 1,07 MPa 3097 1.12 MPa 3153 56 1.81
ts 0.3 mm 3097 0.32 mm 3196 99 3.20
NOTE Example case: D17, 3/160.001P, c = 30 mm, ts = 0.3 mm. Partially
potted.Failuremode:Coreshear.
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Sensitivity of In-plane
ts
21%
Example case
Partially potted
bp
46%
D17,3/16-0.001P,
w c=30mm, ts=0.3mm
12%
Qult=3097N
Total improvement 468N

fy
21%
Figure149:Inplanecapability:Contributionsofthemaincomponentson
improvedcoreshear
14.3.6 Effect of thin CFRP face sheet

Theadvantagesrelatedtothedesigncanbeaffectedwhenappliedtoinsertsinsandwichpanelswith
thinCFRPfacesheets,[Seealso:Clause9;10.2;10.9].
When inplane load is applied on an insert, the load is by bearing pressure in the face sheet. The
supportoftheCFRPfacesheetbytheclampingforce,createdbetweenthepottingandbracketbythe
preloadoninsertbolt,canbeaffectedbyoneorthecombinationofseveralslighttolerancesbetween
theelementsinvolved,i.e.:
The insert can be potted slightly too low, such that the area enabling the transfer of bearing
pressureisreducedorisinsufficient
Thecapabilitytotransferinplaneloadsbybearingcanbecomedependentonthesharpnessof
theinsertflange.
The finishing of protruding inserts after potting can be deleterious with respect to damage of
thinCFRPlaminates.
Slippage between the brackets and face sheet, e.g. under vibration loads, can damage the
surfacesoftheCFRPfacesheets.
Nonperfect parallel planes in the contact area can result in local gaps such that the intended
supportaroundtheinsertholeisnotachieved.
Undersuchconditionsitisnotcleariftheadvantagesofthedesigncanbemaintainedwithverythin
CFRPfacesheets.
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14.4 References
14.4.1 General
facings
[142] W.Hertel,W.Paul&D.Wagner
Standardisationprogramondesign,analysisandtestingofinserts
FinalreportESACR(P)1498,February1981
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15
Bending strength
15.1 Bending load

Ingeneral,subjectinginsertstobendingloadsisnotadvisable;asshowninFigure151.
Where it cannot be avoided, e.g. by using coupled inserts that convert the load to tension or
compression,thediameterDofthefootoftheattachedpartshouldbeatleastaslargeasthepotting
diameter2bp,i.e.asforshearloadedinserts.
[Seealso:14.1]Forinsertsinnonmetalliccores,thebendingcapabilitydeterminedbythismethodis
consideredasanestimatepossiblyforpreliminarydesignpurposes.
Standardpartiallyandfullypottedinsertsarecoveredbythedesignrulesgivenhere.Forthrough
thethicknessinserts,analternativeloadpathexistswhichnormallymakessuchinsertssignificantly
strongerforthisloadingapplication,[See:15.2].
[Seealso:A.3andF.6fornonstandardinserts]
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Figure151:Insertsloadedinbending:Clampingconditions
15.2 Permissible bending load

The design rules discussed here cover standard partially and fullypotted inserts. Throughthe
thicknessinsertshaveanalternativeloadpaththatnormallymakessuchinsertssignificantlystronger,
[Seealso:15.1].
Thedesignshouldprecludetheheadofaninsertfromsubmariningunderthepanelfacesheets.
Theinsertbody,andanyfastenersused,shouldbecapableoftransferringtheloadsintothetwoface
sheets,i.e.thebendingallowable=min.(D1shearallowablefacesheet2,D1shearallowableface
sheet1);asshownschematicallyinFigure152.
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Face sheet 2
D1
Neutral Axis
Face sheet 1
Figure152:Bendingload:Schematicofloadtransfer
Itisbaseduponthepremisethatthesumoftheloadinfacesheet1plusfacesheet2iszeroforapure
moment.Theallowableisthereforedependentupontheweakestfacesheet,[See:14.2].
Inthecaseofamomentplusashearload,themomentaddstotheshearononesideandsubtractfrom
the shear on the other face. Depending upon the relative strengths of the two face sheets and the
loadingconditions,theaddedshearloadcanincreaseordecreasethepermittedmoment.
Under the conditions given in 15.1, the permissible bending load, MSS to which the insert can be
subjectedisgivenby:
M ss PSSc bi [15.21]
were:
PSSc permissiblecompressiveloads,[See:13.2].
bi radiusofinsert.

Inserts are considered to be very sensitive to bending, so every attempt is made to avoid such
conditionsinadesign,i.e.momentsarereactedbygroupsofinserts,[151].
Anexpressionusedtoassesstheeffectofsecondarybending,is:
M crit Pcrit bi [15.31]
Where:
Pcrit criticaloutofplaneload;
bi insert(hole)diameter.
This expression does not take into account coupling of the potting on the lower face sheet and
becomesmoreconservativeforafullypottedinsert.
Itisalsopossibletoobtainahighercriticalbendingmoment,Mcrit,byusingalargerfootprintinsert,as
showninFigure153.
Owing to the complexity of CFRP face sheets, bending moments should be carried by a couple of
inserts.
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Figure153:Bendingload:Insertfootprintonmomentloading
[Seealso:10.2]
15.4 References
15.4.1 General
facings
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16
Torsional strength
16.1 Torsional load

Likebendingloads,torsionalloadsonsingleinsertsareavoidedbyusingcoupledinserts,[See:15.1].
Ifthisisnotpossible,thediameterDofthefootoftheattachedpartshouldbeatleastaslargeasthe
pottingdiameter,i.e.D 2(bi + 4mm).
[Seealso:Figure141][Seealso:16.3forcompositefacesheets]
16.2 Permissible torsion load
16.2.1 General
Themostunfavourablecaseisashearruptureofthecellwallsenclosingthepotting,withoutanyload
participationbyotherpartsofthesandwichinsertcombination,[Seealso:16.3].
16.2.2 Metallic core

Theshearstrengthofthecellwallsisthatofthefoilmaterial,e.g.:
For5052H38: 0 crit =180N/mm2

For5056H38: 0 crit =220N/mm2
Themaximumtorsionload,TSS,whichasingleinsertinametalliccorecansupportisgivenby:
TSS 4 bR2 t0 0 crit [16.21]
were:
bR realpottingradius,[See:Table122].t0 corefoilthickness,[See:Table63].
NOTE Althoughminimum,averageandtypicalvaluesarestated,minimum
valuesareapplied.
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16.2.3 Non-metallic core

Itisadvisedtodeterminethepermissibletorsionloadofinsertsinnonmetalliccoresbytest.
16.3 Composite face sheets

Torsionloadsoninsertsisusuallyminimisedbyplacinggroupsoftheminthepanel.
Owing to the deformation or installation of the connecting bolt, torsional loads cannot always be
totallyavoided.Underthesecircumstances,anexpressionthatcanbeusedis:
Tcrit 4 bR2 t0 0 crit [16.31]
where:
bR realpottingradius,
t0 foilthicknessofcore,
0crit shearstrengthofcorematerial.
[Seealso:Figure161fornomenclature]
Owing to the complexity of CFRP face sheets, torsional moments are carried collectively by several
inserts.
Figure161:Torsionalload:Nomenclature
[Seealso:10.2]
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16.4 References
16.4.1 General
facings
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17
Combined loads
17.1 Inclined load

ThemostcommonloadcombinationistheinclinedloadFwhichisacombinationofanormalloadP
(tensileorcompressive)andashearloadQ,asshowninFigure171.
Figure171:Insertsubmittedtoaninclinedload
where:
P=Fsin componentinnormal(outofplane)direction;
Q=Fcos componentinshear(inplane)direction;
F appliedinclinedorangleload;
anglebetweenappliedloadFandsandwichplane.
WithknowncomponentsQandP,itisshownthat:

P 2
PSS
Q 2
QSS 1 [17.11]
Withgivenangleofresultant,theallowableFSSbecomes:
PSS QSS
FSS 2 [17.12]
PSS cos 2 QSS
2
sin 2
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where:
PSS permissibletensileorcompressiveload,[See:12.5tensile;13.2compression
QSS permissibleshearload,[See:14.2;Eqn.[14.21].
17.2 General load combinations

Theloadconditionsdescribeaninsertsubmittedsimultaneouslyto:
Normal(tensileorcompressive)load,P;
Shear(inplane)load,Q;
Bendingmoment,M;
Torsionalmoment,T.
Partially and fullypotted inserts are covered by these design guidelines. For throughthethickness
inserts, the shear and moment components should be resolved into one shear component prior to
calculation,i.e.thesingleshearcomponent,Q=shearcomponentinthefacesheetfromappliedshear
+shearcomponentresultingfromreactingtheappliedmoment.
Thereby QSS becomes the shear permissible load for the calculated face sheet. Both face sheets are
calculatedandthesheetwiththelowestvalueofQSS/QisthenusedinEqn.[17.21].
Shear(inplane)load,Q;
Bendingmoment,M;
Torsionalmoment,T.
Partially and fullypotted inserts are covered by these
design guidelines. For throughthethickness inserts, the
shearandmomentcomponentsshouldberesolvedintoone
shear component prior to calculation, i.e. the single shear
component, Q = shear component in the face sheet from
[17.21]
applied shear + shear component resulting from reacting
theappliedmoment.
Thereby QSS becomes the shear permissible load for the
calculatedfacesheet.Bothfacesheetsarecalculatedandthe
sheet with the lowest value of QSS/Q is then used in Eqn.
[17.21].
1
P 2
PSS
Q 2
Q SS
M 2
M SS
T 2
TSS

where:
PSS permissibletensileorcompressiveload,[See:12.5tensile;13.2compression
QSS permissible (inplane) shear load, [See: 14.2; Eqn. [14.21]. For throughthe
thickness inserts, the value of QSS is the lowest value
determinedforeachfacesheet.
MSS bendingpermissibleload,[See:15.2;Eqn.[15.21].
TSS torsionpermissibleload,[See:16.2;Eqn.[16.21].Bendingandtorsionloads
need to be covered by adequate design, e.g. by large footprints, groups of
inserts,[Seealso:15.1;16.1]
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Anadequatemarginofsafetyshouldbefullyconsideredandappliedtovariables.
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18
Edge influence
18.1 Edge distance: Out-of-plane loading

Thedistancebetweenthecentrelineofaninsertandtheedgeofthesandwichpanelisknownasthe
edgedistance,e.Theedgedistanceeffectforoutofplaneloadingislargelycoredependent.
Theedgeofasandwichpanelcanbeeitherfree,i.e.withoutanyformofclosure,orclosed,i.e.with
some form of closeout or edge member. The effect on the loadbearing capacity of the insert,
presented here, applies to free edges only. For sandwich panels with an edge closeout, the edge
coefficientis1.
Iftwoinsertsareplacedclosetoeachotherthattheireffectivepottingradiiarealmosttogether,then
thetwoinsertsbehaveasone.
Thereducedloadcarryingcapacityofinsertslocatedclosetoafreepaneledge,canbeexpressedby:
P
*
P SS
SS EN
[18.11]
Where:
P*SS insertcapabilityundernormalload,reducedbyedgeinfluence.
PSS initialcapabilityofinsert,[See:19.1;19.2].
EN edgecoefficient,fornormallyloadedinserts.
Theedgecoefficient,EN isdeterminedby:
EN 0.55 e
bp 0.05 e
bp for e 5bp
[18.12]
EN 1 for e > 5bp
NOTE Forsandwichpanelswithcloseouts, EN 1 .
Provided that the closeout material, has some minimal degree of
stiffness.
where:
e distancebetweeninsertcentreandpaneledge.
NOTE Anedgedistancecannotbesmallerthanbp (e < bp ).
The edge coefficient for normally loaded inserts, EN , is plotted as a function of the relative edge
distancee/bpinFigure181.
[Seealso:18.2foredgecoefficients,EQforshearloadedinserts;18.3forcompositefacesheets
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Figure181:Edgedistance:Effectoninsertstaticstrengthcapability
18.2 Edge distance: Shear loaded
18.2.1 General
Theedgeofasandwichpanelcanbeeitherfree,i.e.withoutanyformofclosure,orclosed,i.e.with
some form of closeout or edge member. The effect on the loadbearing capacity of the insert,
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presentedhere,appliestofreeedgesonly.Forsandwichpanelswithacloseoutontheedge,theedge
coefficientis1,[Seealso:18.1fornormallyloadedinserts,ENvalues].
Investigation of stress concentrations of shear (inplane) loaded metallic structures has shown that
severeinteractionsbetweentwoormoreholesexist.Thisisespeciallytruewhentheholesconsidered
are:
Pinloadedholeslocatedclosetoasandwichpanelsedge.or
Severaladjacentholesareloadedindifferentloaddirections.
Thisresultsinacombinedstressdistribution,i.e.combinedpanelstress,holestressandpinloading.
Thereducedloadcarryingcapacityofinsertsundershearloadinglocatedclosetoafreepaneledge,
canbeexpressedby:

*
Q SS
Q
SS EQ
[18.21]
where:
Q*SS shearloadcapabilityoftheinsert,reducedduetotheproximityofthepanel
edge.
QSS initialshearloadcapabilityofinsert,[See:14.1]
EQ edgecoefficientforshearloadedinserts.
[See:Figure181foredgecoefficients(EQ)ofshearloadedinserts]
18.2.2 Metallic face sheets

EQ 0.66 e
bp
0.06 e
bp for e 3bp
[18.22]
EQ 1 for e > 3bp
NOTE Forsandwichpanelswithcloseouts, EQ 1 .
where:
e distancebetweeninsertcentreandpaneledge.
NOTE Anedgedistancecannotbesmallerthanbp (e < bp ).
18.2.3 Non-metallic face sheets

[See:18.3]
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18.3.1 Out-of-plane loading

[Seealso:18.1]
Twoinsertscanbeplacedclosetoeachothersothattheireffectivepottingradiiarealmosttogether.If
bothinsertsareloadedbyoutofplaneloads,shearforcescannotbecreatedintheadjacentcellwalls.
Inthiscase,thesetwoinsertsactasone.Theedgedistanceeffectforanoutofplaneloadedinsertis
primarilyrelatedtothecoreused.
Therefore, the edge distance effect can be considered relevant for sandwich panels with CFRP face
sheets,[181]
18.3.2 In-plane loaded inserts

[Seealso:18.2]
Basedontheinvestigationofstressconcentrationsforthecaseofinplaneloadedmetallicstructures,it
isknownthatsevereinteractionsbetweentwoormoreholesexist,[181].Thisisespeciallytruewhen
theholesconsideredare:
pinloadedholeslocatedclosetoasandwichpanelsedge,or
severaladjacentholesareloadedindifferentloaddirections.
The global stress of the panel, the stress concentration effect of the insert hole and the localstresses
inducedbytheinsert(pin)loadarecombined.Inthecaseofseveraladjacentinserts,thesituationis
morecomplex.
CFRPfacesheetshaveabrittlefailurebehaviour,sometimeswithadamagetoleranceofanequivalent
hole of between 3 mm and 5 mm. This is not always serious with respect to the inplane load
capabilityofaninsert,butimplementationofaninsertcanresultinatotalfailureofthepanelitself.
A CFRP panel can not be adequately designed without reflecting such effects. They are highly
relevant with respect to the correct superposition of local stress failure criteria which are valid for
CFRP.
OwingtothecomplicatednatureofCFRPcomposites,itcanbeconcludedthattestsarenecessaryto
obtainreliabledataforedgecoefficients.
18.4 References
18.4.1 General
facings
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19
Insert groups
19.1 Two inserts: Loaded in same direction
19.1.1 General
Iftwoadjacentinsertsaresimultaneouslyloadedinthesamedirection,thestaticstrengthcapabilityof
eachinsertisreducedbythestressfieldoftheotherinsert,accordingto:

*
P SS 1 IS 1 P SS 1
[19.11]
Where:
P*SS1 reducedcapabilityofinsert1,duetoinsert2.
PSS1 initialcapabilityofinsert1,withoutinfluenceofinsert2.
Dependingontheirdistanceapart,theinterferenceeffectofoneinsertontheothercanbeconsidered
aseither:
Close,or
Distant.
[Seealso:19.2;19.3]
19.1.2 Close inserts

Ifthedistancebetweentheinserts,a,doesnotexceed:
a 5(bp1 bp 2 ) [19.12]
IS1 interferencecoefficientofinsert1,whensimultaneouslyloadedinthe
samedirectionasinsert2:
b p1

b p2 a 1
IS1 1 [19.13]
1 b p1 5b p1 1 b p1
b p 2 b p 2
where:
bp1 pottingforinsert1.
bp2 pottingradiusforinsert2.
a centretocentredistancebetweeninserts.
[Seealso:Figure191]
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19.1.3 Distant inserts

Ifthedistancebetweentheinserts,a,exceeds:
a 5(bp1 bp 2 )
Then,themutualinfluenceofbothinsertsisnegligible,i.e.:
IS 1 IS 2 1 for a 5(bp1 bp 2 ) [19.14]
Where:
IS2 interferencecoefficientofinsert2,whensimultaneouslyloadedinthe
samedirectionasinsert1:
1
b p1
b

p1
b p2
1 a bp2

[19.15]
1
5b p1 1

b
1 p1
1 b p1

b p2 b p2

Insert2sreductionofthecapabilityofinsert1,givenbyIS1,isonlyfullyeffectiveifinsert2is
itselfloadeduptoitsowncapability:

*
P SS 2 IS 2 P SS 2
[19.16]
where:
P*SS2 reducedcapabilityofinsert2,duetoinsert1.
19.1.4 Effect of load

*
Ifinsert2issubmittedtoanactualloadP2thatislowerthanthereducedloadcapability P SS 2 ofthis
insert,thereducinginfluenceoninsert1issmaller.
Theloadcapabilityreductionofinsert1isthengivenby:

I
1 1 P 2
* [19.17]
IS 1 IS 1
P SS 2
Thiscasecanberelevantifbothinsertsarenotsimultaneouslyloadeduptotheirrespective,reduced
capabilitiesP*SS1andP*SS2.
In Figure 191, IS1 and IS2 are plotted as a function of the relative insert distance a/bpi ; where the
parameteristheratioofpottingradiibp1 /bp2.
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Figure191:Insertgroups:Reducedinsertcapabilitytwoadjacentinsertsloaded
inthesamedirection
19.2 Two inserts: Loaded in opposite directions
19.2.1 General
Iftwoadjacentinsertsaresimultaneouslyloadedinoppositedirections,i.e.P1 = -P2,thestaticstrength
capabilityofeachinsertisonlyslightlyreducedbythestressfieldoftheotherinsert.
Dependingontheirdistanceapart,theinterferenceeffectofoneinsertontheothercanbeconsidered
aseither:
close,or
distant.
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Fordesignpurposes,thereducedcapabilityoftwoinsertsloadedinoppositedirectionsisgivenby:
P SS
*
P SS IC
[19.21]
where:
P*SS capabilityofinsert1reducedbytheinsert2.
PSS initialcapabilityofasingleinsert
IC interferencecoefficientforoppositeloading.
[Seealso:19.1;19.3]
19.2.2 Close inserts

InEqn.[19.21]:
IC=0.9 for a5(bp1+bp2)
[Seealso:Figure191forgeometricconfiguration]
19.2.3 Distant inserts

InEqn..[19.21]:
IC=1.0 for a>5(bp1+bp2)
[Seealso:Figure191forgeometricconfiguration]
19.3 Series of inserts: Loaded in same direction
19.3.1 Overview
Theeffectoncapabilityforaseriesofinsertsisconsideredfor:
Firstandlastinserts,and
Intermediateinserts.
Thisisillustratedbyanexample.
19.3.2 First and last inserts

Thefirstandlastinserts inaseriesareprimarilyinfluencedbyonlyoneadjacentinsert;asshownin
Figure192.
ThereducedcapabilityisdeterminedbyEqn.[19.11],[See:19.1],i.e.:
P*SS1 = PSS1IS1
where:
P*SS1 capabilityoffirstorlastinsertreducedbysecondorlastbutoneinsert
PSS1 initialcapabilityoffirstorlastinsert
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IS1 interferencecoefficientoffirstorlastinsertrelatedtothesecondorlastbut
one insert, [See: 19.1; Eqn. [19.12]].
Figure192:Insertgroups:Seriesofinsertsloadedinsamedirection
19.3.3 Intermediate inserts

Theintermediateinserts,iareprimarilyinfluencedbytheinsertimmediatelytotheirleft,landright,
r.Theirreducedcapabilityis:
P
*
SSi

P SSi
ISl

ISr

1 [19.31]
where:
P*SSi capabilityofintermediateinsertinfluencedbybothadjacentinserts.
PSSi initialcapabilityofintermediateinsert.
ISl interferencecoefficientofintermediateinsertrelatedtoleftinsert;[See:Eqn.
19.1;[19.12]],with:
bp1=pottingradiusofintermediateinsert,
bp2=pottingradiusofleftinsert,and
a=al=distancebetweenthecentresofintermediateandleftinsert.
ISr interferencecoefficientofintermediateinsertrelatedtotherightinsert;[See:
19.1;[19.12]],with:
bp1=pottingradiusofintermediateinsert,
bp2=pottingradiusofrightinsert,and
a=ar=distancebetweenthecentresofintermediateandrightinsert.
19.3.4 Example
Determinationoftheinsertcapabilityforaconfigurationwhere:
Seriesof5equalinserts;
Equalpottingradiusbpforallinserts;
Equalinsertdistancea=6bp.
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19.3.4.1 Interference coefficient
FromFigure191,theinterferencecoefficientcorrespondingtobp1/bp2=1anda/bp1=6isidenticalfor
allinserts,i.e.:
IS1=ISl=ISr=0.8
19.3.4.2 Static strength

Thestaticstrengthcapabilitiesarethen:
P*SS1=0.8PSS forinserts1and5.
P*SSi=PSS(0.8+0.81)=0.6PSS forinserts2,3and4.
where:
PSS initial static strength capability of the used insert.
19.3.4.3 Validation
These formulae are considered valid if the distance a between the insert and its neighbour is large
enough,i.e.
a' 5(bpi + bpi2) [19.32]
Otherwise,thenextbutoneinsertalsoinfluencestheinsertconsidered.
Inthiscase,thetotalcapabilityoftheseriesP*SS (asdeterminedbytheformulaecited)remainsvalid,
whereasthedistributionoftheloadovertheinsertsisincorrect.
19.4 Series of inserts: Loaded in opposite directions
19.4.1 Overview
Figure193showstheloadingconfiguration.
Figure193Insertgroups:seriesofinsertsloadedinoppositedirections
Thereducedloadcapabilityofeachinsertcanbeestimatedforthe:
Firstandlastinsert,and
Intermediateinserts.
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19.4.2 First and last insert

UsingEqn.[19.11]andEqn.[19.21]gives:
P SS1
*
P SS 1 IS 1 IC
[19.41]
19.4.3 Intermediate inserts

UsingEqn.16.03.1andEqn.16.02.1gives:
P
*
SSi
P SSi ISl

ISr
1 IC
[19.42]
where:
=0.9 fora5(bpi1+bpi2)
IC [19.43]
=1.0 fora>5(bpi1+bpi2)
a distancebetweeninsertseries.
bpi1 pottingradiusforinsertNo.ioffirstseries.
bpi2 pottingradiusforinsertNo.iofsecondseries.
[Seealso:Figure193]
19.5 Insert groups: Loaded in same direction
19.5.1 General
Higherloadscanbeappliedtoanumberofinsertsusingbrackets,e.g.agroupof3,4,5or6inserts,as
showninFigure194.
19.5.2 Equal and equidistant inserts

Forequalandequidistantinserts,theloadcapabilityofeachinsertofthegroupis:

G P SS
*
P SS [19.51]
where:
P*SS reducedcapabilityofinsert.
PSS initialcapabilityofsingleinsert.
G interferencecoefficientforagroupofequidistantinserts,dependingonthe
numberofinserts:
n 1 1
G
2
n
IS
0.5
n
[19.52]
where:
n numberofinsertsinthegroup;
IS interferencecoefficientfor2insertsloadedinthesamedirection,[See:19.1;
Eqn.[19.11]]withbpi=bp1=bp:i.e.bp1/bp2 =1,gives:
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IS = 1/2 (1 + a/10bp) [19.53]
19.5.2.1 Boundary values

Eqn.[19.52]satisfiestheboundaryvalues:
G= 1 fora/bp=10orIS=1
(nofurthermutualinterference)
G= 1/n fora/bp=0orIS=0.5
(ninsertsconcentratedin1insert)
19.5.2.2 Validity
Eqn.[19.52]andEqn.[19.53]areonlyvalidfora 10bp.
Foragreaterinsertdistance:
G = IS = 1 for a > 10bp [19.54]
Figure194showsaplotofEqn.[19.52]andEqn.[19.53].
Figure194:Insertgroups:Interferencecoefficientforagroupofequaland
equidistantinserts
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19.6.1 Out-of-plane loading

Twoinsertscanbeplacedclosetoeachothersothattheireffectivepottingradiiarenearlytogether.If
bothinsertsareloadedbyoutofplaneloads,shearforcescannotbecreatedintheadjacentcellwalls.
Inthiscase,thesetwoinsertsactasoneinsert,[191].
Thegroupeffectofoutofplaneloadedinsertsisprimarilyrelatedtothecoreused.
Therefore,thegroupeffectcanbeconsideredrelevantforsandwichpanelswithCFRPfacesheets.
19.6.2 In-plane loaded inserts

Based on the investigation of stress concentrations in metallic structures it is known that severe
interactionsbetweentwoormoreholesexist.Thisisespeciallytruewhentheholesareconsideredas
pin loaded and located close to a sandwich panels edge or if several adjacent holes are loaded in
differentloaddirections,[191].
The global stress of the panel, the stress concentration effect of the insert hole and the localstresses
inducedbytheinsert(pin)loadactincombination.Inthecaseofseveraladjacentinserts,thesituation
ismorecomplex.
CFRPfacesheetshavebrittlefailurebehaviour,sometimeswithadamagetoleranceofanequivalent
holeofbetween3mmand5mm.
Thisisnotalwayscriticalwithrespecttotheinplaneloadcapabilityofaninsert,butimplementation
ofaninsertcanresultinatotalfailureofthepanelitself.
A CFRP sandwich panel cannot be adequately designed without reflecting such effects. They are
highlyrelevantwithrespecttothecorrectsuperpositionoflocalstressfailurecriteria,whicharevalid
forCFRP.
OwingtothecomplicatednatureoftheCFRPcomposites,itcanbeconcludedthattestsarenecessary
toobtainreliabledataforgroupeffects.
19.7 References
19.7.1 General
facings
StandardisationProgrammeforDesignandTestingofInserts,ESACR
(P)1498,ESAContractNo.3442/77/NL/PP,1981.
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[193] W.Pauland D.WagnerERNORaumfahrttechnikGmbH,
StandardisationProgrammeforDesignandTestingofInserts,RiderII,
ESACR(P)1665,ESAContractNo.3442/77/NL/PP,1981.
[194] ReevaluationofPottingProcedureFinalReport,July1990.MBBERNO
(Bremen).ESTECContractNo.7830/88/NL/PH(SC)
[195] Standardisationofdesignanalysisandtestingofinsertsinstructural
sandwichelementsFinalReport.MBBERNO(3442/77/NL/PP)
sandwichelementsFinalReport.MBBERNO(3442/77/NL/PPRider1)
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20
Stiffness
20.1 Introduction
20.1.1 Overview
The insert stiffness can be an important factor for the evaluation of loads at fixing points. Two
particularcasesarehighlighted,[201]:
Rotationalstiffness
Inplanestiffness
20.1.2 Rotational stiffness

Iftherotationalstiffness,Kistoohigh,thenunrealisticbendingmomentscanbecalculatedbyfinite
element models. This results in local oversizing of the structure and fixing elements, e.g. bolts or
washers,[See:20.2].
20.1.3 In-plane stiffness

Iftheinplanestiffness,Kin-planeistoohigh,unrealisticinplaneloadscanbecalculatedandalsoresult
inoversizing,[See:20.2].
NOTE Example: Inplane stiffness has a significant effect on the inplane
interface forces between an aluminium alloy equipment box and a
sandwichpanelwithCFRPfacesheetsinathermalenvironment.
20.1.4 Out-of-plane stiffness

Similarly if the outofplane stiffness, Kout-of-plane is too high, calculation and oversizing effects are
possible,[See:20.2].
NOTE Example: Axial stiffness is an important parameter in some design
cases, e.g. struts or point fixings of solar arrays to sandwich panels.
Usually the fixing bracket has a specified stiffness that can influence
theinsertsandwichsystemstiffness.
[Seealso:20.2foranalysisandtestofanexamplefromSILEX]
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20.2 Analysis and test
20.2.1 General
The different values of insert stiffness determined by analysis and testing are described, using an
examplefromtheSILEXproject,[201].
Generalcommentsregardingthe determinationinsertstiffnessforsandwichpanelshavingcomposite
facesheetsarealsogiven.
20.2.2 Analysis
HandcalculationsorFE,indicatestiffnessvaluesof,[201]:
Rotationalstiffness:K=1104mN/rad;
Inplanestiffness:Kin-plane=1108N/m.
20.2.3 Testing
20.2.3.1 Configuration
IntheSILEXproject,testsoninsertconfigurationsdeterminedthestiffnessvalues.Table201liststhe
sandwichconstructionandinserts,[201].
Table201:Insertstiffness:SILEXtestconfiguration
Facesheets CFRPM55J/914;Quasiisotropiclayup.Thickness=0.8mm
Core 5056320;height=16.5mm
Standard:14mmdia.;h=15mm
Inserts
Specialthrough:14mmdia.;h=18.1mm
20.2.3.2 Stiffness values

Thevaluesdeterminedbytestingwere:
Rotational: 2103<K<4103mN/rad
Inplane: 1107<Kin-plane<5107N/m
Outofplane: 5106<Kout-of-plane<1.2107N/m
20.2.4 Comparison of analysis and test values

Table202comparesstiffnessvaluesobtainedbyanalysiswiththoseobtainedbytesting,[201].
The results are not very accurate because many assumptions were made to obtain a stiffness of the
insertalone,i.e.excludingtheotherpartsoftheassembly;testjig.However,theygiveagoodorder
ofmagnituderesultandindicatethatthevaluesobtainedbyanalysisarehigh.
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Table202:Insertstiffness:Comparisonofanalysisandtest
Insertstiffness Analysis Test
Rotational(mN/rad) 1104 2103<K<4103
Inplane(N/m) 1108 1107<Kinplane<5107
Outofplane(N/m) 5106<Koutofplane<1.2107
20.2.5 Composite face sheets
20.2.5.1 Out-of-plane stiffness

Outofplane stiffness is determined by outofplane tests using proper instrumentation to measure
displacementandforce.
Although anestimation of the outofplanestiffnesscan be madeby FEanalysis, reliable resultsare
obtainedonlybytest.
20.3 References
20.3.1 General
[201] MMSContributiontoESAInsertDesignHandbook
MatraMarconiSpaceReportNo.NT/102/BG/355013.96(December1996).
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21
Fatigue
21.1 Insert fatigue life
21.1.1 General
Theloadcarryingcapabilityofallthecomponentpartsofapottedinsertsystem,i.e.core,potting,face
sheet,insertandbolt,canbedegradedbyrepeatedloadingastheservicelifeincreases.
The failure of the insert element itself is not experienced provided that there is an adequate fillet
radiusofthelowerflangeconnection,whichisdefinedinmoststandards.
Failuresofthefacesheetshaveneverbeenexperiencedinspacecraftinsertpaneldesign.
NOTE Thedimensionsofthebracketfootcanberelevant,[See:21.4].
Boltsininsertsarenotcoveredhere,andarespecifiedinaccordancewithappropriatestandards,[See:
ECSSQST7046].
Theremainingcomponentsrelevanttodegradationunderoperationalloadsarethe:
Potting,
Honeycombcore.
21.1.2 Potting
A correctly potted body is not subject to fatigue degradation if the surface treatment of the inner
flangeprovidesagoodadhesivebondwiththeresin,[211].[Seealso:5.5].Thestrengthofthepotting
bodyunderoperationalconditionisinfluencedbyelevatedtemperatures,[Seealso:22.1].
21.1.3 Honeycomb core

Thehoneycombcoreissignificantlystressedbyloadsnormaltotheplaneofthefacesheet.
Cyclingbendingortorsionofinsertsneedstobeexcludedindesign,e.g.byusingasufficientlylong
bracketfoot;insertgroups.
Theaccumulatedfatiguedamageinthecoreunderrepeatedloadsnormaltoplaneisdependentupon
threemajorvariables:
Localshearstresses:pottingdimensions,heightofcore,stressconcentrations,[See:21.2]
Appliedloadsequence:meanstress,alternatingstress,numberofcycles,[See:21.3;21.4]
Materialfatigueresistance,[See:21.5]
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21.2 Core local stress: Normal loads to plane
21.2.1 General
ThecoreshearstressaroundapottedinsertisdeterminedusingthemathematicalmodelinAnnexC.
TheultimatetensilecapabilitiesPSSarebasedonthecorec crit minvalues.
NOTE For guidance, Annex B contains examples of plots for individual
insert configurations. These implicitly contain the loadcore stress c
data.
21.2.2 Core circular stress

According to the model in Annex C, the circular shear stress in the core becomes, [See also: Figure
161]:
*
C2Kr
c
bc
max
F [21.21]
p
with:
c = c crit min and F = PSS ,

Thefirsttermisknown:
c crit min
C Kr
*
max
[21.22]
P SS min 2b c p
ThereforethecircularstresscunderaloadPis:

c crit min
F [21.23]
c
P SS min
[Seealso:Table63andTable64forcoreproperties]
PSSvaluesareshowninFigure211,[Seealso:AnnexB].
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[See:Table63andTable64]
Figure211:Staticstrengthvalueswithcoreheight
21.2.3 Example
Giventhesandwichinsertconfiguration:
Aluminiumcore:3/165052.0007P;
Coreheight,c=30mm;
Aluminiumfacesheets:0.4mmthick;
Insertdiameter=14mm.
21.2.3.1 Core stress

Fromcapabilityplots,[See:AnnexB;Table63andTable64].
0.57
cmin p
1290
[21.24]
1
4
4.4 10 p
mm
2
Thiscorestress,cisseenasthemaximum(axiallysymmetrical)grossvalueoccurringinthevicinity
ofthefullypottedbodyinaninfinitesandwichplate.Consequentlyitdoesnotcontain:
Shearstressvariationversusheightinducedbypartialpotting;
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Influencesfromtheedgesclosetotheinsert;
Influencesfromotherinsertsadjacenttotheconsideredinsert;
c local = c Kt [21.25]
s
with:
K t
K t j [21.26]
j 1
where:
s=numberofeffectsapplicable(tobesuperimposed).
21.2.3.2 Stress concentration factors

Table 211 summarises different reasons for locally increased stresses (with links to relevant
information)andmeansofdeterminingKt withrespecttoultimatestrength,[See:12.1]
NOTE1 Cyclic torsion or bending of inserts is avoided by using appropriate
insertgroups.
NOTE2 Ifsignificantcyclictorsionorbendingcannotbeavoided,verification
isbasedondetailedtests.
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Table211:Fatigue:Stressconcentrationfactorsforlocalstress
Effect Stressconcentrationfactor(Kt) Comment/Link
n
c
Partialpotting K tpp n=0.8foraluminium
h p
core

1
K tFB FB
FB
Influenceoffreeborder (1) 2 [See:18.1]

1
K tAJ AJ
AJ
Insertsclosetoeachother(1) 2 [See:19.1]

1
Elevatedtemperature (1) K TN [See:22.1]
TH
1
Longterminfluences (1) K tLT [See:22.1]
LT
Combinationof: ProvidedthattheloadQ
Normalloads,Fand

tQ
1 K
actsinplaneofface

Shearloads,Q. sheet,[See:17.1].
NOTE(1)Thesevaluesareforpreliminarydesignandneedtobesupportedbytesting.
s
local K t i i1
NOTE(2)Localstress:
Inthisexamplecase,assumingthattheinsertloadisrelatedlinearlytoacceleration,eachseti, i+1of
cyclicloadwithconstantamplitudeisrepresentedby:
Meanload: P mean i ,i 1

Loadamplitude: P Ai ,i 1

Numberofcycles: N i ,i 1
N i 1 N i
Figure212showsaschematicofadesignloadspectrum,[Seealso:21.4].
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Figure212:Schematic:Designloadspectrum
21.3 Load-stress sequence: Constant amplitude
21.3.1 General
Theloadorlocalstresssequencecanbesinusoidalwithanamplitudeof localstressa,andamean
valueofmean:
mean 1a sin (t ) [21.31]
21.3.2 Mean stress ratio

Themaximumcorestress mean a canbeexpressedbyameanstressratio.
Astheshearloadedcorewebsundertensileloadreactinmuchthesamewayasundercompressive
load,therelevantRratiobecomes:
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R
mean
A
[21.32]
mean
A
21.3.3 Maximum peak load

Sometimesitispreferabletousethemaximumpeakload F or :
F 2P a
[21.33]
1 R
2 a
[21.34]
1 R
21.4 Load-stress sequence: Spectra of constant amplitude
21.4.1 General
Withinadesign,differentsetsofloadamplitude(Rratios)andnumberofoccurrencescanbeneeded.
Thesespectraarealsopresentedasadistribution.
21.4.2 Example
Figure 212 shows the number of times a certain acceleration level is exceeded with constant mean
acceleration, which can also be approximated by certain steps, i. N is the accumulated number of
timesacertainloadlevelisexceeded.
Astheamplitude(FA i. i+1)isdifferentforeach step,themeanstressratio Risalso differentforeach
individualstep.
Specialattentionisnecessaryifthetotalsequenceofloadhistoryisformedbydifferentspectrawith
significantlydifferentmeanloads.Sometimesthesevariationsformthemajorpartoftheloadhistory
withrespecttofatiguedamage,e.g.thegroundtoairtogroundcycle.Suchvariationsofmeanloads
shouldbeconsideredasadditionalcycles.
21.5 Fatigue life: Constant load amplitude
21.5.1 Fatigue damage

Fatiguedamageisanirreversibleresponseoftheinsertsystem(especiallythecore)torepeatedcyclic
loading.
Afteracertaindamageaccumulation,theitemfailsundertheappliedpeakload.
[Seealso:21.6forfatiguedamageaccumulation]
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21.5.2 Fatigue life

TheresultsofacyclicloadingtesttofailureareshownintheclassicalS/Nplotswhich,inthecaseof
insertapplication,canbeapproximatedby:
1
a C N for mean A ccrit [21.51]
ThecoefficientCdependsonthemeanstressmean,whichcanbeconsideredasequaltothealternating
stressA.
AsthemeanstressratioR,[See:21.3;Eqn.[21.32]isusuallynotconstant,thenEqn.[21.52]ismore
suitablefortheanalysis:
m
2
ccrit

1
C N for [21.52]
K
a A
1 R t
Often,stressesareavailableforthemaximumpeakloadFresultinginamaximumlocalpeakstress
.
With:
2
a [21.53]
1 R
Eqn.[21.52]becomes:
m 1
2
C N
1
[21.54]
1 R
A
Togetherwith:
2b c
F
p
* c [21.55]
CK r max
And:

K
c [21.56]
t
[See:21.2]
m 1
2b p c 2
C N
1
F [21.57]
K 1 R
*
CK
A
r max t
orwith:
P
c
SS
crit
[21.58]
[See:21.2]
m 1
1 2
F P SS
1
C N [21.59]
ccrit min K t 1 R
A
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CoefficientsforEqn.18.05.9fordifferenthoneycombtypesaregiveninTable212
Inaccordancewithstaticstrengthcapabilities:
minimumvaluesarebasedon:
Minimumstaticcorestrength,
Minimumbutproperpottingsize,and
Lowerboundaryvariationofthemathematicalmodel.
typicalvaluesarebasedon:
Averagetypicalstrengthofcore,
Typicalpottinggeometry,and
Typicalvaluesofthemathematicalmodel.
NOTE It is advisable to use minimum data only to ensure safety and
reliabilitywherethefailureofonesingleinsertshouldbeavoided.
21.5.3 Re-evaluation of core strength variation

Thevariationofthecorestatic strength,Wcanalsoinfluencethefatiguelifebehaviourofanactual
batchofcorematerial.Thiswasfoundtobetrueforlowcyclefatigueareasonly.
Foralifeof200000cycles,thetolerablestress wasnotaffectedatall.
WhereN=1,thetolerablestressbecomes min N 1 ,ifWisactuallyW.
Based on these findings, the linear reduction of CA by the ratio Wmin/Wactual and Wtyp/Wactual
usedpreviouslywasfoundrathercrudeandtooconservativeforN<200000.
AreevaluationofthevaluesCA and1/,[211]isshowninbracketsinTable212.
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Table212:Fatigue:Coefficientstodeterminepeakload
Coretype(metallic) CA(1)(3) 1/(1)(3)
3/165052.0007p 1.1968 0.1129

3/165052.0010p (1.86) (0.113)
3/165056.0007p 1.4040 0.126
3/165056.0010p (2.19) (0.126
1/85052.0007p (1.86) (0.113
1/85052.0010p (2.83) (0.113
1/85052.0015p 4.30 0.103

1/85056.0007p (2.19) (0.126
1/85056.0010p (3.32) (0.126)
NOTE(1) Valuesinbracketstakenfromtestresultsfromareevaluationofcoredensity.
NOTE(2)
F
PSS
c

h p 0.8
c
12R m 1 C A N 1

[21.510]
where:
m+1= 0.3556;PSS= staticstrength;c= coreheight;
c=min.circularcoreshearstrength;hp=pottingheight
NOTE(3) Usingminimumcorepropertiesandtypicalpottingdiameter(hptyp).Ascatterfactor
of4shouldbeused.
21.5.4 Insert fatigue life: Metallic cores
21.5.4.1 Core type: 3/16-5052-.0007p

Thefatiguelifebehaviourofinsertsusedinthemostfrequentlyaluminiumcoretypes,arepresented
graphically.
Thesegraphswerederivedfor:
Coreheight:20mm;
2024aluminiumfacesheetthickness:0.1mm.
Correctivecoefficientsaretabulatedfor:
Facesheetthickness;
Coreheight(Fcf):
Partialpotting(Fpp);
Productofcorrectionfactors(Fcf Fpp).
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21.5.4.2 Links to fatigue life data
Table213:Linkstofatiguelifedata
Insertdiameter.(mm) Correctionfactors Fatiguegraph
9 Table214 Figure213
17.5 Table217 Figure216
NOTE Allgraphsbasedon:
Coretype:3/165052.0007p;Coreheight20mm;
Facesheet:2024aluminium,0.1mmthick;
Insertheight9mm.
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Table214:Insertdiameter9mm:Fatiguecorrectionfactors
Multiplythegivencorrectionfactors(Fcf)and(Fpp)withtheloadvaluesfromFigure213.
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[SeeTable214]
Figure213:Insertfatiquelife:Insertdiameter9mm
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[SeeTable215]
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[SeeTable216]
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Table217:Insertdiameter17.5mm:Fatiguecorrectionfactors
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[SeeTable217]
Figure216:Insertfatiquelife:Insertdiameter17.5mm
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Table218:Insertdiameter22.5mm:Fatiguecorrectionfactors
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[SeeTable218]
Figure217:Insertfatiquelife:Insertdiameter22.5mm
21.5.5 Insert fatigue life: Non-metallic cores

[See:21.7]
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21.6 Fatigue damage accumulation

AccordingtoPalmgreenandMiner,alinearaccumulationofdamagecanbeusedtoassessthefatigue
behaviourofinsertsundercyclicloads.
n
D i
k [21.61]
i
N i
Where:
ni numberofcyclesapplied;
Ni numberofcyclesapplicableuptofailure,underloadamplitude.
Under constantamplitude load, an accumulated sum of damage is acceptable provided that the
degreeofconfidenceinthefatiguedataandtheprobabilityofhavingnofailuremeetthespecification.
Avalueofk=0.25iscommonlyusedforinitialassessments.
21.7 Non-metallic core

Fatigue data for inserts in sandwich panels using a nonmetallic core, e.g. Nomex, GFRP; are
insufficienttoenableamodeltobegeneratedthatcoverssufficientinsertandpanelconfigurations.
Figure218andFigure219showS/NcurvesoftheworstRratio(R=1).Theseenableafirstestimate
ofthefatiguelifeinanearlydesignphase,butneedsupportingtests.
NOTE Nomex and GFRP nonmetallic cores are known to be sensitive to
severepartialpotting,i.e.wherec>>hp.
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Figure218:Fatiguelife:NonmetallicGFRPcore
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Figure219:Fatiguelife:NonmetallicNomex core

Thefailureoffacesheetsonsandwichpanelsisextremelyrare.Ingeneral,thefailureofcomposites
undercyclicloadingisaprogressiveaccumulationofdamageratherthanasinglecrackgrowingtoa
criticaldimension;asseeninfatiguefailuresofmetals,[See:ECSSEHB3220].
Anareathatneedsconsiderationistheinterfacebetweenthecompositefacesheetandtheadhesive
bond to the core. Depending on the particular composite used and the layup, the resin in the
composite can fail before the adhesive bond and lead to firstply delamination. This effect has been
observedinstructuraladhesivebondsmadewithsomehighperformancefibreprepregs,[See:ECSS
EHB3221].
21.9 References
21.9.1 General
[211] StandardizationofDesignAnalysisandTestingofInsertsinNon
metallicStructuralSandwichElements.
PhaseIReport,ESTECContractNo.440/80/NL/AK(SC).
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ECSSE30series Spaceengineering
ECSSQST7046 Requirementsformanufacturingand
procurementofthreadedfasteners
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22
Environmental effects
22.1 Insert under thermal conditions
22.1.1 General
Thermalconditionscanreduceinsertcapabilities,[221].
Figure221showsthereductionresultingfromthreedifferenttypesofthermalconditions,i.e.
Mechanicalloadinginathermalenvironment;
Mechanicalloadingafterexposuretoathermalenvironment;
Mechanicalloadingafterthermalcycling.
[Seealso:22.2foreffectsonpermissibleloads]
22.1.2 Mechanical loading in a thermal environment

Theeffectscanbegroupedbytemperature,i.e.
Between160Cand40C,theinsertcapabilityisnotaffected.Testshaveshownthattheinsert
capabilityevenincreaseswithdecreasingtemperature.
Above40C,theinsertcapabilitydecreases.
Above 100C, the tensile strength of potting materials decreases dramatically, as shown in
Figure222.Thisshouldbeavoidedwhencoupledwithsimultaneousmechanicalloadingofthe
insert.
22.1.3 Mechanical loading after exposure to a thermal

environment
Theeffectscanbegroupedbytemperature,i.e.
Below100C,theinsertcapabilityisnotaffected.
Above100C,theinsertcapabilityisslightlydecreased.
22.1.4 Mechanical loading after thermal cycling

Thermal cycling between +120C and 160C can reduce insert capability by 90% of that of an
unexposedinsertsandwichsystem.
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Figure221:Thermaleffects:Reductionofinsertcapability
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Figure222:
Thermaleffects:Reductionofpottingresinstrength
22.2 Thermal: Reduction of permissible load
22.2.1 Effect on permissible loads

Thethermalenvironmentaffectsprimarilythe:
Permissibletensileload,[See:12.5];
Permissiblecompressiveload,[See:13.2];
Permissiblebendingload,[See:15.2].
NOTE The permissible shear and torsional loads are not affected by the
thermalenvironment.
22.2.2 Coefficient of thermal degradation

The reduction of the permissible loads is accounted for by means of a coefficient of the thermal
degradation,accordingtotheexpression,[221]:
PTi P Ti [22.21]
where:
PTi permissibleloadreducedbythermalenvironment;
P permissibleloadwithoutthermalinfluence,
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[See:12.5;13.2;15.212.2]
Ti coefficientofthermaldegradation,
Where:i=c,a,borR
[See:Figure221;Figure222]:
Figure223summarisesthethermaldegradationcoefficientbythethermalconditions,[Seealso:22.1]:
Mechanicalloadinginathermalenvironment,where:
Ta,thepermissibleloadsarelimitedbythecoreproperties;
TR,thepermissibleloadsarelimitedbythepropertiesofthepottingcompound.
Mechanicalloadingaftersubmissiontoathermalenvironment,i.e.Tb
Mechanicalloadingafterthermalcycling,whereTc isvalidfor100cyclesintherange160Cto
+150C.
[Seealso:Figure221;Figure222]
Figure223:Thermaleffects:Coefficientofthermaldegradation
22.3 Other conditions

Influencesofasecondarynatureare:
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Humidity,underatmosphericenvironmentalconditions;
Vacuum,underspaceenvironmentalconditions;
Radiation.
[Seealso:ECSSQST70;ECSSQ7071]
Eachoftheseconditionscandegradethepottingmassandconsequentlydecreasetheinsertcapability
toacertainextent.
The potting mass is usually wellprotected by the surrounding structure, often made of aluminium,
whichmeansthatadeteriorationofthepottingmassonlyoccursunderextremeconditions.
Particularattentionisneededintheselectionofapottingmassthatishighlyresistantwhenextreme
conditionsareexpected.
22.4.1 In-plane load under thermal conditions

The reduction in strength of CFRP face sheets under elevated temperature is distinguished with
respecttoitseffectonoutofplaneandinplaneloading,[221].
Inplaneloadsareprimarilyreactedbythefacesheets.Lossesareconsidereddirectlyrelatedtothein
planeloadcarryingcapabilityofinserts.
Theinfluenceneedscarefulinvestigationiftheeffectofelevatedtemperaturesiscoveredbystandard
procedures.
Owing to the different influences on the fibre and matrix, the failure mechanism seems to become
nonlinearandthereforerathercomplex.
An extensive investigation using test and analysis is considered necessary in order to provide a
simplified,approximateprocedureabletohandleelevatedtemperatures.
22.5 References
22.5.1 General
facings

ECSSQST70 Materials,mechanicalpartsandprocesses
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ECSSQ7071 Datafortheselectionofspacematerialsand
processes
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Manufacturing procedures
23.1 Sequence
23.1.1 General
Figure 231 summarises a basic manufacturing sequence for potting standardtypes of inserts into
existingsandwichpanels.Italsoincludeslinkstoappropriateinformation.
NOTE The manufacturing procedure for nonstandard inserts, in particular
carbonfibre tube inserts, is described in Annex A, [See: A.3] and by
exampleinAnnexF,[SeeF.6].
23.1.2 Sandwich panels

Most inserts are potted into existing sandwich panels comprising of metal or composite face sheets
andametalorcompositecore:
Metalfacesheetsareadhesivelybondedtothecore.
Compositefacesheetscanbe:
adhesivelybondedaslaminatestothecore,or
Cocuredwiththeadhesivelayerbetweenthefacesheetandthecore.
NOTE1 Forthedesignandmanufacturingofsandwichpanels,[See:ECSSE
HB3220].
NOTE2 Seealso:ECSSwebsite:www.ecss.nl.
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Incominginspection[See:26.1]
Drillboreholes
[See: 24.2]
Perforatedcore
Fitinserts
Referencesample[See:23.6
[See: 23.2]
Tearouttest[See:23.6
Nonperforatedcore
Introduce

pottingcompound
[See: 23.3]
Curecycle
[See:23.4]
Finalmachining
[See: 23.5]
Proofload Inspection Repair

[See: 23.7] [See: 23.8] [See:23.9]
Figure231:BasicmanufacturingsequenceFit inserts
23.2.1 General
Inserts are only fitted after the bore holes have been machined, [See: 24.2], inspected and any
correctiveactionstakentopreventbentordislocatedcellwallsimpedingthe:
Displacementoftrappedair;
Flowofpottingcompound.
23.2.2 Positioning
Standard, commerciallyavailable inserts are normally supplied with a positioning tool which aids
theirplacement,i.e.flushorrecessedsubflush,[2316].
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Special,nonstandardinsertsandthosepositionedoverflushorprotrudingoftenneedaspecialtool
toensureacceptableflatnessofaninsertoragroupofinserts,[2316].
[Seealso:F.6forcarbonfibretubeinserts]
23.2.3 Perforated core

Theprotectivelayercoveringthefacesheetsneartheboreholeisremovedtotheextentneededbythe
bondingtabs,[235].
Insertsneedbondingtabs,[235],placedsuchthattheinjectionholesarecongruent.
The inserts are then fitted into their respective bore holes by the bonding tabs, so that they are the
samewithrespecttothefacesheet.
Ifthedistancebetweenthefittedinsertandthefacesheetatthebottomoftheholeislessthan3mm,
anappropriateamountofinsertpottingcompoundisappliedtothebottomoftheinsertpriortoits
insertion.Thisenablestheloosefacesheettobesupportedaftertheinsertisfitted.
NOTE1 Potting compounds are classed as limited shelflife materials, [See:
ECSSQST7022].
NOTE2 The stated pot life of potting compounds cannot be exceeded, [See:
25.2;23.3]
If two or more inserts are located at the same position e.g. as shown in Figure 232, then particular
careisneededtoensurethattheopposinginsertdoesnotliftduringthepottingprocedure.
Figure232:Insertswithconnectedpottingmass
23.2.4 Non-perforated core

Nonperforatedcoresneedventinginordertoenabletheairinthesandwichboreholetobedisplaced
bythepottingcompound.Otherwisecellsunderneaththeinsertdonotfillproperly.
Studies of potting compound flow in nonperforated cores have shown that the insert vent hole is
sealedbypottingcompoundpriortocompleteinsertpotting.Thereforeadequateventingoftrapped
airisessentialforsuccessfulpotting,[2314].
A venting tube is inserted into one of the insert holes so that it reaches the opposite face sheet, as
showninFigure233
Sizesofventingtubeare,typically:
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Innerdiameterexceeds0.3mm
Outerdiameter,oftheorderof1.5mm
Theendsarecutdiagonallyatanangleofabout45.
Theventtubecanremaininthepottingorberemovedbeforecuring.
NOTE If the vent tube remains in the potting, it should be made from an
acceptablematerialforspaceuse.
Figure233:Ventingofnonperforatedcore
23.3 Inject potting compound
23.3.1 General
Injectionoftheinsertpottingcompoundiscarriedoutwhenallthepreparationstagesarecomplete
andshowntomeetwithqualitycontrolprocedures,[Seealso:28.1].
Forstandardtypesofpottedinserts,theapplicablestepsare:
Boreholes:
drilling,[See:24.1];
inspection,[See:28.2].
Insertpretreatment,[See:25.1].
Fittinginserts,[See:23.2].
Perforatedcores;
Nonperforatedcores,withadditionalventing.
Mixingpottingcompound,[See:25.2].
[Seealso:F.6fornonstandardcarbonfibretubeinserts]
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23.3.2 Process
23.3.2.1 Single-sided injection

Thepottingcompoundisinjectedunderpressureintooneofthetwoholesinthebondingtabsuntilit
isseentoleavetheopposite(vent)hole.
Astrandofpottingcompoundabout6mmlongappearingfromtheventholeindicatesthatthebore
cavityandthesurroundinghoneycombcellsarewellfilled.
NOTE Potlifecannotbeexceeded,[See:25.2].
Pottingresincanfirstbeinjectedthroughsmallholesinthefacesheetpriortoinjectingthroughthe
insertflanges,[2316].
23.3.2.2 Double-sided injection

Whereithasprovendifficulttoensurefullandproperpottingfromonesidebysinglesidedinjection,
pottingcompoundcanbeinjectedfrombothsidesofthepanel(doublesidedinjection).
SuchatechniquewasusedsuccessfullyintheASAP5projectforspecialthroughthethicknessinserts
installedinthickcores,i.e.exceeding60mmheight,[2316].
23.3.3 Flow characteristics
23.3.3.1 General
Factorsaffectingtheflowofpottingcompoundaroundinsertsinsandwichpanelsinclude:
Materialcharacteristics,e.g.viscosity,[See:7.1;25.3
Boreholegeometry,[See:23.2;28.2].
23.3.3.2 Fully potted inserts

Theflowcharacteristicsofpottingcompoundaroundthroughthethicknessorfullypottedinserts,
i.e.whereinsertheightisthesameasthecoreheight(hi=c),indicatethatthecavityisfilledfromthe
bottomupwards.Thisnormallyprovidescorrectcouplingbetweenthepanelstructureandtheinsert,
[2314].
23.3.3.3 Partially potted inserts

Wheretheinsertheightislessthanthecoreheight(hi<c),i.e.partiallypotted,theflowcharacteristics
ofthepottingcompoundaroundandundertheinsertarebalancedtoensureadequatepotting.
The volume under the insert does not fill fully if the flow around the insert is faster than the flow
undertheinsert.
Thevolumebetweentheinsertflangeandthepanelstructuredoesnotfillfullyifflowisfasterunder
theinsertthanaroundit.
A balanced flow (around and under the insert) is largely dictated by the bore hole depth to insert
height,[2314].
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23.3.3.4 Perforated core
Duringthefillingprocess,theperforationsenableventingofairtrappedwithintheboreholeduring
potting,[2314].
23.3.3.5 Non-perforated core

Adifferenceintheflowofpottingcompoundaroundandunderinsertscanleadtotheventhole(at
topofinsert)becomingblockedbeforepottingiscomplete.Anyairremainingintheboreholecannot
bedisplacedandthiscausesvoids,[2314].Hence,additionalventingisnecessary,[See:23.2].
23.4 Cure cycle
23.4.1 General
Whenalltheinsertshavebeencorrectlypottedinthesandwichpanel,thepottingcompoundisthen
cured.
The cure cycle used largely depends on the chemical formulation of the resin used for potting and
whether the resin or assembly can be cured at elevated temperature without causing damage, e.g.
thermallyinduced damage to composite face sheets; adhesive bond between core and face sheets;
cores.Incaseswheretheinsertsarecocured,thepottingresinissubjectedtothesamecurecycleas
therestoftheassembly.
23.4.2 Resin system: Shur-Lok SLE 3010

[See:25.2]
23.4.3 Potting foam: Lekutherm X227+T3

[See:25.2]
23.4.4 Other resin systems

[See:7.1]
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23.5 Corrective actions
23.5.1 General
Onceaninsertis pottedintoasandwichpanel,therearelimitedopportunitiestocorrectanyerrors.
Thisiswhypropermanufacturingprocesses,andtheircontrol,areessential.
23.5.2 Final machining
23.5.2.1 General
The processes described are used when a potted insert is found to deviate from the stated
requirements during the manufacture. Final machining processes can be stipulated as part of the
overallprocessing,ratherthansolelyascorrectiveactions.Forexample,machiningofflangedinserts
toimproveflatness,changefrictioncoefficientandpreventstressconcentrationsbetweenattachment
pointsandpanels,[Seealso:Table51;10.3].
23.5.2.2 Protruding inserts

Protrudinginsertscanbemachinedbacktothefacesheetsurface.
NOTE1 Typicalmachiningtolerance:0.03mm.
NOTE2 Thefacesheetcannotbedamagedduringfinalmachining.
23.5.2.3 Angled inserts

Insertsthatarenotnormaltothepanelsurface canonlybecorrectedbymachining providedthatthe
insertshaftisnotdamaged,[2314].
23.5.2.4 Insert protective coating

Machined surfaces of fitted inserts need a protective coating, This is applied using a chemical
oxidising process,e.g.anonelectrolyticprocess,suchasAlodine1200(identificationnumber1101),
[236]. Using this surface treatment results in an electrically conductive, chromated (mixedmetal,
chromiumoxide)film,typicallylessthan1mthick.
[Seealso:ECSSQ7071]
NOTE Any penetration of the oxidising chemical into the insert thread
shouldbeprevented.
23.6 Reference sample
23.6.1 General
Reference (or witness) samples assess the potting process. The reference sample is produced at the
same time as the manufactured assembly and undergoes all the same processes, e.g. machining,
potting, cure. The potting process is evaluated by a vertical insert pullout strength test. This is a
destructivemechanicaltestthattearstheinsertoutofthereferencesample,[Seealso:27.3].
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23.6.2 Materials
Thereferencesampleismadefromexactlythesamematerialsusedinthemanufacturedassembly,i.e.
thesame:
Sandwich;
Insert;
Pottingmaterial.
23.6.3 Manufacture
Referencesamplesare:
Pottedatthesametimeastheproductionsandwichpanel;
Curedtogetherwiththeproductionsandwichpanel.
NOTE Allreferencesamplesareclearlyidentified,e.g.bydrawingnumber;
markingwithadhesivetape.
23.6.4 Number of samples

Thenumberofreferencesamples,nneededdependsontheircriticality,i.e.:
N
n 1 ges
[23.61]
standard
100
N
n 2 ges
[23.62]
safetycrit
10
where:
n roundeduptowholenumberofsamples;
Ngesnumberofpottedinsertsproducedperday,i.e.dailycharge,fromthesame
mix,[2317].
23.6.5 Pull-out strength test

Theverticalpulloutstrengthisdeterminednotearlierthan2daysafterpotting.
Theotherconditionsare:
Testspecimen,asshowninFigure234.
Loadapplicationrate2mm/min,typically,[See:27.3].
Testrecord,aforcedeflectioncurveisusedtodeterminethepulloutstrength.
NOTE Pulloutofaninsert1mmto2mmabovethefacesheetisconsidered
adequate.
[Seealso:27.3]
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Figure234:Referencesample:PulloutstrengthtestspecimenProof load
Proofloadingofinsertsinflightdestineditemscanbestipulatedforhighreliabilityapplications.
Thelevelofproofloading,i.e.howmuchhigherthanlimitload,hasbeeninvestigated,[2313].
NOTE Proof loading and loadlevels conform to those defined within the
structuraldesigndocumentation.
23.8 Inspection
Thebasicsetofinspectioncriteriaforstandard,pottedinsertsare:
Machinedboreholeforinsert:
actualdiameter;
actualdepth;
Checkfordetachmentoffacesheetsfromthehoneycombcore;
Cleanlinessoftheboreholepriortothepotting;
Insertposition,withrespecttosandwichfacesheet:
flush:maximumtolerance0.03mm;
Perpendicular:maximumtolerance:0.5.
Fillingoftheinsertinjectionandventingholeswithpottingcompound.
Otherinspectioncriteriacanbestipulatedfornonstandardinserts.
NOTE All inspection criteria are checked, documented and compared with
the requirements to establish if potted inserts are acceptable or
unacceptable.
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23.9 Repair
23.9.1 General
Therepairofinsertsisoccasionallynecessaryto:
Replaceadamagedinsert;
Reinforceadamagedcoresurroundinganinsert;
Replaceaninsertwithanother,e.g.increasestrength;
Repositionaninsert,e.g.
originalslightlymisplaced;
fixingpointchanged.
The repair process used depends on whether the core and face sheets are damaged or not. The
processes described apply to standardtype inserts. Nonstandard types can need different repair
methods.
23.9.2 Undamaged core or face-sheet

If the surrounding sandwich core and face sheet are undamaged, a damaged insert can be replaced
reliablybyaninsertofthesamedimensions,i.e.di old=di new ;hi old=hi new.
23.9.2.1 Process
Drilloutoldinsert;
NOTE Avoidoverheatingandhighdrillingforces;drilldiameter:d i 2mm.
Extendboreholebymilledundercut,asshowninFigure235;
Extendboreholebypuncturingcuredpottingcompoundandunfilledcorecells,Figure235
Removeresidualupperflangeofoldinsertwithtweezers;
Reamborehole:tolerance0to+0.03mm;
Apply appropriate amount of potting compound, i.e. to fill the hole and support the lower
flangeofthenewinsert;
Fitnewinsert,[See:23.2];
Potnewinsert,[See:23.3].
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Repairdimensions:
1.0
a ri 23 S c
b hi 3.0 1.0
c 1.5 1.0
Figure235:Insertrepair:Geometry
23.9.3 Damaged core and face sheet

Insertswithdamagetothesurroundingsandwichpanel,needreinforcinginthedamagezone.
Asuitablemethodistheinjectionofliquidresinintoeachcellofthecorethroughsmallholesdrilled
inthefacesheets.
Forinsertsneartheedgeofasandwichpanel,theresincanbeinjectedfromthesideofthepanel.
23.9.4 Replace or reposition inserts

Thisappliesto:
Slightlymisplacedinsertstobereplacedbyalargerdiameter;
Replacementwithastrongerinsert,i.e.withalargerdiameterwithorwithoutincreasedheight,
[See:12.6].
After drilling out the old insert, any remaining cured potting compound needs reworking to
guaranteeapositiveconnection,[See:Figure235
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23.10 Defects
Themajorityofdefectscanbeavoidedbythecreation,strictadherenceto,andcontrolofallprocess
procedures,covering:
Incominginspection:
Honeycomb,[See:26.2];
Resin,[See:26.3].
Manufacture:
Processes,[Seealso:Figure231];
Mechanicaltests,[See:27.1;29.1;AnnexH];
NonDestructivetest,[See:27.1].
Qualityassurance:
Borehole,[See:28.2];
Potting,[See:28.3];
Core,[See:28.4].
Theeffectsofsomedefectsoninsertcapabilityaredescribed,alongwithanycorrectiveactionstaken,
[2316].
[Seealso:23.5]
23.10.1 Poor storage of potting compound

Inadequatestorageofpottingcompoundcomponents,i.e.baseresin,hardeners,catalysts,candegrade
thepropertiesofthecuredmaterial.Thisisreflectedinlowerthanexpectedinsertcapabilities.
NOTE The component parts of potting compounds are classed as limited
shelflife materials and measures for their control are stipulated in
ECSSQST7022.
Table 231gives an indication of the insert tensile property loss associated with bad storage of a
pottingcompoundfor,[2316]:
Core:honeycomb440AG5,height=40mm;
Facesheets:7075T6(AZ5GU),thickness=1mm;
Pottingcompound:SLE3010,RTcure;
Insert:ShurlokSL601M615.9S:17.4mmdia.;15mmheight.
Table231:Insertcapability:Effectofpoorstorageofpottingcompound
Tensile load (1)
No. of
Storage
Average Minimum samples
(N) (N)
Good 6830 6080 5
Poor 5575 4190 7

NOTE(1) Single insert test.
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23.10.1.1 Corrective action

Theinsertsandthepottingcompoundwereremovedandreplacedbynewones.
NOTE As more cells were opened in the removal and refitting process, the
effective potting radius increased, and so did the loadbearing
capability,[2316].
23.10.2 Poor potting compound distribution

Ifthepottingcompoundisnotspreadevenlyorconsistentlyaroundtheinsert,thetensilestrengthcan
bereducedseverely,[See:28.3].Itcanoccurifthecontrolproceduresfortheboreholeareinadequate,
andcellsarenotopentotheflowofinjectedpottingcompound,[Seealso:24.4;23.1]
Table232indicatesthelossoftensilestrengththatcanoccurduetopoorpottingfor,[2316]:
Core:honeycomb350AG5,height=12mm
Facesheets:CFRPBrochier10842G814NT,0.36mmthick
Pottingcompound:notstated,RTcure
Insert:throughthethickness,[Seealso:SchematicinTable232]
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Table232:Insertcapability:Effectofpoordistributionofpottingcompound
Pull-out
Insert tensile load No. of
Potting samples
Average (N)
Fully potted 6040 10
Poor (1) 624 7
NOTE(1) Bad injection of potting compound; adhesive only present

between the flange and the face sheet, [23-16].
23.10.3 Poor positioning of insert
23.10.3.1 Insert not flush

If the insert is not flush with the surface of the panel, the shear load capability can be affected, e.g.
reducedorinconsistent.
Table 233 indicates the effect of poor insert positioning on the shear load, compared with the
calculatedvaluefor,[2316]:
Facesheets:AU2GN,thickness=0.5mm;
Insert:ShurlokSL607M510S,11.48mmdia.;13.07mmheight;partiallypotted.
Table233:Insertcapability:Effectofpoorpositioningofinsert
Shearload
InsertPosition No.ofsamples
(N)
Good 3670 calculated
2760
Poor 2
3788
23.10.3.2 Angled insert

If the insert is at an angle with respect to the panel surface or to the equipment (or structure) to be
boltedtoit,thentheloadtransferacrosstheinterface isuneven.Theinsertcanbecomeoverloaded
andcandeform,[2316].
NOTE This was noted in the ARIANE 4 Equipment Bay at one equipment
fixingpoint.
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23.10.4 Oversized bore hole size

Boreholesinsandwichpanelsaredimensionedfortheparticularinserttobeused,withappropriate
(low)dimensionaltolerances.Iftheboreholeistoolarge,thentheshearloadcapabilitydecreases.
Table234indicatesthereductionofshearloadassociatedwithanoversizedboreholefor,[2316]:
Facesheets:AU2GN,thickness=0.5mm;
Insert:ShurlokSL607M510S,11.48mmdia.;13.07mmheight;partiallypotted.
Table234:Insertcapability:Effectofoversizedborehole
Holediameter Shearload
No.ofsamples
(mm) (N)
2760
11.48 2
3788
600
12.4 2
800
23.11 References
23.11.1 General
[231] Insertsforsandwichstructures,closed,selflockingwithfloatingand
removablenut,screwsecuring
ENN366(MBBERNO)
[232] Titlenotstated
ENN379(MBB/ERNO)
[233] Insertsforsandwichstructuresclosed,selflocking
ENN386(MBB/ERNO)
[234] Insertsforsandwichconstructions,closed,withscrewlockinghelicalcoil
insert
ENN398(MBB/ERNO)
[235] Bondingtabs
ENN34602(MBB/ERNO)
[236] Designationofthesurfacetreatment
LN9368(BeuthVerlag,Germany)
[237] Standardclimateconditions
DIN50014(BeuthVerlag,Germany)
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[238] Instructionsfortheissuanceoffailuremessagesandfailureelimination
RL0008021
[239] SLE301072970:Productdata
[2310] LekuthermX227+T3:Processinginstructions
BayerGmbH
[2311] Applicationoftoxic,volatile,nonflammablesolventsforcleaning
purposes
UVV11.2(VBG87)
[2312] Applicationofadhesivewitheasilyvolatile,flammablesolvents
VBG81
[2313] StandardizationofDesignAnalysisandTestingofInsertsinNon
MetallicStructuralSandwichElements,PhaseIReportNo.
440/80/NL/AK(SC)
[2314] ReevaluationofPottingProcedureFinalReport,July1990.MBBERNO
(Bremen).
[2315] ESTECContractNo.7830/88/NL/PH(SC)
[2316] MMSContributiontoESAInsertDesignHandbook
MatraMarconiSpaceReportNo.NT/102/BG/355013.96(December1996).
[2317] ESTEC/MMSUKPrivatecommunication(April1999).

ECSSQST7022 Controloflimitedshelflifematerials
ECSSQ7071 Datafortheselectionofspacematerialsandprocesses
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24
Sandwich panel machining
24.1 Drilling bore holes

Thetwomainstepsininstallingastandardinsertelementintoasandwichpanelare:
Boreholedrilling,[See:24.2;24.4].
Pottingofinserts,[See:25.2].
NOTE For nonstandard inserts, potting can be replaced by an equivalent
procedure,[See:A.3;F.6].
Processes for drilling bore holes in honeycomb sandwich panels for potted inserts should avoid
damagetothesurroundingcore,[241],[242].
NOTE1 The manufacture of sandwich panel should meet the relevant
standards,e.g.MILHDBK23,[Seealso:ECSSEST3220].
NOTE2 Foradditionaleffectsofcorestrengthoninsertcapabilities,[Seealso:
6.5forcoreshearstrength;26.2forcoreincominginspectiontesting].
24.1.1 Bore hole geometry

Bore hole geometry has a strong influence on the flow of the potting compound around the insert.
Thisinturnaffectstheinsertstrengthcapability.
Threeimportantvaluesrelatedtogeometryarethe:
Effectivepottingradius,[See:7.3]
Realpottingradius,[See:7.4]
Pottingheight,[See:7.5]
24.1.1.1 Diameter
Theboreholediameterisdefinedbytheparticularinsertdiametertobeused.
NOTE Nolargetolerancesareacceptable.
24.1.1.2 Depth
The bore hole depth should be optimised because it defines the freevolume under an insert, which
affectstheflowofpottingcompound,[242].
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24.2 Processing
Drilling of bore holes for inserts can be achieved by two different methods using single or
combinedtools,i.e.:
Drillfacesheetthencuthoneycombcore.
Drillfacesheetandhoneycombcore.
NOTE Lubricants or coolants cannot be used during any drilling or cutting
processes.
Alldrillingprocessesshouldavoiddamageto thesurroundingcore.Coredamagecanoccurduring
the drilling process when the core is stressed in a direction other than its highstiffness (normal)
direction.
The increasing demands for placing (and easy replacement) of brackets and boxes on sandwich
panels, using inserts, means that the precision provided by coordinate drilling is replacing the
previoussequencedrillingprocesses,[242].
24.2.1 Combined tool

Figure241showsacombineddrillandpunchtoolanditsoperationprinciple.
Figure241:Sandwichpanelmachining:Combineddrillandpunchtool
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24.2.2 Single tools

Figure241showsaseriesofindividualtoolsinvolvedinmachiningboreholes:
Drilltoproduceacentreboreintothefacesheet(1);
Specialdrillforcuttingthefacesheetborehole(2);
Punchingtubefornonrotatingcorecutting(3);
Combinationpunchingtubewithinnercoremillingtool(4);
Innermillingtool;shownseparately(5).
Figure242Sandwichpanelmachining:Seriesofsingletoolsandtheiruses
24.2.3 Drill face sheet then cut honeycomb core
24.2.3.1 Drilling bore holes in face sheet

processes.
Theinsertlocationisfixedbyacentreboreof6mmor8mmdiameter.
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Aspecialdrillisusedthatonlycutstheouterdiameterofthebore.Thisproducesadiscintheface
sheet;asshowninFigure242(No.2).
NOTE Whenacoordinatedrillingmachineisavailable,thespecialdrillcan
beusedwithoutsettingacentrebore.
Thefacesheetdiscisthenpulledoffthecorewithapairoftweezers.
NOTE Thetolerancesoftheboreholeinthefacesheetarewithin0to+0.03
mmofthenominalinsertdiameter.
24.2.3.2 Cutting of honeycomb core

Apunchingtube(maintainedperpendiculartothesandwichplate)isusedtocutacylindricalpartof
thecoretothenecessarydepth.
NOTE1 Theboreholedepthexceedstheinsertheightby3mmto4mm.
NOTE2 Thedepthislargelydeterminedbythepottingheight,[See:7.5].
Simultaneously,adrillactinginsidethetuberemovesthecutcylindricalcorewiththetubeactingasa
drilljig.
NOTE Thistechniqueensuresthatprocesscontrolismetreliably,[See:24.4].
After machining, any bent or dislocated core cells are removed or straightened so that the insert
pottingcompoundcanflowundisturbedintoallopenhoneycombcells.
24.2.4 Drill face sheet and honeycomb core

processes.
Adrill(diameter:di 2mm),maintainedperpendiculartothesandwichplate,producesaholeofthe
necessarydepth.
NOTE Thedepthislargelydeterminedbythepottingheight,[See:7.5].
Then,areamerisusedtoextendtheboreholetothenominalinsertdiameter.
NOTE Thetolerancesoftheboreholeinthefacesheetarewithin0to+0.03
mmofthenominalinsertdiameter.
After machining, any bent or dislocated core cells are removed or straightened so that the insert
pottingcompoundcanflowundisturbedintoallopenhoneycombcells.
24.2.5 Coordinate drilling machines

Processesusingcoordinatedrillingshouldavoidthetwocommonlyfoundproblems:
Bendingcorefoilsduringcutting;
Tendency toproduce conical holes (smallerdiameter at the bottom) rather than the necessary
parallelbore.
Asforsequencedrillingprocesses,anybentordislocatedcorecellsarecorrectedafterdrilling.
Conical holes arise due to the reduced supporting effect of the bonded face sheet on the core at
increasingholedepth.
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The machining processes and tools used for composite materials are different from those used on
metals.Thisisespeciallytruewhenmachiningverythinhighperformancecomposites,suchasthose
usedasfacesheetsonsandwichpanels.
Different machiningprocessesareappliedtononmetalliccores,e.g.NomexorGFRPhoneycombor
foams,[Seealso:24.4].
In addition to the precautions taken to avoid deformation and damage to the core, extreme care is
exercisednottodamagethefacesheets,eitherlocallyaroundthemachiningsiteorglobally,e.g.by
excessiveclampingforces,[Seealso:24.4].
Relevantstandardsprovideguidanceonmachiningcomposites,[See:MILHDBK17andECSSEST
3220].
24.4 Process control

Bore hole machining processes are included in the overall quality assurance plan and subsequently
controlled,[See:28.2].
24.4.1 Potential problems
24.4.1.1 Bore hole geometry

[See:24.2forcommentsonconicalholes]
24.4.1.2 Cores
Perforatedaluminiumcoresareeasytodrill.
UnperforatedcorewiththinfoilsandthetighttypeofNomexandGFRPcorecancreateproblems
duetothepossiblelowgaspressurewithintheclosedcells;causedbythesandwichbondingprocess.
Thiscanresultin:
Deformationofthefacesheetonthebackfaceacrosstheborediameter;
Corefailureduetoinstabilityofcellwalls.
Althoughitisdifficulttoavoidsuchdistortions,e.g.byventingwiththeaidofaneedle,itisusefulto
knowthattheyarelikelytooccur.
24.4.1.3 Composite face-sheets

Highperformance composites can delaminate if incorrect tools and machining processes are used.
Theusualapproachforalaminateistoproviderigidsupportbehinditduringmachining.Thislimits
breakoutanddelaminationatandaroundcutedges,[See:ECSSEST3220].
WhilstthebackfaceofsandwichpanelswithverythinCFRPfacesheetscanbeeasilysupported,the
frontfacesheetreliesonthesupportofferedbythecore.Dependingontheposition,asmallmachined
holecanfallintracelloratthepositionofahoneycombcellwall.Largerholes,asneededforinserts,
crossseveralcellwallsandintracellspaces,consequentlythesupportprovidedvaries.
Relevant standards provide guidance on machining composites, [See: ECSSEST3220 and MIL
HDBK17].
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24.5 References
24.5.1 General
[241] MILHDBK17CompositeMaterialsHandbook
[242] MILHDBK23StructuralSandwichComposites
NOTE MILHDBK23isunderreviewforpartialincorporationasVolume6
MILHDBK17.

ECSSEST3220 Structuralmaterialshandbook
ECSSQ7071 Datafortheselectionofspacematerialsandprocesses
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25 Potting
25.1 General
The comments apply to the manufacturing process of potting inserts into sandwich panels or
structuresforspacevehicles,[See:25.2;25.3;23.1].
[Seealso:ECSSE30series;ECSSQST70materialsandprocessrelatedstandards]
25.1.1 Environmental conditions

The environmental conditions for the mixing, potting, and curing of the inserts are stipulated as
standardclimaticconditionsofrelevantspecifications,e.g.23/50ofDIN50014.
Normallaboratoryconditionsareapplicableduringmanufacturing.
[Seealso:ECSSQST7022forlimitedshelflifematerials]
25.1.2 Face sheet protection

Thefacesheetsofsandwichpanelsareprotectedwithatemporarylayer,e.g.foil;selfadhesivepaper.
NOTE Anyprotectivelayershould be removed easily and without
leaving any residues that are difficult to clean, i.e. cannot cause
contamination.
25.1.3 Degreasing of inserts

Before potting, inserts are degreased in a perchlorethylene steam bath. (Identification No. 0001.LN
9368).
Alternatively, an acetone bath can be used, but frequent changing of the contaminated liquid is
necessary.
NOTE1 Thetimebetweendegreasingandpottingcannotexceed8hours.
NOTE2 After degreasing, inserts are handled with clean lintfree gloves or
withtheaidoftongs.
25.2 Manufacturing process

Themanufacturingprocessstipulatesthatthe:
Workpiece,i.e.thesandwichpanel(orstructure),conformstotheworkshopdrawing.
Insert meets the appropriate standards or specifications, [251], [252], [253], [254]; [See also:
AnnexA].
Pottingresinmeetstheappropriatestandardsorspecifications,[259],[2510];[See:25.3].
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25.3 Potting compounds

Suitable commercial potting resins, [See: 7.1]tend to be modified with a high content of glass
microballoonstoproducealightviscouspaste.Thespecificgravityoftheresinmixtureistypically0.6
to0.7.
NOTE The component parts of potting compounds (resin, hardener,
accelerators)areclassedaslimitedshelflifematerialsandneedstrict
control of their storage, usable life and working conditions, e.g.
workshop environment and pot life, [See: 25.1[See also: ECSSQST
7022].
25.3.1 Flow characteristics
25.3.1.1 General
Theflowcharacteristicsofthepottingcompoundhaveastronginfluenceonthesuccessorfailureof
insertpotting.Flowisaffectedby,[2513]:
Resinsystemviscosity;
Type,shape,contentanddistributionoffillermaterial,e.g.glassmicroballoons;
Appliedpressure;
Temperature:
Mixedresinexothermicreaction;
Ambient.
The precise control of individual materialrelated variables (resin, hardener, filler) has proven to be
extremely difficult, e.g. batch variations; dryness, settling and size distribution of filler. Therefore
control of the mixed potting compound viscosity just before its use is necessary to aid potting
reproducibility.
Atypicalviscosityrangeisbetween45Pa.sand58Pa.s,[2513].
NOTE Low viscosity potting compounds (below 3Pa.s) produce severe
pottingdefects,[2513].
Viscosityisalsotheparameterwhichdeterminesusablepotlife,whichisstipulatedaspartofprocess
controlactivities.
25.3.1.2 Processing
Althoughmadeofaninertsubstance,glassmicroballonsareusuallydriedbeforeincorporationinto
theresin.Thisavoidsanymoisturepresentaffectingthecureorresultingproperties.
Pottingcompoundsareprocessedwiththeaidofacompressedaircartridge,e.g.Semco.
Theinjectionpressureappearstohavenoeffectonthedistributionofthepottingcompound,although
the size and shape of the injection tool needs to be optimised. An injection pressure of 1 bar has
provensuccessful,[2513].
Themixedresinundergoesanexothermicreactionduringcure.Thisisacceleratedbythepresenceof
low thermal conductivity fillers, e.g. glass microballoons. As the ambient temperature also affects
viscosity,ittooneedscontrol,[2513].
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25.3.2 Resin system: Shur-Lok SLE 3010

This resin system is especially suitable for inserts and is widely used. The resin and hardener
components, which are contained separately in the cartridge cases, are mixed according to the
instructionssuppliedandcanthenbeprocessedintheoriginalcartridge,[259].
Processingtime:20min.atRT
Curecycletime:24hrs.atRT
Storagetime:12monthsatRTmaximum.
Optimumcharacteristics:after7daysatRT
NOTE This resin does not meet the outgassing limits of 1% TML and 0.1%
VCM,[See:ECSSQST7002].
25.3.3 Potting foam: Lekutherm X227+T3

Themixingratiois:
LekuthermX227resin:100partsbyweight
T3hardener:30partsbyweight
Aftermixing,add
MicroballoonsB23500(3MCorp.):40partsbyweight
Throughmixingresultsinasoftpaste,whichdoesnotflowinsmallquantities,e.g.about1cm3 to2
cm3adherestothemixingspatula.
Deviation from the viscosity needed can be corrected by further addition of microballoons or pure
resinmixture.
The prepared insert potting foam is then to be placed in a Semco cartridge without cavities. The
orificenozzlediameterisabout2mm,[[2510]:KL43022handlingprocedure].
Processingtime:70min.atRT
Curecycletime:
24hrsatRT:forfinalmachining,[See:23.5]
48hrsatRT:forrepair,[See:23.9].
Storagetime:12monthsatRTmaximum.
Adjustmentofairpressure:2.5barto3.5bar.
NOTE Neukadur EP 270, which is widely used forinsert potting, isamore
recent variant of the Lekutherm X227 epoxy system. Some variation
within properties can therefore be expected between the two resin
systems,[See:7.1].
25.3.4 Other potting materials

Whenothermaterialsareusedforpotting,processrelatedmethodsandconditionsneedoptimisation
andadequatecontroltoensuregoodandrepeatableinsertpotting.
[Seealso:7.1;ECSSQ7071]
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25.4 References
25.4.1 General
[251] Insertsforsandwichstructures,closed,selflockingwithfloatingand
removablenut,screwsecuring
ENN366(MBBERNO)
[252] Titlenotstated
ENN379(MBB/ERNO)
[253] Insertsforsandwichstructuresclosed,selflocking
ENN386(MBB/ERNO)
[254] Insertsforsandwichconstructions,closed,withscrewlockinghelicalcoil
insert
ENN398(MBB/ERNO)
[255] Bondingtabs
ENN34602(MBB/ERNO)
[256] Designationofthesurfacetreatment
LN9368(BeuthVerlag,Germany)
[257] Standardclimateconditions
DIN50014(BeuthVerlag,Germany)
[258] Instructionsfortheissuanceoffailuremessagesandfailureelimination.
RL0008021
[259] SLE3010:Productdata(72970)
[2510] LekuthermX227+T3:Processinginstructions
BayerGmbH
[2511] Applicationoftoxic,volatile,nonflammablesolventsforcleaning
purposes.UVV11.2(VBG87)
[2512] Applicationofadhesivewitheasilyvolatile,flammablesolvents.VBG81
[2513] ReevaluationofpottingprocedureFinalReport,
July1990.MBBERNO(Bremen).ESTECContractNo.
7830/88/NL/PH(SC)
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ECSSE30series Spaceengineeringseries
ECSSQST7002 Thermalvacuumoutgassingtestforthescreeningof
spacematerials
processes
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26
Incoming inspection
26.1 Tests
26.1.1 Material specifications

Material incoming inspection tests are performed in accordance with the relevant material
specification. These tests guarantee the minimum values that have a 99% probability of being
exceeded.
26.1.2 Additional tests

Additionaltestsarenecessarytoguaranteeorpredicttheinsertstrengthwithmorereliability.These
testsrelatetothe:
Honeycombcore,[See:26.2].
PottingResin,[See:26.3].
Compositefacesheets,[261],[See:26.4].
26.2 Honeycomb core
26.2.1 Core properties

Incoming inspection test methods for honeycomb cores determine the actual core properties, [262].
Thesecover:
Density;
Compressivestrength(1);
Shearstrength;
Foilthickness.
NOTE(1) Within the IATP insert allowable test programme, a minimum
stabilisedstrengthwasstipulated,[See:AnnexE].
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26.2.2 Insert strength

Therelationshipofinsertstrengthtoactualcorestrengthisconsideredfortwolevels,[See:12.3]:
Average;
Minimum.
[Seealso:Figure64fordeviationofactualcorestrengthfromguaranteedvalues
NOTE Theguaranteedvaluesarelow.
26.3 Potting resin

Insertpottingresinsareusuallyepoxybasedproducts,[Seealso:7.1;25.2].Variationsbetweenbatches
ofmaterialarenotuncommon.
Storageconditionscanaffectthefinalpropertiesofcuredresins,[See:23.10;ECSSQST7022].
Incominginspectionisimportantfor:
Pottingcompoundsforstandardtypesofinserts;
Resins used for bonding nonstandard inserts, where potting is replaced by an equivalent
bondingprocess,[See:A.3;F.6].
NOTE It is increasingly common for all the constituent parts of resintype
materials to be subjected to quality assurance procedures, including
fillers.Thiscanalsoextendtoconsumablesusedintheprocessing.
26.3.1 Strength
26.3.1.1 General
Testingisnecessarywhenaguaranteedvalueofpottingresinstrengthisneededfor,e.g.:
Coredensitiesexceeding50kg/m3
Largecoreheightwithpartialpotting.
26.3.1.2 Test methods

SuitabletestmethodsaregiveninTable261fordetermining:
Bending;
Tensile.
Thesecanbeappliedasalternatives.
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Table261:Incominginspection:Pottingresinstrengthtests
Sampledimensions Acceptancestrength(1)
Testmethod Teststandard
(mm) (N/mm2)
Bending DIN53452 31580 110
Tensile DIN53455 320150 60
(1)Proposedacceptancevaluesapplytopureresinswithoutfilleradditives,e.g.microballoons.
NOTE The IATP insert allowable test programme stipulated a compression

test to ASTM D 695M to provide an average value for potting
compounds,[261],[Seealso:AnnexE].
26.3.2 Hardness
A hardness test on each batch of mixed resin and hardener provides a cure check on the potting
compound.Thiscanformpartofthemanufacturingprocesscontrol,[261].
[Seealso:27.1]

Inspectionandtestproceduresappliedtocompositefacesheetmaterials canbegroupedas,[Seealso:
ECSSEST3220,ASTMwebsite]:
Characteristicsofthebasicmaterial,e.g.oftenasprepreg;
Propertiesofthecuredcompositelaminate.
NOTE Acceptable defect levels form part of the incoming inspection of
compositematerials.
26.4.1 Material characteristics

Therequirementsstatedinmaterialsspecificationsarechecked.Thesearenormallyanaveragevalue
withatolerance,e.g.fibrecontent60%2%.
Testsareconductedtorecognisedstandards,e.g.ASTMorequivalents,andcaninclude,[261]:
Fibrecontent(%);
Resincontent(%);
Arealweight,i.e.massperunitareafor:
prepreg.
dryfabricorcloth.
Volatilecontent(%).
26.4.2 Composite laminate properties

Therequirementsforminimumandaveragevaluesarechecked.Theseinclude,[261]:
Interlaminarshearstrength,ILSS;
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4pointflexuraltest,toprovidevaluesof:
Strength;
Stiffness.
Thesetestsareconductedinaccordancetorecognisedstandards,e.g.ASTMorequivalents.
NOTE Testsamplesreplicateexactlythesandwichfacesheet,e.g.materials,
layup,numberofplies,curecycle.
26.4.3 Consumables
Itisincreasinglycommonforconsumablesusedincompositeprocessing,e.g.releaseplies,peelplies
andcleaningagents,to besubjectedtoincominginspectionprocedures.Thisisespeciallytruewhere
structuraladhesivebondingisusedasanassemblyprocess,e.g.bondingCFRPfacesheetsontocores
toproducesandwichpanels,[Seealso:ECSSEHB3221].
26.5 References
26.5.1 General
[261] InsertAllowableTestProgrammeIATP2
KongsbergGruppenReportNo.02TR68040906(October1997).
[262] MILC7438
Corematerialaluminum,forsandwichconstruction

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27
Manufacture control
27.1 Testing
27.1.1 General
Thetestsconductedaspartofmanufacturecontrolaregroupedas:
Mechanical,[See:27.3];
Nondestructive,[See:27.4].
[Seealso:Clause29fortestmethodsfordeterminingpermissibleloadsanddesignallowables]
27.1.2 Mechanical
Destructivemechanicaltestsareconductedonreferencesamples,[See:23.6].
[See:27.3]
27.1.3 Non-destructive
Nondestructivetesting(orinspection)iscarriedouton:
Samples,and
Manufacturedflightarticle.
[See:27.4]
27.1.4 Development tests
27.1.4.1 General
Teststodetermineinsertstrengthvalues(notcoveredbythishandbook)canbenecessary,e.g.:
Specialtypesofcore;
Nonstandardinserts,[Seealso:AnnexFforcasestudies];
Novelinsertarrangements.
Basictestprogrammeinformationisgivenin[271],[272].
[Seealso:Clause29]
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27.1.4.2 Potting process
Thefactorstestedandinspectedinthedevelopmentofapottingprocess,[273],include:
Borehole,e.g.drilling,dimensions,adjacentcellwalls;
Core,e.g.perforation;
Pottingcompound,e.g.viscosity,temperature.
Otherfactorswhichcanhaveaninfluenceare:
Features at the bottom of the bore hole, e.g. corner at coretobottom face sheet, which can
affectflowofpottingcompound;
Injectionpressureprofileonflowofpottingcompound;
Injectionnozzleshapeandsize.
27.2 Reference samples

Thepurposeoftestingreferencesamplesistoconfirmthatthepottingprocessusedonflightarticles
meetsthosestipulatedinthedesign.
[Seealso:23.6forreferencesamplemanufacture;27.3formechanicaltestingAcceptanceloads
Theacceptancevaluesaredefinedinthedesigndocumentation.
Unlessstatedotherwiseinthedocumentation,thecriteriaappliedare:
Pass:Strengthvalues80%orgreaterofPSS ave .
Reject:Strengthvalueslessthan80%ofPSS ave .
27.3 Mechanical testing

Mechanicaltestsusedtoevaluateinsertcapabilityare,[274],[275]:
TensilePullOut:
singleinsert.
groupsofinserts.
Shear;
Bending;
Torsion.
Destructivetestsareappliedtoreferencesamples.Theposttestsamplesarethensectionedtoevaluate
thequalityofthepotting.
Mechanical tests are also used on qualification and flight structures, but to lower (nondestructive)
loadlevels,[274].
[Seealso: Clause29 for test methods used to determine designallowables;Annex F for case studies
includingtestmethodsusedinsomeEuropeanprojects]
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27.3.1 Tensile pull-out test
27.3.1.1 Sample
Reference samples are manufactured at the same time as the flight structure from exactly the same
materials,[See:23.6;Figure234].
NOTE The sandwich sample height, H in Figure 234 is the same as that of
theflightstructure.Test fixture
Figure271showsasimpletestfixtureforoutofplanetensileloadingtestsonsandwichspecimensof
80mm80mmsizewithacentrallylocatedinsert.Aversionforcompressionorfatigueoutofplane
testingisshowninFigure272fortwodifferentsandwichthicknesses,[275].
Whenloadisactingontheinsert,thesandwichplateispressedagainstone(forpuretension)ortwo
(fortensionandcompression)aluminiumplateswhichbothhaveacentralhole,70mmindiameter,to
ensureasufficientfreeareaaroundtheinsert.
Thetestfixtureissuitableforsandwichthicknesses,(c +2f)ofupto60mmandforinsertdiameters,di
upto22mm.Itcanbeusedineitherstaticordynamic(servohydraulic)testmachines.
[Seealso:H.1fortheengineeringdrawingsofthetestfixture.AphotoisshowninFigureF12]
Notethatforinsert/sandwichconfigurationswithhigherloadbearingcapability,asizeof80mm80
mmforthesamplesandthecorrespondingcoverplatesofthetestfixturecanbetoosmall.Underhigh
outofplaneforcestheremainingsmallsupportareaofthecoverplateoutsidethecentralholeof 70
mmdiametercanthenleadtosuchstressconcentrationsthatstrongcrushingofthehoneycombcore
isobserved[275].Inthiscase,anenlargementofthedimensionsto100mm100mmorevenmoreis
necessary.
Figure271:Manufacturecontrol:Outofplanetestfixturefortension(pullout)
tests
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Figure272:Manufacturecontrol:Outofplanetestfixtureforcompressionor
fatiguetests
27.3.1.3 Test
Thetestisperformedinanelectronicallycontrolledtensiletestingmachinethatcanrecordtheload
deflection.Asuitableloadingrateis1mm/min.Loadingisstoppedafterthemaximumloadhasbeen
reached,i.e.atabout2mmconstantdeflectionofthefacesheet.Thismakesiteasiertojudgefracture
conditionsaftersampleshavebeentaken,[275].
27.3.1.4 Evaluation: Pass and reject criteria

If the stated pass value is attained then the acceptance conditions are met, [See: 27.2 acceptance
loads].
27.3.1.5 Sample examination

A sample of potting is removed from the tested sample to evaluate the quality of the potting. This
enables a steady improvement in potting technology. It is important to investigate any correlation
betweenpottingfailuresandboreholedrilling,[See:Figure281].
27.3.2 Shear test

Figure273showsthefrontandrearviewofatestfixtureforinplaneloading(shear)testsoninserts,
[275].
In static tests, the bar acting on the insert screw issimply pulled out of the Ushaped groove in the
baseplate.Thesandwichisthenpressedagainstacrossbarontheinnersideofthebaseplate.
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Indynamic(fatigue)teststheforceisappliedinbothdirections.Thereforethereisasecondcrossbar
on the top side of the base plate. In order to avoid slipping of the sandwich specimen, the exact
positionofthissecond(upper)crossbarcanbeadjustedbymeansofeccentricscrewsaccordingtothe
actualspecimensize.
The test fixture is suitable for sandwich specimens of 80 mm 80 mm; as shown. The maximum
sandwich thickness, (c+2f) depends only on the screw length between the two plates. The insert
diameter,dicanbe20mmforflushmountedinserts,butslightmodificationsoftheloadingbarcan
benecessaryforlargerorprotrudinginserts.
Figure273:Manufacturecontrol:InplanetestfixtureforshearBendingtest
Figure274showsatestfixtureforstaticbendingtestsoninserts.Thesandwichspecimenof80mm
80 mm size with a thickness of up to 60 mm is fastened in a cage of aluminium plates, which is
mounted on a back side structure attached to the test machine. There is a free area of 70 mm in
diameteraroundtheinsert,[275].
Thebendingmomentisappliedbymeansofarigidcantileverbeam,linkingtothecrossheadofthe
test machine. The distance at which the crosshead links to the cantilever beam is adjustable. The
threadconnectionandthecontactareabetweenthebeamandtheinsertarepreciselyaligned.
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Figure274:Manufacturecontrol:Bendingtestfixture
27.3.3 Torsion test

Figure 275 shows a configuration for torsion tests on inserts. The fixture of the sandwich specimen
(onthelefthandside)isidenticaltothatforbendingtests,[275].
Ontherighthandsidethereisawheelfromwhichasteelribbonisspooledoffwhenthecrossheadof
thetestmachinepullsontheendpiece.Thusadefinedtorquecanbeapplied.Therotatingaxishasan
end piece with halfinch square section so that a standard socket from an ordinary toolbox can be
attached.Thissocket,andthecorrespondinginsertscrew,canbeselectedaccordingtoinserttype,e.g.
size,thread.
Figure275:Manufacturecontrol:Torsiontestfixture
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27.4 Non-destructive testing
27.4.1 Radiography
TheactualconditionofpottingmassaftermanufacturingcanonlybejudgedbyanXrayviewparallel
totheaxisofaninsert.However,thisonlyprovidesa2dimensionalviewofthepotting.
Thefeaturestobeexaminedare:
Numberoffilledcells;
Numberofconnectedcellwalls;
Estimation of potting height: by comparing the Xray with potted inserts of known potting
height;
Largeairinclusionsinthepottingmass.
NOTE Knowingthenumberofconnectedcellwallsisparticularlyimportant
to:
reducevariabilityofstrengthvalues,or
calculatetheactualloadcarryingcapabilityofaninsert.
[See:7.3]

Compositefacesheetsareessentiallythinlaminates.Themanufacturecontrolproceduresappliedto
laminatesarethereforeappropriatetofacesheetsonsandwichpanels.
Inadditiontoincominginspectionandchecksmadeduringthelayup,e.g.numberofpliesandtheir
orientation,postmanufacturecontrolmeasuresinclude:
Inspectionfordelamination,flawsanddefects;
Testing(onreferenceorwitnesssamples)toconfirmmechanicalproperties.
Afterthefacesheetsarebondedtothecore,thesandwichpanelisthensubjectedtofurtherinspection,
e.g.
Debondsbetweenthecoreandfacesheet;
Deformationordamagetothefacesheets;
Deformationordamagetothecore.
[Seealso:ECSSEST3220;ECSSEHB3221]
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27.6 References
27.6.1 General
[271] StandardizationofDesignAnalysisandTestingofinStructural
SandwichElements,Finalreport.ESTECContractNo.3442/77/NL/PP.
[272] StandardisationofDesignAnalysisandTestingofInsertsinStructural
Elements,Finalreport.ESTECContractNo.3442/77/NL/PPRider1.
[273] ReevaluationofPottingProcedureFinalReport,
July1990.MBBERNO(Bremen).ESTECContractNo.
7830/88/NL/PH(SC)
[274] MMSContributiontoESAInsertDesignHandbookMatraMarconi
SpaceReportNo.NT/102/BG/355013.96(December1996).
DLRBraunschweig/HelsinkiUniv.Technology/Patria/ESTEC
ESTECContractNo.16822/02/NL/PA(2004)

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28
Quality control
28.1 General
Qualitycontrolactivitiesconductedatvariousstagesofdesign,manufacturingandtestingformpart
of the overall quality assurance plan associated with the project. The precise details are given in
appropriatestandardsandspecifications,[See:ECSSwebsite:www.ecss.nl].
28.1.1 Materials and processes
28.1.1.1 Overview
All standard activities related to quality control of materials and processes are applied to sandwich
panelsandtheircomponentparts,includingbutnotlimitedto,[See:ECSSQST70;ECSSQ7071]:
Materials,
core;
facesheet;
adhesive;
coatings.
Components:
inserts;
fasteners.
Processes:
machining,[See:28.2];
potting,[See:28.3].
28.1.1.2 Potting
Control of the potting process is particularly important because it is a chemical process that is
sensitivetoinaccuraciesthatcanresultinfailures,[Seealso:23.10fordefects].
NOTE Permissiblevaluescitedwithinthishandbookarebasedonacorrectly
performedpottingprocesswithoutsignificantfailures.
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28.1.2 Documentation and traceability

AllaspectsofmaterialsandprocessescontrolmeettheapplicableECSSstandardsorotherapproved
specifications cited within the design documentation. Notification and control of nonconformances
arealsogovernedbytheappropriatestandards,[See:ECSSQST70].
28.1.3 Personnel
All aspects relating to personnel using materials, processes and their control are applied and
documentedinaccordancewiththegoverningstandards.
28.1.4 Health and safety

Safetyproceduresandpracticesconformtotheappropriateoccupationalhealthandsafetystandards.
Safety equipment is maintained, is made available and used by personnel during the various
manufacturingstages.
Any particular requirements stated in safety notices supplied with materials are included in the
overall safety plan, e.g. resins and hardener systems that can cause skin irritation and respiratory
problems;skinprotectionduringtheuseofoxidisingchemicals;dustremoval.
28.2 Control of bore hole
28.2.1 Inspection criteria

Allboreholesarevisuallyinspectedpriortoinsertpotting.Theinspectioncriteriainclude:
Diameterofaboreholeinthefacesheetiswithinatoleranceof0to+0.03mmofthenominal
insertdiameter;
Boreholesareaconstantdiameterovertheirmachineddepth,i.e.parallelsidesanddefinitely
notconical,[281];
Boreholesarenormaltothepanel,i.e.toavoidunacceptablebendingloads,[See:Figure151];
Depthofboresinthehoneycombsandwichstructureexceedtheoverallheightoftheinsertby5
mm,[281];
Thebottomofthemachinedboreholeisflat,i.e.withoutbentordislocatedcellfoilsthatcan
otherwise:
Impedeflowofpottingcompound;
Positioningofinsert(normaltothepanelandatthecorrectdepth).
Toenablefreeflowofpottingcompoundintoopencells,theareasurroundingtheboreinthe
honeycombcoreare:
freeFromdefects;
Withoutanybentcellwalls,[281];
Dislocatedlayersofcorefoil.
Toenablefreeflowofpottingcompoundundertheinsert,thecorecellsbeneaththeinsertare
open,i.e.:
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Freefromanybentcellwalls,[281];
Dislocatedlayersofcorefoil.
Undercutting or detachment of the core from the face sheet caused by mechanical damage or
overheatingcannotexceedtheradiusbymorethan2mm.
Radius of core bore hole is never less than the nominal dimensions of the insert flanges. This
leads to a strength reduction below the minimum permissible values, [See: 28.3; Figure 281,
part4].
NOTE1 This can occur if a blunt or damaged punching tube is used or the
boreholedrillingandreamingprocessisinsufficient.
NOTE2 Toavoidcontamination,lubricantsorcoolingfluidcannotbeused.
28.3 Control of potting

ThepottingprocessshouldavoidthetypesoffailuresshowninFigure281andlistedinTable281.
Themethodsappliedforfailuredetectionare:
Stepbystepprocesscontrol;
Strengthtestonreferencesamples,[See:23.6;27.3];
Proofloading(100%orless)allinserts,[See:23.7].
Noneofthesemethodsaloneguaranteesdetectionofallfailures,[See:Table281
Consequently,acombinationofcontrolmethodsisstronglyadvised.
NOTE Processcontrolisveryimportantbecauseitdetectsmostfailuretypes.
[Seealso:25.1;25.2;25.3forpottingprocess]
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Too short duration of

Incomplete injection
1
filling Unperforatedcore, too high
viscosity
Air inclusion
Toolowviscosityofpotting
2 underneath
mass
insertboreholes
Distance between insert

Incomplete bottomandcoreislessthan
3
filling 3 mm, or cell walls are
dislocated
Potting radius A damaged or blunt

smaller than punchingtubemakesacore
4
insert radius bp bore hole smaller than the
< bi nominalinsertdiameter.
Figure281:QA:PoorpottingcausingstrengthdegradationTable281:QA:Potting
failureanddetectability
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Effect Detectableby
100%Loadcontrol
Dynamicloadloss
Referencesample
Processcontrol
Strengthloss
Totalloss(1)
Outgassing
Item Reason
1 mixingratio
Resin, 2 poormixing
hardener,filler
(5),(6) 3 wrongcomponent
4 storage(2)
5 poorcleaning
Adhesion
6 contamination(4)
7 boreholefailure
8 poorfilling(5),(6) (3)
Process
9 airbubbles(small)
10 humidity
KEY: Yes; No; Possible.
(1) Tearoutatlowload.
(2) Incorrectstorageorshelflifeexpired.
(3) Inspectionofboreholesafterfilling.
(4) Postcleaning.
(5) Viscositycontrolofmixedpottingcompoundnecessary,[281].
(6) Temperaturecontrolofmixedpottingcompoundandworkingenvironmentnecessary,[281].
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28.4 Core incoming inspection
28.4.1 Minimum core strength values

TheminimumcoreshearstrengthWminandcmincanbeunacceptablylowbecauseof:
Minimumfoilthickness,i.e.densitylessthanN;
Veryhighdegreeofexpansion;
Verylowmaterialstrengthoffoils;
Extensivedistortionandbuckling.
Thiscanappearveryconservative,asthereisatendencyfor:
Densitytobeevenhigherthannominal;
Underexpansionduetoconstraintsfromtheouterborderduringpanelmanufacturing.
28.4.2 Inspection sequence

Aninspectionsequence,showninFigure282,issuccessfulby:
Simplifyingincominginspection,and
Enablingasimpleinsertselectionwithoutextensiveanalysis.
NOTE Compliance with the standard means that minimum core strength
valuescanbeapplied.
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1 Standard
Material Procurement (1)
2 Incoming Inspection
3 Compliance
REJECT
to Standard (1)
No
Yes
ACCEPTABLE for minimum core values
(1)StandardMILC7438
Figure282:QA:Honeycombcoreincominginspection
28.4.3 Perforated cores

Perforations in cores have a profound effect on potting compound flow, hence the success of the
pottingprocess,[281].
Conformanceofcorestomaterialspecificationsincludescheckingforthepresenceofperforationsbya
visualinspection,[281].
28.5 Core normalised density
28.5.1 Procedure
Todeterminethedensityundernominaldegreeofexpansion,theprocedureusedis:
Cuttestpiecesfromcorematerial(MILC7438);
Weighsamples;
Calculateactualdensity;
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Determinationofactualcellsizebycounting10cellsandmeasuringtheiroveralllengthinW
direction;
Calculateofactualdegreeofexpansion,in%,by:
actual cell size
nominal cell size
100 [%] [28.51]
Determinethecorrectionfactor,Kex;anexamplecurveisshowninFigure283;
Correctactualdensity,toobtainnormaliseddensity,N:
N K ex act [28.52]
Figure283:QA:Coredensitycorrectionfactorfordegreeofexpansion
28.6 References
28.6.1 General
[281] ReevaluationofPottingProcedureFinalReport,
July1990.MBBERNO(Bremen).
ESTECContractNo.7830/88/NL/PH(SC)
[282] MILC7438
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processes
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29
Testing
29.1 General
The Test procedures and techniques for determining permissible loads and design features are
described.Thesecover:
Insertstaticstrength,[See:29.2]:
Outofplane;
Inplane;
Bending;
Torsion.
Geometriceffectsoninsertstaticstrength,[See:29.3]:
Edgedistance;
Insertproximity.
Insertdynamictests,[See:29.4]:
Sinusoidalloading;
Staticresidualstrength.
[Seealso:27.1;27.3;AnnexHforothermechanicaltestsandassociatedtestjigsusedinmanufacture
control]
29.2 Insert static strength tests
29.2.1 Out-of-plane tests

Thepurposeofthetestistomeasuretheultimateoutofplaneinsertload,i.e.tensionorcompression.
The deflection is also measured and the deflection behaviour recorded as a curve. The general test
arrangementisshownschematicallyinFigure291.ArealtestfixtureofthistypeisdepictedinFigure
271andFigure272,[Seealso:Photo:FigureF12,Technicaldrawings:H.2].
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T e n s i o n Co m p r e s s i o n
Figure291:Testing:Insertstaticoutofplanestrengthfixture
Thetestsamplesizeisatleast80mm80mm,[291]stipulates100mm100mm.Largerdimensions
are necessary for insert/sandwich configurations with high loadbearing capability to ensure a
sufficient support area around the central hole of 70 mm. Otherwise, at higher outofplane forces,
honeycombcorecrushingcanoccur.
Thetestisperformedinatensiletestingmachine,whichenablestherecordingofloaddisplacement
values.
Aloadingrateof2mm/minwaschosenbecauseadeflectionof2mmincludestheultimateloadforall
sandwich conditions. One minute is a typical loading time and failures usually occur after about a
minute.
Loadingisstoppedafterthemaximumloadhasbeenreached,whenthedeflectionofthefacesheetis
about 2 mm. This makes it easier to judge fracture conditions when samples are subsequently
examined.
NOTE The test conditions stated are also valid for specimens that are pre
treatedbydynamicorthermalloading.
A typical forcedisplacement curve has a linear region at first, then a nonlinear region before the
maximumload.Theendofthelinearregionismeasuredfromthecurvesandthevalueisknownas
thefirstpeakvalue.
29.2.2 In-plane tests

Thepurposeofthetestistothemeasuretheultimateinplaneloadoftheinsert.Itisalsopossibleto
measuretheultimateloadinotherdirections,e.g.30and60.Thegeneraltestarrangementisshown
schematicallyinFigure292.
Arealtestfixtureofthistype,butonlyfor0orientation,isdepictedinFigure273,
[Seealso:Photo:FigureF12,Technicaldrawings:H.3].
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Figure292:Testing:Insertstaticinplanestrengthfixture
Thetestisperformedinatensiletestingmachine,whichenablestherecordingofaloaddisplacement
curve.
Theloadingrateis2mm/min.
29.2.2.1 ASTM method

Anotherinplanetestmethodisalsoused;ASTMF60695b,[292].ThistestfixtureisshowninFigure
293.
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Strap plates
Test sample
Figure293:Testing:ASTMinsertstaticinplanestrengthfixture
Thedimensionsofthespecimensare180mm60mm.Thestrapplatesare130mm40mm5mm
fora throughthethickness specimen in the symmetric load case. For other cases, the dimensions of
thestrapplatesare200mm40mm5mm.
Thetestisperformedinaseriesofsequentialsteps:
1. The temperature and humidity measurement system of the test room is activated. The
measured temperature and humidity values are stored in a computer. The test is
performedatroomtemperature.
2. Strapplates areclampedfirsttothelowergripandthentotheuppergripofthetesting
machine.Throughthethicknesstestsneedspecialfixtures.Oneofthetwothroughthe
thickness testing fixtures, connected to the specimens with the shear pin, is clamped to
theuppergripofthetestingmachine.Theothertestingfixtureisclampedtothelower
grip of the testing machine. The lower grip is then raised to enable the connection
betweenthestrapplateandthelowertestingfixturebymeansofanothershearpin.
3. Avisualinspectionisperformedtoverifythealignmentofthespecimenwiththetesting
machine.
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4. Theloadisappliedatarateof2mm/min;strokecontrolisused.
5. At the beginning of the test, slippage occurs between the insert flange and the strap
plates.Slippageisconsideredtooccurwhenaconstantordecreasingvalueoftheloadis
registeredwhilethestrokeisstillincreasing.Theloadatwhichslippageoccursisnoted.
6. A failure of the specimen is considered to occur when a load drop equal to 20% of the
maximumloadisregistered.Thefailureloadisrecorded,i.e.thepeakvalue.
7. Thefailuremodeisdeterminedandthespecimenphotographedfrombothsides.
29.2.3 Bending tests

The purpose of the test is to measure the ultimate bending load capability of an insert, to measure
bendingdeflectionandtoexaminethebehaviourusingaloaddeflectioncurve.
Theloadingrateis2mm/min.ThegeneraltestarrangementisshownschematicallyinFigure294.
A real test fixture of this type is depicted in Figure 274, [See also: Photo: Figure F12, Technical
drawings:H.4].
Figure294:Testing:Bendingfixture
29.2.4 Torsion tests

Thepurposeofthetestistomeasuretheultimatetorsionloadofoneinsert.Thetestisperformedina
torsiontestingmachine.
A suitable torsion test device is depicted in Figure 275, [See also: Photo: Figure F12, Technical
drawings:H.5].
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29.3 Geometric effects: Insert static strength tests

The position of inserts from the edge of a sandwich panel (edge distance), the distances between
inserts(proximity)andtheloadingdirectionsonadjacentinsertscanallaffectinsertcapability.
[See:Clause18foredgeinfluence;Clause19forinsertgroups]
29.3.1 Edge distance

The purpose of the test is to measure the ultimate outofplane and inplane load capability of the
insert,whichisdependentonthevariousdistancestotheedgeofthesandwichplate.
Thetestisperformedinatensiontestmachine,whichenablestherecordingofaloaddisplacement
curve.ThetestfixtureandsetupareshowninFigure295.
Theloadingrateis2mm/min.
Figure295:Testing:Edgedistancefixture
29.3.2 Insert proximity

The distance between adjacent inserts, i.e. their proximity, and the loading directions (same or
opposite)canaffectinsertcapability.
The purpose of the test is to measure the ultimate outofplane tension (same) and the tension
compression(opposite)loads,whicharedependentonthevariousdistancesbetweeninserts.
Thetestisperformedinatensiletestingmachine,whichenablestherecordingofaloaddisplacement
value.Theloadingrateis2mm/min.
Figure296showsthetestfixtureandsetupfortensileloadinginthesamedirection;theloadisthe
sameonbothinserts.
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Figure296:Testing:Insertproximitytensilefixture
The tensioncompression proximity testing fixture for inserts, i.e. loaded in opposite directions, is
showninFigure297.
Figure297:Testing:Insertproximitytensilecompressionfixture
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29.4 Dynamic tests
29.4.1 Sinusoidal loads

The purpose of the test is to determine the number of load cycles to failure at different load
amplitudes. The results enable the generation of S/Ncurves for the selected sandwich and load
parameters.
Another task is the control and determination of the deflection behaviour during loading, to
determinethepoint(loadcyclenumber)atwhichcoredamagefirstoccurs.Thispointisdetectableby
anincreaseofthedeflectionamplitudeatconstantloadamplitude.
Therearetwodifferenttestswithdifferentcapabilities:
Samplesatlowandmediumloadlevelsunderalargenumberofloadcycles.
Samplesathighloadlevelunderasmallnumberofloadcycles.
TheloadlevelandthenumberofcyclesaregiveninTable291.
For endurance tests, i.e. test of ultimate life, 106 load cycles are suggested with a test frequency of
about10Hz.
Table291:Testing:Dynamictestloadlevelsandnumberofcycles
%ofStatic Frequency
Loadlevel Cycles
ultimateload (Hz)
High,S1 80 ~500 ~50
Medium,S2 60 ~5000 ~50
Low,S3 45 ~50000 ~50
The load levels givenareestimations that can be adjusted depending upon the real number of load
cyclessupportedbythefirstsampletobetested.
The load and deflection amplitudes are recorded during the dynamic test. For high and medium
numbersofloadcycles,recordsaretakenatchosenintervals.Theyshowincreaseddeflectioncaused
bythedamagegrowthduringloading.Theloadamplitudeiskeptconstant.
29.4.2 Static residual strength test

Residualstrengthtestsareconductedatvariouspointsduringthedynamicloadingtest.Thepurpose
of the test is to determine the static residual strength of samples subjected to different numbers of
dynamicloadcycles.
The points at which dynamic loading is stopped in order to conduct a residual strength test are
determinedfromthedynamictestrecords;asshowninFigure298.
PointsN2andN5areknownfromsinusoidaltesting,whereastheotherpointsarechosendepending
onfixedvalues,[Seealso:Table291].
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Figure298:Testing:Determinationofpointsforresidualstrengthtest
29.5 References
29.5.1 General
[291] L.Syvnenetal:PatriaFinaviacompOy,Finland
facings
[292] ASTMF606
Standardtestmethodsfordeterminingthemechanicalpropertiesof
externallyandinternallythreadedfasteners,washers,andrivets
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Annex A
Inserts
A.1 Introduction
InsertsusedinEuropeanspaceapplicationsaresummarised,[293],[294],[295].Thesearegrouped
as:
Commerciallyavailable,i.e.standardspecifieditems,thatarenormallysuppliedbyShurlok,
[Seealso:A.2];
Non standard, i.e. designed and manufactured inhouse for particular project applications,
[See:A.3]andcoversthose:
based on conventional insert designs, where dimensions or the materials used are
different;
novel insert designs, e.g. Carbonfibre tube inserts, [See: A.3], which were originally
developedfortheROSETTALanderproject,[Seealso:F.6forcasestudy].
[Seealso:AnnexFCasestudies]
A.2 Commercial products

Table A.02.1 summarises an industry survey of insert technology, [293], and compilation of insert
applicationsinEuropeanspaceprojects,[294].
NOTE [294] covers axisymmetrical inserts fitted in sandwich panels only.
Cocuringpanelswithinsertsandedgeinsertsareexcluded.
AllcommerciallyavailableproductsweresuppliedbyShurlok.
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TableA1:Commerciallyavailableinsertsusedinspace
ProductCode Comment/Project Company/[References]
AA2024(3.1354.T851);anodisedto
ENN366 DASARI[293]
MILA8625
AA2024(3.1354.T851);anodisedto
ENN379 DASARI[293]
MILA8625
AA2024(3.1354.T851);anodisedto DASARI[293]
ENN398
MILA8625 AleniaSpazio[293]
LN9038 AleniaSpazio[293]
LN9499 AleniaSpazio[293]
NAS1834 BAeAirbus[293]
NAS1836 BAeAirbus[293]
CASESPOT5:Equipment
SL100530 SONACA[294]
[See:F.7Casestudy]
SILEX:Structure;Equipment
SL10068 MANTech.[294]
[See:F.9Casestudy]
NILESAT(battery):Structure;panel
SL10068 assembly;satelliteinterface. BTS[294]
[See:F.11Casestudy]
Supplier:Shurlok
SL1019608 BAeAirbus[293]
SL10218H394/Z Contraves[293]
SL10218M494/Z Contraves[293]
SL10414 Steel;cadmiumplated Westlands[293]
SL10807 AleniaSpazio[293]]
SL10807 CASA[293]
SL10968 CASA[293]
SL601 AleniaSpazio[293]
UMSSST:Structure
SL601M49.5A Aerospatiale[294]
[See:F.8Casestudy]
ASAP4(AR4):Structure;equipment;
SL601M615.9S I/Fmicrosatellite UTAIndustrie[294]
[See:0Casestudy]
SL606 AleniaSpazio[293]
ARIANE4:Equipment
SL607 CASA[294]
[See:F.3Casestudy]
ARIANE5:Equipment
SL607 MMSUK[294]
[See:F.5Casestudy]
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A.3 Non-standard
Table A2 summarises an industry survey of insert technology, [293], and compilation of insert
applicationsinEuropeanspaceprojects,[294].
Nonstandardinsertscanbegroupedas:
Inhouse,or
Noveldesign
NOTE [294] covers axisymmetrical inserts fitted in sandwich panels only.
Cocuringpanelswithinsertsandedgeinsertsareexcluded.
A.3.1 In-house
Insertsaredesignedandmanufacturedinhousewherecommerciallyavailablestandardinsertsare
inadequate,e.g.throughthethicknessinsertsinthicksandwichpanels.
Inhouseinsertstendtofollowtheconventionalinsertdesign,e.g.metalliccomponentspottedinto
sandwichpanels;withtheuseofnuts,boltsandhelicoilsasthemechanicalconnectionmethod.
A.3.2 Novel design

Significantadvantageswithrespecttomasssaving,insertdensityperarea,orassemblyeffortscanbe
achievedincaseswhereclassicallypottedallmetalinsertscanbereplacedbynoveldesigns.Thisis
demonstratedbytheCarbonfibretubeinserts,originallydevelopedforROSETTALander,[Seealso:
F.6].
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TableA2:Nonstandardinsertsusedinspaceapplications
Company/
Description Project/Comment
[References]
HRGCL:Electronicequipment
AA2024T351 MATRADef.[294]
[See:F.10Casestudy]
ARIANE4:Structurehandling
AA2024T4 CASA[294]
[See:F.4Casestudy]
Aluminium Urenco[293]
Aluminium(AA7075;AA6061);Titanium
AlcatelEspace[293]
(TA6V;T40);cocuredwithpanel
Aluminiumalloy,anodised.Through
AleniaSpazio[293]
thickness;highloads
Throughthickness Contraves[293]
ASAP4(AR4):Structure
Throughthickness;AA2024T6 UTAIndustrie[294]
[See:F.4Casestudy]
Supplier:Inhouse
SILEXGEO:Structure
Throughthickness;AA7075T73 MANTech.[294]
[See:F.9Casestudy]
NILESAT(battery):Structure
Throughthickness;AA7075T7351or
handling;radiatorplate. BTS[294]
AA7175T7351
[See:F.11Casestudy]
SPOT5:I/Fplatformstructure
Throughthickness;AA7175T7351 SONACA[294]
[See:F.7Casestudy]
ASAP5:Structure;separation
systemminiandmicro
Throughthickness;AA7175T7351 MMSUK[294]
satellites
[See:F.5Casestudy]
Throughthickness;AluminiumAU4G1 UMSSST:Structure
Aerospatiale[294]
T351 [See:F.8Casestudy]
Throughthickness;spools CASA[293]
Aluminium Raufoss[293]
Carbonfibretubeinserts ROSETTALander, DLR[295]
(withaspreadableCFRPtubebondedin ESAstudyoncarbonfibretube
thecoreandwithmetallicendcaps) inserts
[See:F.6Casestudy]
A.3.3 Carbon fibre tube inserts

CarbonfibretubeinsertswereatfirstdevelopedbyDLRforuseontheLanderofESAscornerstone
missionROSETTA,[Seealso:F.6].In2003/04theywereinvestigatedmorethoroughlyinthecourseof
anESAfundedstudy,[295].
FigureA1showsthedesignprincipleincomparisonwithaclassicalpottedinsert,[295].
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C la s s i c p o tt e d i n s e rt Ca rb o n fi bre tu b e in se rt
FigureA1:Carbonfibretubeinserts:Comparisonofdesignprinciples
The load introduction from the metallic insert part into the sandwich is not performed by
conventional epoxy resin potting, but by means of an extremely stiff, thinwalled carbon fibre tube
whichfitsexactlybetweenthefacesheetsandisbondedtothehoneycombcorebyaepoxyadhesive
layer. This adhesive layer can be relatively thin. Only a small amount of resin is needed to ensure
goodcontactwiththesurroundingcellwallsofthehoneycombcore.
However,thefulllengthofthe(extremelystiff)carbonfibretubeactivelycontributestotheshearload
transfer into the (much softer) honeycomb core, because the tube always goes through the whole
sandwich thickness. The formlocking contact under both face sheets makes the sandwich in the
vicinityoftheinsertpracticallyincompressible.
The carbon fibre tube contains unidirectional highmodulus carbon fibres and is slit lengthways
duringmanufacture.Thisallowsfoldingoroverlappingtoreducethediameterforfeedingitthrough
theboreholeinthefacesheet;showninFigureA2.
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FigureA2:Carbonfibretubeinserts:FittingofspreadableCFRPtube
After placement, the carbon fibre tube is spread and aligned by means of a simple tool, so that the
endsofthetubefitjustunderneaththefacesheets.Theinnerradiusofthetubeisidenticalwiththe
boreholeradiusofthefacesheets.
After curing of the adhesive, the carbon fibre tube is ready for fitting of one or two metallic insert
caps.Twobasictypeshavebeendeveloped.Theseareknownas,[295]:
Type1,whichreplacestheconventionalthroughthethicknessinsert;asshowninFigureA3.
Type2,whichreplacestheconventionalpottedinsert;asshowninFigureA4.
A.3.3.2 Type 1
Athreadelementisinsertedintothebottomsandwichface,i.e.oppositetothesidefromwhichthe
screwisfitted.Thesmallermetalliccaponthetopsideservesonlyasaguidingelementforthescrew.
Itcaneitherbeflushorprotrudebeyondthesurfacebyanydistanceneeded,[See:FigureA3].
Type 1 tube inserts are particularly suited for high forces, where both face sheets contribute to the
loadcarryingcapability.
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FigureA3:Carbonfibretubeinsert:Type1cap
A.3.3.3 Type 2
FigureA4showsType2,whichneedsonlyasinglemetalliccap;thisreplacestheconventionalpotted
insert,e.g.usedforunilateralfixationofpayloadunits.
FigureA4:Carbonfibretubeinsert:Type2cap
The cylindrical metallic part has collars at the top and bottom; shown in Figure A5. The standard
diameterofthesecollarsis11mm,correspondingtotheinnerdiameterofthecarbonfibretubeinsert.
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Carbon fibre sleeve Type 2

(separate) insert cap
FigureA5:Carbonfibretubeinsert:Type2insertcapandcarbon
fibresleeve
Betweenthetwocollars,theradiusisreducedby0.7mmtoenableaslitcarbonfibresleeveof0.6mm
wall thickness to snap around it. When the assembled cap is bonded into the carbon fibre tube
insert,the0.1mmclearanceisfortheadhesivelayer.Thecarbonfibresleeveiscutpreciselytolength
sothat,oncesnappedaroundthemetallicpart,accurateformlockingcontactbetweenthetwocollars
isachievedandanyslippingisavoided.
ThelengthoftheType2capdeterminesthesizeofthebondedareabetweenthecarbonfibresleeve
on the cap and the carbon fibre tube in the sandwich. The loadbearing capability can be chosen
accordingly.GoodadhesivebondingcanbereadilyachievedbetweenthetwoCFRPcomponents.
[Seealso:F.6forexperimentalandanalyticalresults,[295]]
A.3.3.4 Advantages
Threesignificantadvantagesofcarbonfibretubeinsertsare:
Close mounting: The radius of a carbon fibre tube insert, consisting of the radius of the tube
itself plus a thin adhesive layer, is smaller than the radius of a conventional potted insert of
equivalent loadbearing capability. Consequently the insert density per area of the sandwich
canbehigher.
Masssaving:Duetothelowweightofthecarbonfibretubesandthesmallamountofadhesive
needed,themasscontributionisonly~0.05grammespermillimetreofsandwichthicknessplus
themassofthemetallicinsertcap(from1.9gforM3upto3.2gforM6).Thisissignificantly
lighter than comparable potted inserts for sandwich thicknesses up to 50 mm. For very thick
sandwiches, carbon fibre tube inserts may become slightly heavier (due to the long tube) but
theiroutofplaneloadbearingcapabilityisfarsuperior.
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Easy implementation: The implementation of carbon fibre tube inserts into bore holes in the
sandwich is relatively easy. Special expertise and training regarding the proper injection of
pottingcompoundisnotnecessary.Thiscanplayapartinreducingcosts.
A.3.4 Other novel designs

As carbon fibre tube inserts have successfully demonstrated, significant advantages regarding mass
saving,arealinsertdensityorassemblyeffortcanbeachievedincaseswhereconventionallypotted,
allmetalinsertscanbereplacedbynoveldesigns.
Similar developments, which are currently the subject of evaluation exercises, will be included in
futurehandbookrevisions.
A.4 References
A.4.1 General
[293] InsertTechnologyIndustrySurvey(1995)
MMSRef.NT/102/BG/355013.96(Dec.1996)
DLRBraunschweig/HelsinkiUniv.Technology/Patria/ESA/ESTEC
StudyonCarbonFibreTubeInserts
ESTECContractNo.16822/02/NL/PA,(2004)
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Annex B
Permissible loads
B.1 Introduction
Thesetofdesigngraphs,presentedinB.2,arebasedontheanalyticalexpressionsfor:
Predictingstaticloadcarryingcapabilityofinsertssubjectedtooutofplaneloading,[See:D.1].
ReliabilitycoefficientsRC,[See:D.7;TableD2]
ThisAnnexpresentsgraphsof:
Tensilepermissibleloads.
Compressivepermissibleloads.
NOTE See:B.2forindextodesigngraphs
Seealso:D.8foradescriptionofthegraphs.
B.1.1 Core types

Thetypesofcoresaregroupedas:
Metallic,[Seealso:Table63].
Nonmetallic,i.e.NomexorGFRPglassfibrereinforcedplastic,[Seealso:Table64].
B.1.2 Core height
B.1.2.1 Permissible tensile loads

Althoughthegraphsareplotteduptocoreheightsof60mm,recentworkhasqueriedtheiraccuracy
forgreatercoreheights,[296].
Ascoreheightincreasesfromabout40mmto60mmtypically,thereisatransitionpointatwhichthe
insertbehaviourchangesfromfullypotted,i.e.smallcoreheights;toapartiallypottedresponseand
pottingrupture.
Abovethetransitionpoint,boththecalculatedminimumandaveragepermissibletensileloads,[296]
are lower than those shown on the design graphs. Table B1 summarises transition points for four
insertsandwichconfigurations,[296].
The difference between values can be between 20% and 60%, depending on the particular insert
sandwichpanelconfiguration.AnexampleisshowninTableB2.
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When the core height approaches 40 mm, the permissible tensile load is determined for all three
potting behaviours, i.e. fully potted, partially potted and potting rupture; and the lowest value
obtainedisapplied;asshowninTableB2.
NOTE This applies to tensile permissible loads only. Compression
permissibleloadsdonotshowsuchatransitioneffect.
TableB1:Coreheight:Permissibletensileloadstransitionpoints
Insert Facesheet Transitionpoint(1)
Core (mm) (mm) Coreheight(mm)
dia. height thickness Min. Ave.
3/1650560.0007 14 9 0.2 42 45
3/1650560.0007 14 9 0.4 43 46
3/1650560.0007 14 9 0.6 42 45
3/1650560.0007 14 9 0.8 38 44
NOTE (1) Transition from 'fully potted' to 'partially potted' behaviour.
TableB2:Coreheight:Examplepermissibletensileloads
Minimumtensilepermissibleload(N)
Method
Fullypotted Partiallypotted Pottingfailure
Calculated,[296] 2200 1748 1896
FromIDH,[297] 2200
NOTE Core: Type 3/16-5050-0.0007; height: 55 mm; Insert: diameter = 14 mm;
height = 9 mm; Face sheet thickness = 0.4 mm
B.2 Index to permissible-load graphs

TableB3listssomeofthetypicalcombinationsofhoneycombcoresusedinsandwichpanelsinwhich
insertsarepotted.
Thegraphsareaccessedbylinksinthecoredesignationcolumn,whichshowstheavailableplotsfor
standard inserts of various common sizes loaded in tension or compression. Links to each of the
individualgraphscanthenbeselected.
NOTE1 Not all available core and insert combinations are plotted, so the
graphsillustratethebehaviourofcommoninsertandsandwichpanel
combinations.
NOTE2 Allthegraphsarereproducedfromthepreviousversionoftheinsert
design handbook, [297]. Any errors in either the original graphs, or
resultingfromredrawing,meanthatthegraphscannottobeusedfor
designpurposeswithoutfurtherverification.
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TableB3:Designgraphs:Indextopermissiblestaticloads
CoreType CoreDesignation(1)
3/1650520.0007
3/1650520.001
1/850520.0007
1/850520.001
Aluminiumalloy
3/1650560.0007
3/1650560.001
1/850560.0007
1/850560.001
HRH103/162.0
HRH103/163.0
Nomex HRH103/164.0
(aramidtypefibre/phenolresin) HRH101/81.8
HRH101/83.0
HRH101/84.0
GFRP HRP3/164.0
(glassfibrereinforcedplastic) HRP3/165.5
NOTE(1)
Aluminiumalloy:cellsizecorealloyfoilthickness.
Nonmetallic:materialcellsizedensity.
B.3 References
B.3.1 General
[296] M.AGygax:ContravesSpace(CH):
ESAPSS031202Issue1Rev.1FaxcommunicationtoESTEC;October
1997
[297] ESAPSS031202(Issue1,Revision1)September1990:Insertdesign
handbook
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Annex C
Analytical determination
C.1 Introduction
TheanalysispresentedinAnnexCappliestothedeterminationofthestaticcapabilityofaninsertina
largesandwichpanel,withtheloadnormaltothepanel.
NOTE The principles discussed here relate to the MBBERNOderived
antiplane theory. An extended antiplane theory is presented in
AnnexD.
C.1.1 How to use the formula
C.1.1.1 Determine full or partial potting

The relationship between the insert height, potting height and the core height determine which
analyticalapproachisused.
Iftheinsertheighthiorthepottingheighthp coincidewiththecoreheightc,thentheinsertistruly
fullypotted.
TheinsertcapabilityPcritisdeterminedbyusingequationsgivenin:
C.2:(Eqn.[C.210]);(Eqn.[C.214]);(Eqn.[C.215]);(Eqn.[C.26]);(Eqn.[C.217]);
C.5: (Eqn. [C.51]) for compression load and thick facing sheets. If the insert height hi and,
especially, the potting height hp are smaller than the core height c, two insert capability values are
determined:
Pcritofanidenticalinsertsystemwhichisassumedtobefullypotted;
P p critofthepartiallypottedinsert,using:
C.3:(Eqn.[C.310]);(Eqn.[C.311]);
C.5:(Eqn.[C.52])forcompressionloadandthickfacesheets
Thelowervalueofinsertcapabilityisimportant:
Pcrit<Ppcrit:thepartiallypottedinsertbehaveslikeafullypottedinsert.
Ppcrit<Pcrit:thepartiallypottedinsertbehaveslikeapartiallypottedinsert.
[Seealso:FigureC1andFigureC2]
C.1.2 Potting resin

Thepottingresinfailsif,simultaneously:
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PRcrit<Pcrit,and
PRcrit<Ppcrit
Tensile rupture of the potting resin should be avoided. This is described in C.3 and C.4; using
supplementaryequations:(Eqn.[C.311]);(Eqn.[C.43]);(Eqn.[C.411]);(Eqn.[C.412]).
C.1.3 Validity of equations

The validity of the formulae presented in Annex C, based on those in [299] , [2910], have been
provenin[2911],[2912].
C.1.3.1 Boundary conditions

The equations cited, particularly the fundamental (Eqn. [C.21]), are valid independent of the outer
boundaryconditionsofthepanel,providedthatthepanelradius,a,islargeenough.
Ifa>2b,thecriticalareaneartheinsert,wheremaxoccurs,isdeterminedwithanacceptableaccuracy.
C.1.3.2 Clamped inserts

Theequationsarevalidonlyforaclampedinsert,whichistheusualcase.
C.2 Fully potted insert

NOTE See:C.1todeterminefullorpartialpotting.
Theshearstressdistributioninthecoreofacircularsandwichpanelwitharigid,centralandclamped
insertsubjectedtonormalloadisgivenby,[Seealso:12.2]:
P Ip 1 I 1 r b p K ( b p ) a K 1 ( a )
(r ) (
(h c) I r a b p I 1 ( a ) K 1 ( b p ) I 1 ( b p ) K 1 ( a )
K 1 ( r ) a I 1 ( a ) b p I 1 ( b p )
)
a b p I 1 ( a ) K 1 ( b p ) I 1 ( b p ) K 1 ( a )
[C.21]
Where:
(r) shearstressinthecoreatradiusr;asshowninFigureC1.
P appliedoutofplaneload
coreshearstress
ts facesheetthickness;assumedthatbothfacesheetsaresimilar
h totalsandwichthickness=c+ts1+ts2
outerradiusofpanel
bp effectivepottingradius
b R realpottingradius
Ip momentofinertiaofthepanel
ts1ts 2 (h c) 2
=
4(h c)
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Is momentofinertiaofthefacesheets
3 3
ts1 ts 2
=
12
I = Ip+Is
ratioofstiffnessbetweencoreandfacesheets
Gc (h c) I
=
E c t s1 t s 2 I s
Gc shearmodulusofthecore
Es
E =
1 s
2
I1(x), K1(x) Besselfunctions,wherex = r, a, b
:Fullypotted
insert
Forr,aandb >5,themodifiedBesselfunctionsbecometheexponentialfunctions:
e 2x
x 12
I1(x) =
[C.22]
= e 2 x
1
x 2
K1(x)
Substitutionof(Eqn.[C.22])into(Eqn.[C.21])gives:
r PI m
K [C.23]
bh c I
With:
b b e r b
e
a r b
a e a r
e
a r

K 1 r
e
a b a a b
[C.24]
r ab e
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Or:
b b sinh r b a sinh a r
K 1 r [C.25]
r ab sinh a b
Forr < a, agoodapproximationforKis:
b r b r
be
K 1 [C.26]
r
Forf'=f,byrearrangementoftheequations:
Im=
f c f 2
2

3
If=
f 6

f c 2 cf 2 f 3
2 2
I=

1 G c
12 1 2 1 32
2
[C.27]
f E f
f
P 1
(r ) K
2 bc
2
2 4 3 [C.28]
With:
=c/f [C.29]
For10,i.e.c10mmandf1mm,(Eqn.[C.27])and(Eqn.[C.28])canbeapproximatedby:

1 G c
12 1 1 2 2
[C.210]
f E f
f
P
(r ) K [C.211]
2 bc 1
Withanerroroflessthan0.5%.
Thecoreshearstressdistributioncanbeexpressedby:
*
(r ) nom C K [C.212]
With:
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nom p / 2 bc [C.213]
C* / ( 1) [C.214]
b r b r
be
K 1 [C.26]
r
r max b
1 e c 2 ( b ) n
[C.215]
With:
c2 =0.931714
n =0.262866
Thevalueofr maxisusedin(Eqn.[C.26])toobtainKmaxthatisusedin(Eqn.[C.21])togive:
max nom C * K max [C.216]
Ifmaxreachesthecoreshearstrength C crit,theinsertcapabilityisgivenby:
pcrit 2bc c crit C *K max [C.217]
NOTE Eqn.[C.217]isvalidforbothtensileandcompressiveloads.
C.3 Partial potting

Theevaluationcoverspartiallypottedinsertsin:
Metalliccore;
Nonmetalliccore,e.g.GFRP,Nomex.
NOTE See:C.1todeterminefullorpartialpotting.
See:C.2forfullypottedinsert.
C.3.1 Metallic core

Forapartiallypottedinsertinanaluminiumcore,theloadPp appliedtotheinsertsandwichsystem
hasthreecomponentparts,asshowninFigureC2:
PF:loadcomponentcarriedbytheupperfacesheet;
PS :loadcomponentcarriedasshearstressinthecorearoundthepotting;
PN :loadcomponentcarriedbynormalstressinthecoreunderthepotting.
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FigureC2:Partiallypottedinsert
Theseloadcomponentsaregivenby:
PF
P max 2r max c max [C.31]
2
Ps 2r max hp max [C.32]
PN r2max c [C.33]
With:
P max 2 bc max (C * K max ) [C.34]
Thisistheloadofafullypottedinsert correspondingto max,whichbecomesPcrit

formax=ccritfrom(Eqn.[C.217]).
where:
rmax=distanceofmaximumcoreshearstrengthfrominsertcentre,from(Eqn.[C.215])
c =normalstressinthecorebeneaththepotting;
whichare:
ct=tensilestressfortensileload;
cc=compressivestressforcompressiveload.
hp =pottingheight.
Foraninsertwithaheightofh i ,theminimumpottingheightnecessaryis:
hp min hi 7 mm [C.35]
NOTE 7mmisusedwhateverthecoreheight,c.
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Thetypicalvalueofh pdependsonthecoreheight:
hp min A tanh(c hmin )
hp typ [C.36]
hp min
Where:
A=5 forcellsizeSC=4.8mm(1/8core);
A=2.5 forcellsizeSC=3.2mm(3/16core).
tanhisahyperbolictangent
NOTE Eqn.[C.36]isonlyvalidforpartialpotting,i.e.c > h i+7mm.
PS :islimitedbythecoreshearstrength c crit.
PN :islimitedbythecore:
tensilestrengthc crit t;
compressivestrengthc crit c;
Theoretically,foralinearbehaviour,thetwofailuremodesdonotoccurtogether,i.e.:
shearrupture;
tensile(orcompressive)ruptureofcore.
But in reality, owing to nonlinearity effects, the shear strength and the tensile (or compressive)
strengthofthecorearereachedtogether.
Thereforethecomponentsofthecriticalloadofpartiallypottedinsertsare:
PF crit Pcrit 2 r max c c crit 2 [C.37]
PS crit 2r max hp c crit [C.38]
PN crit r2max c crit [C.39]
Where:
crit=ccrittfortensileload;
crit=ccritcforcompressiveload.
Thus,thecapabilityofapartiallypottedinsertisgivenby:
Pp crit 12 Pcrit r max (2h p c) c crit r2max c crit [C.310]
C.3.2 Non-metallic core

Owing to the inability of rigid, nonmetallic cores, e.g. GFRP and Nomex, to distribute stress
concentrationsbydeforminglocally, the insertcapabilityonlyincreasesslightlyforconstanthpwith
increasingcoreheight,c.
Thestressconcentrationforapartiallypottedinsertisconsideredtobeconservativelycoveredby:
1
Pss pp Pss fp [C.311]
K t pp
Where:
Psspp=Permissibleloadofapartiallypottedinsert(hp<c).
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From(Eqn.[C.217]):
2bp c c crit
Pss pf [C.312]
C * K max
Where:
Psspf=Permissibleloadofapartiallypottedinsert(hp=c).
0.62
1 hp
[C.313]
K t pp c
Where:
1/Ktpp=Stressconcentrationfactor.
For c > 2.5 h p , the permissible load of a partially potted insert in a nonmetallic core is considered
quasilinear.
C.4 Potting failure

Theanalysiscoversfailureofthepottingresinunderneathaninsert,for:
Partialpotting;
Heavycoreshavinghightensilestrengths:
metallic(seeC.4.1)aluminium;
nonmetallic(seeC.4.1.2),e.g.GFRP,Nomex.
NOTE Thistypeoffailureonlyoccursundertensileload.
C.4.1 Heavy metal core

TheloadPR appliedtoaninsertsandwichsystemhasthreecomponentparts,[Seealso:C.3;FigureC2]:
PF :loadcomponentcarriedbytheupperfacesheet,givenby:
PF 12 ( P max 2r max c max ) [C.31]
PSR : load component carried as shear stress in the core around the potting, over the insert
height,givenby:
PSR 2r max hi max [C.41]
PNR :loadcomponentcarriedbynormalstressinthepottingresinundertheinsert:
PNR bR2 R [C.42]
Where:
hi=insertheight;
bR=realpottingradius,[See:Note];
R=tensilestrengthofthepotting;
PR=PF+PSR+PNR [C.43]
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NOTE bR isnotidenticaltotheequivalentpottingradius,binC.2,[Seealso:
7.4].
PNRcanalsobeexpressedby:
PF ( PR 2 PF )(c hi )
PNR
c [C.44]
PF (1 2 ) PR
Where:
c h c
i
[C.45]
PF PNR 1 2 PR 1 2 [C.46]
C.4.1.2 Spreadsheet users

NOTE Eqn. [C.46] becomes singular when c = 2 hi and can produce a
dividebyzeroerrorwhenusingaspreadsheet.
Users of spread sheettype applications are advised to use an
alternativederivationforPR ,[298].
[See:NotesforspreadsheetusersDerivationofPR]
Using(Eqn.[C.217])and(Eqn.[C.311]), PSRcanbeexpressedintermsofPRby:

PR 2bc C *max
K max
[C.47]
2 max PRC * K max b1c [C.48]
PSR 2r max hi max [C.49]
hi
PSR PRC * K max r max b c
[C.410]
When(Eqn.[C.46])and(Eqn.[C.410])aresubstitutedinto(Eqn.[C.43]),thecriticalinsertloadunder
whichthepottingresinfailsisgivenby:
PR crit 2 PNR crit

1
1 2

[C.411]
1
1 2 C *K max r max hi
bc
Where:
PNR crit = bR2 R crit [C.412]
Rcrit=tensilestrengthofpottingresin.
C.4.2 Heavy non-metallic core

ThepermissibleloadPSSappliedtotheinsertsandwichsystemisdeterminedby,[See:C.3]:
Pss pp Pss fp 1
K t pp
[C.311]
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where:
PSSfp=Permissibleloadofapartiallypottedinsert(hp<c).
2bp c c crit
Pss fp [C.312]
C * K max
0.62
1 h
p [C.313]
K t pp c
PSSppisquasiconstantforc>2.5hp.
Pottingfailureofaninsertinanonmetalliccoreisconsideredtooccurwhen:
Pss pp bR2 R crit [C.413]
where:
bR=realpottingradius;
Rcrit=tensilestrengthofpottingresin.
C.4.3 Notes for spreadsheet users - Derivation of PR

Intheanalysisofpottingfailure,[See:C.4],(Eqn.[C.46])becomessingularwhenc = 2 hi
This can produce a divide by zero error when using a spread sheet. Users of spreadsheettype
applicationsarethereforeadvisedtousethisalternativederivationofPR ,[298].
From(Eqn.[C.217]):
2bc
PR max
C * K max
PRC * K max
Hence max
2bc
From(Eqn.[C.31]):
2bc 2c
PF max max r max
2C * K max 2
bc
Hence PF max c r max
C * K max
From(Eqn[C.41]):
PSR 2hi max r max
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PRC * K max
Hence PSR 2r max hi
2bc
From(Eqn.[C.43]):
PR PF PSP PNR
1 C * K max c
Hence PNR PR r max hi
2 bc 2
From(Eqn.[C.42]):
PNR bR2 R
Rearrangingtheabove,gives:
bR2 R
PR
0.5 C
* K max
bc
r c
max 2 hi
Thusatc = 2 hi
bR2 R
PR
0.5
C.5 Compressive loading

This analysis applies to compressivelyloaded inserts in sandwich panels having thick face sheets,
with:
Metalliccore;
Nonmetalliccore.
C.5.1 Metallic core

Undercompression,ifthethicknessofthealuminiumfacesheetislessthan0.6mm,thenitdoesnot
contributetotheinsertcapability.Thisisduetotensileruptureofthebondbetweenthecoreandthe
upperfacesheetneartheinsert.
Underthesecircumstances,theinsertcapabilityisreduced.
C.5.1.1 Fully potted inserts

Pcrit
Pcrit c 2
r max cc crit [C.51]
Where:
Pcritcomesfrom(Eqn[C.217])
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C.5.1.2 Partially potted inserts
Pp crit c 2r max h p max r2max c crit c [C.52]
C.5.2 Non-metallic core

Theinsertcapabilityisalsoreduced.
C.5.2.1 Fully potted inserts

P
Pcrit c crit r max c c crit [C.51]
2
Where:
Pcritcomesfrom(Eqn.[C.217])
C.5.2.2 Partially potted inserts

P 1
Pcrit c crit r max c c crit [C.53]
2 K t pp
Where:
0.62
1 hp
[C.313]
K t pp c
C.6 Reliability
C.6.1 Correlation coefficients

Comparisonofthetheoreticalanalysiswithtestresults,[2911],providedcorrelationcoefficients,CC
for the various cases considered in Annex C; as given in Table C1, where: CC = Pcrit test / Pcrit
theory
TableC1:Correlationcoefficients
Correlation Standard
Potting Appliedload coefficient deviation
(CC)(1) (G)
Fullypottedinsert,orbehavingas Tensile
0.993 0.059
fullypotted(2) Compressive
Partiallypotted Tensile 1.043 0.52
Partiallypotted Compressive 0.998 0.072
NOTE (1) CC=Pcrittest/Pcrittheory
NOTE (2) Seealso:C.1todeterminefullorpartialpotting.
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C.6.2 Reliability coefficients

Toensureareliabilityof99%,thetheoreticalvaluesaremultipliedbythereliabilitycoefficient,RC.
TheminimumandaveragesvaluesaregiveninTableC2,[2911].
TableC2:Reliabilitycoefficients
Tensile Tensile Compressive
Metallicun
perforated Metallic
Core Metallicperforated
GFRP (alltypes)
Nomex
Minimumvalue:
RC =1.1720.0063.c0.2641.f 0.91 0.89
Averagevalue:
RC =1.2070.00544.c0.2088.f 1 1
NOTEc=coreheight,formerlyshownashc,inPSSIDH[2913].
C.7 References
C.7.1 General
[298] S.BrownESTECYME/SIIKOSS(Fax1997)
[299] Erickson,W.S.Thebendingofacircularsandwichplateundernormal
load,ForestProductsLaboratoryReportNo.1828(1953)
[2910] Young,W.S.andKuenzi,E.W.Stressesincludedinasandwichpanelby
loadappliedataninsert,ForestProductsLaboratoryReportNo.1845
(1955)
sandwichelementsFinalReport.MBBERNO(3442/77/NL/PP)
sandwichelementsFinalReport.MBBERNO(3442/77/NL/PPRider1)
handbook
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Annex D
Estimation of static load-carrying
capability
D.1 Introduction
The approximation, presented in Annex D, applies to the determination of the static loadcarrying
capabilityofaninsertinalargesandwichpanel,[2914].
NOTE As far as loads normal to the sandwich panel are concerned, the
principlesdiscussedhererelatetoextendedantiplanetheory.
[See also: Annex C for analysis by MBBERNOderived antiplane
theory]
D.1.1 Background
Thegeneralproblemofanalysingasandwichpanelloadedthroughaninsertisdifficult,[See:section
8]. The constituent parts of the sandwich panel interact in complex ways in the regions close to the
insert; hence in the active loadtransfer mechanisms appear to be very complicated. Much of this
results from local changes in the sandwich panel. The individual face sheets of the sandwich panel
tend to bend about their own neutral planes rather than about the neutral plane of the sandwich
panel.
Fromthepointofviewofpracticaldesign,theevidentconclusionisthatclassicalantiplanesandwich
theory, which is very simple, generally cannot be used for predicting the loadbearing capability of
sandwichplateswithinsertssubjectedtoarbitraryexternalloads.
Thereis,however,oneveryimportantexceptiontothis.Inthecaseofsandwichpanels withinserts
loadednormaltotheplaneofthesandwichpanel(tensileorcompressiveloading),theactivefailure
mechanismisnearlyalwaysshearruptureofthehoneycombcoreattheinterfacebetweenthepotting
andthehoneycomb;especiallybyshearruptureoftheundoubledcorefoils.
The peak shear stress in the honeycomb material is located exactly at the pottingtohoneycomb
interface, and this stress component is predicted with sufficient accuracy by classical antiplane
sandwich theory, [[2915] to [2918], [2925]; provided that the correct location is assumed for peak
shearstress,r = bp.
D.1.2 How to use the formulae
D.1.2.1 Determine full or partial potting

Iftheinsertheighthi orthepottingheighthpcoincidewiththecoreheightc,theinsertisthroughthe
thicknessorfullypotted.Then,thestaticloadcarryingcapabilityPcrit canbedeterminedby:
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Tension,[See:D.3;Eqn.[D.32]];
Compressionloadingandthickfacesheets,[See:D.6;Eqn.0].
If the insert height hi and, especially, the potting height hp are smaller than the core height c, two
quantitieshavetobedetermined:
The static loadcarrying capability, Pcrit of an identical insert system, which is assumed to be
fullypotted(throughthethickness)usingexpressions:
tension:(Eqn.[D.32]),or
compression:(Eqn.0).
Thestaticloadcarryingcapability,Pp crit ofthepartiallypottedinsertusingexpressionsfor:
tension,[See:D.4]:aluminiumcore:(Eqn.[D.410]);nonmetalliccore:(Eqn.[D.411]).
compression and thick face sheets, [See: D.6]: aluminium core: (Eqn. [D.61]); non
metalliccore:(Eqn.[D.62]).
NOTE Thelowerofthetwoinsertstrengthpredictionsisused.
IfPcrit < Pp crit,apartiallypottedinsertbehaveslikeafullypotted(throughthethickness)insert.
IfPcrit > Pp crit,thenthepartiallypottedinsertbehaveslikeatruepartiallypottedinsert.
In addition to the above design calculations, it is necessary to ensure that tensile rupture does not
occurinthepottingresinunderneaththeinsertorunderneaththepotting.
Thiscanbedeterminedusingtheexpressions:
aluminiumcore,[See:D.5;Eqn.[D.59]];
nonmetalliccore,[See:D.5;Eqn.[D.511]].
D.2 Out of plane loading

Onlytheshearstressesinthesandwichplateareneeded,[See:D.1].Todeterminetheshearstressesin
alargesandwichplatewithaninsertsubjectedtooutofplaneloading,itisnecessarytoextendthe
resultsofthesimpleantiplanesandwichbeamtheory,[Seesection:8].
The necessary extension of the classical antiplane sandwich beam theory is easily achieved for the
caseofcircularsandwichplatesubjectedtoaxisymmetricloading;fromtheoryin[2918].
Inthemodelling,itisassumedthattheinsertofradiusbiisaninfinitelyrigidbody,butthatboththe
potting compound and the honeycomb core are deformable in shear. This assumption is very
importantbecauseaninfinitelyrigidpottingcompound(whichissometimessuggestedandapplied)
leadstotheincorrectpredictionofzeroshearstressesatthepottingtohoneycombinterface.
NOTE Thepeakhoneycombcoreshearstressoccursexactlyatthepottingto
honeycombinterface.
Figure D1 shows a circularsandwichplate with dissimilarfacesheets with thicknesses f1 (top face)
and f2 (bottom face), and with elastic moduli Ef1 (top face) and Ef2 (bottom face), subjected to an
axisymmetricloadingPappliedthroughacentralthroughthethicknessinsert.
Forthiscase,theradialtransverseshearstressresultantQr(r),whichmaintainstheequilibriumwith
theexternallyappliedloadP,canbeexpressedinthesimpleform:
P
Qr ( r ) , r bi [D.21]
2r
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FigureD1Outofplaneloading:Circularsandwichplatewith
throughthethicknessinsert
Assumingthatthe elastic modulusofthecore,i.e.pottingand honeycomb,ismuchsmallerthanthe
elasticmoduliofthefacesheets,i.e.Ec<<Ef1, Ef2(effectivelyassumingtheinplanestiffnessofthecore
tobeEc 0,i.e.antiplanecore),thecoreshearstressisnearlyconstantovertheheightofthecore,and
thefacesheetshearstressesvaryparabolicallyoverthefacesheetthicknesses.
The shear stresses in the core and in the face sheets can be calculated using the approximate
expressions,where rbi,[See:FigureD1].
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Qr (r ) E f 1 f1 E f 2 f 2 d
c (r )
D E f 1 f1 E f 2 f 2

P E f 1 f1 E f 2 f 2 d

2rD E f 1 f1 E f 2 f 2
Qr (r) E f 1
2
f
f 1(r, z) (d e) 1 z
2
D 2 2
[D.22]
P E f 1
2
f1
(d e) z2
2rD 2 2
f1 f
(d e) z (d e) 1
2 2
Qr (r) E f 2 f2
2

f 2 (r, z) e z
2
D 2 2

P E f 2 f2
2
e z
2
2rD 2 2
f2 f
e z e 2
2 2
where:
c(r) =core(pottingcompoundandhoneycombcore)shearstress.
f1(r,z) =shearstressintopfacesheet.
f2(r,z) =shearstressinbottomfacesheet.
z =thicknesscoordinatemeasuredfromtheneutralsurfaceofthecore.
c =corethickness.
d =d=f1/2+c+f2/2;distancebetweenthefacesheetmiddlesurfaces.
e eEf1f1d/(Ef1f1+Ef2f2);distancefromneutralsurfaceofthecoretothemiddle
surfaceofthebottomfacesheet.
f1 =thicknessesoftopfacesheet.
f2 =thicknessesofbottomfacesheet.
Ef1 =elasticmodulioftopfacesheet.
Ef2 =elasticmoduliofbottomfacesheet.
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ForEc<<Ef1,Ef2,thesandwichplatestiffnessD(Eqn.[D.22])canbeapproximatedby:
E f 1 f f31 E f 2 f f32 E f 1 f1 E f 2 f 2 d 2
D [D.23]
12(1 f 1 ) 12(1 f 2 ) E f 1 f1 E f 2 f 2
2 2
where:
f1, f2 = Poissons ratios of the face sheet materials.

Assumingfurtherthatthethicknessofthecoreismuchlargerthanthethicknessofthefacesheets,i.e.
c>>f1, f2, the two first terms in the expression for D in (Eqn. [D.23]) vanish, and the approximate
expressionsforthecoreandfacesheetshearstressesarefound(againwhererbi)by:
Qr (r ) P
c (r )
d 2rd

P 1 f
f 1 (r , z ) ( d e) 1 z
2rD f1 2
f1 f
( d e) z ( d e) 1
2 2
P 1 f
f 2 (r , z ) e 2 z
2rD f 2 2
f2 f
e z e 2 [D.24]
2 2
From(Eqn.[D.24]),itisseenthat:
cisconstantovertheheightofthecore,and
f1,f2approximatelyvarieslinearlyoverthethicknessofthefacesheets.
externalload,Piscarriedprimarilybythecorematerial,and
cisproportionalto1/r,i.e:
cdisplaysahyperbolicdependencyoftheradialcoordinater,[See:FigureD1].
The approximations imposed in the derivation of (Eqn. [D.24]), i.e. that Ec<<Ef and c>>f1, f2, are
nearlyalwaysfulfilledforsandwichpanelsforspaceapplications.
Theresultsobtainedusing(Eqn.[D.24])arethereforesufficientlyaccuratefordesignpurposes.
D.3 Fully potted inserts

Forsandwichplateswithinsertsofthefullypottedorthroughthethicknesstypes,[See:FigureD1],
failureusuallyoccursinthehoneycombcorenexttothepottingtohoneycombinterface(r=bp),where
thecoreshearstressinthehoneycombreachamaximumc max[[2919],[2920]].
[Seealso:Clause8forbasicmechanicsofsandwichstructures]
NOTE Shear stresses in the potting compound are larger than in the
honeycombcore,[See:D.2;Eqn.[D.24]],butasthepottingcompound
displays much higher shear strength than the honeycomb, failure
usuallyoccursinthehoneycombcore.
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Atthislocation,thecoreshearstresscanbecalculatedusingthefirstpartof(Eqn.[D.24]).Theresult
obtainedis:
P P
cmax c (r bp ) [D.31]
2bp d 2bp d
Failureoccurswhen c max reachesthecoreshearstrength c crit,andthestaticloadcarryingcapability
Pcrit canbeestimatedby:
Pcrit 2bp d c crit [D.32]
NOTE (Eqn. [D.32]) is valid for both tensile and compressive outofplane
loading,P.
D.4 Partially potted inserts

Apartiallypottedinsert,i.e. c>hpsubjectedtoanoutofplaneloadPp isshowninFigureD2.
Forthiscase,thecoreunderneaththepottingissubjectedtotensileorcompressivestresses.
NOTE LoadP,wheresubscript'p'referstoapartiallypottedinsert.
FigureD2:Partiallypottedinsert:outofplaneloading
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D.4.2 Aluminium honeycomb core

For aluminium cores, the tensile stresses underneath the potting increase for constant hp with
increasing core height c, or rather with increasing d (d=f1/2+c+f2/2 increases with increasing core
height,c).
However, up to a certain value of d, failure still occurs due to shear rupture of the core next to the
potting, and the static load carrying capability Pcrit still increases linearly with d; as predicted in by
(Eqn.[D.32]),[See:D.3].
Althoughpartiallypotted,theinsertexhibitsthesamebehaviourasthatofafullypottedorthrough
thethicknessinsert,[2919];[2920].
If (chp) attains a certain limit, [See: Figure D.04.1], the tensile or compressive stress underneath the
pottingreachesthetensileorcompressivestrengthofthecore,c crit t /c crit c;[See:6.6and6.7].
Forlargercoreheights,shearruptureofthehoneycombaroundthepottingandtensileorcompressive
failureofthecoreunderneaththeinsertoccursimultaneously,[2919];[2920].
Thus,thestatic loadcarryingcapabilityissimultaneouslylimitedbyc critandc crit t orc crit c,andis
practicallyindependentoffurtherincreaseincoreheight.
The outofplane load Pp applied to the insertsandwich plate system can be divided into three
contributingparts,[See:FigureD2]:
Pp = Pf + Ps + Pn [D.41]
where:
Pf Loadpartcarriedbytheupperfacesheet.
NOTE It is assumed that the upper and lower face sheets, despite the
possibledifferencesinmaterialpropertiesandthicknesses,carryloads
ofequalmagnitude.
Ps Loadpartcarriedbyshearstressesinthecorearoundthepotting.
Pn Loadpartcarriedbynormalstresses inthehoneycombcoreunderneaththe
pottingmaterial.
NOTE Pfisusuallyquitesmall,comparedwithPs ,forf1, f2<<c,aspredicted
by(Eqn.[D.24]);[See:D.2]
ThecontributingloadpartsPf,Ps andPncanbeestimatedbytheexpressions:
Pf
P c max 2b p c c max [D.42]
2
Ps 2bp hp cmax [D.43]
Pn bp c
2
[D.44]
where:
P cmax 2bp d cmax
Loadcarriedbyfullypottedinsert,correspondingtocmax.
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PcmaxbecomesPcritforcmax=ccritaccordingto(Eqn.[D.32]).
c Normal stress in the honeycomb core underneath the potting, which is

assumedtobeuniformovertheareaofthepottingcompound(bp2).
NOTE ctfortensilenormalstresses.
ccforcompressivenormalstresses.
hp Pottingheight.
For an insert with height hi [See: Figure D2], the minimum potting height hp min needed can be
specifiedbytheempiricalresult[2919];[2920]:
hp min hi 7 mm (whateverthecoreheightc) [D.45]
Empirically,ithasbeenfoundthatthetypicalvalueofhp dependsonthecoreheightc,accordingto,
[2919];[2920]:
c hp min
hp typ hp min A tanh [D.46]
hp min

where:
A=5forhoneycombcellsizeSc=4.8mm(3/16core)
A=2.5forhoneycombcellsizeSc=3.2mm(1/8core)
NOTE (Eqn. [D.46]) is valid for partial potting only, i.e. for c > hi + 7 mm,
[2919];[2920].
Furthermore:
NOTE Psislimitedbythecoreshearstrengthc crit.
Pnislimitedbyeither:
coretensilestrengthc crit t,or
corecompressivestrengthc crit c.
Theoretically,thetwofailuremodesdonotoccursimultaneously,i.e.
Shearrupture,and
Tensileorcompressivecorerupture.
Inreality,theshearstrengthandthetensileorcompressivestrengthofthecorearereached(almost)
simultaneouslyduetononlineareffects,[2919];[2920].
Thus,theloadcomponentsofthecriticalload,Pp crit,forapartiallypottedinsertinasandwichplate
canbeexpressedas:
Pf crit
P
crit 2bp c ccrit
[D.47]
2
Pscrit 2bp hp ccrit [D.48]
Pncrit bp ccrit
2
[D.49]
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where:
ccritt for tensile loading

ccrit [D.410]
ccritc for compressive loading
Using(Eqns.[D.47]to[D.49]),thestaticloadcarryingcapabilityPpcritforapartiallypottedinsertina
largesandwichplatecanbewrittenas:
bp 2hp c ccrit bp2 ccrit

Pcrit
Ppcrit [D.411]
2
Pcrit, which represents the static loadcarrying capability of a fully potted (throughthethickness)
insertinalargesandwichplate,isgivenby(Eqn.[D.32]).
D.4.3 Non-metallic honeycomb cores

Foranonmetalliccore,e.g.NomexorGFRP,thestaticloadcarryingcapabilityforconstanthp[See:
Figure D2], increases only slightly with increasing core height c (or rather with increasing
d=f1/2+c+f2/2).
Thereasonforthisisthatrigidnonmetalliccorescannotadequatelyredistributestressconcentrations
bymeansoflocaldeformations,[2919];[2920].
Anapproximaterelationcanbe usedtoestimatethepermissibleloadonapartiallypottedinsertina
sandwichplatewithnonmetalliccore,using,[2919];[2920]:
Pcrit
Ppnon metallic [D.412]
K tpp
where:
Pcrit Static loadcarrying capability of a fully potted (throughthethickness)
insert,wherePcritisgivenby(Eqn.[D.32]).
Ktpp Empirical stress concentration factor for partial potting, [2919]; [2920],
where:
0.62
h
K tpp p [D.413]
c
(Eqn. D.04.12) provides a conservative estimate of the static loadcarrying capability of a partially
pottedinsertinasandwichplatewithnonmetalliccore,[2919];[2920].
Forc>2.5hpthepermissibleload,i.e.thestatic loadcarryingcapability,ofapartiallypottedinsertina
sandwich plate with nonmetallic core does not increase any further with increasing core thickness,
[2919];[2920].
D.5 Potting failure

Thepottingunderneathapartiallypottedinsertloadedinoutofplanetensionissubjectedtotensile
stresses.
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For a given insert height hi and a given potting height hp [See: Figure D2], these tensile potting
stressesincreasewithincreasingcorethickness,c.
For a certain core thickness, the tensile potting stresses, which are assumed to be uniformly
distributedunderneaththeinsert,canexceedthetensilestrengthR critofthepottingresinbeforethe
tensilestrengthofthehoneycombc crit t underneaththepottingisreached.Thisisthecaseforhigh
densityhoneycombcores,andmayalsooccurforfullypottedinserts,[2919];[2920].
A furtherincreaseofcorethicknesscresultsinaslightdecreaseoftheinsertloadbearingcapability
Pcrit,becausePcritforthisspecificfailuremodeisdeterminedbyR crit.
Owing to the relatively high rigidity of the potting compared with the honeycomb (the potting
materialisusually5to10timesstifferthanthehoneycomb),noadvantagecanbetakenfromthecore
shear strength, because the core shear stresses around the potting decrease with increasing core
thicknessc,[2919];[2920].
D.5.1 Partially potted inserts
D.5.1.1 High-density aluminium core

AsdescribedinD.4,theexternalloadapplied totheinsertsandwichplatesystemcanbedividedinto
threeparts:
NOTE HeretheloadisreferredtoasPR,whereRdenotesresin.
PR = Pf + PsR + PnR [D.51]
where:
Pf Loadpartcarriedbytheupperfacesheet.
PsR Load part carried by shear stresses in the core around the potting over the
heightoftheinsert.
PnR Load part carried by normal stresses in the potting resin underneath the
insert.
NOTE Pf isusuallyquitesmallcomparedwithPs,[See:D.4].
ThethreecontributingloadpartsPf,PsRandPnRcanbeestimatedby:
Pf
P c max 2bp c cmax [D.42]
2
PsR 2bp hi cmax [D.52]
PnR bR 2 R [D.53]
where:
R Tensilestressinthepottingresin,whichisassumedtobeuniformoverthe
areaofthepottingcompound(bR2).
bR Realpottingradius,[See:7.4].
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hi Insertheight.
NOTE bR is the radius of a circle with area equal to the real crosssectional
areaofthepotting.
bpistheeffectivepottingradius(analyticalquantitythatdescribesthe
radialinfluencezoneofthepottingresin).
[Seealso:7.2forpottingdimensions]
PnRcanberewrittenintheform:
c hi
PnR Pf ( PR 2 Pf )
c [D.54]
Pf (1 2 ) PR
PnR
Pf PR [D.55]
1 2 1 2
where:
c hi
[D.56]
c
PsRcanbeexpressedintermsofPR using(Eqn.[D.31]):
PR
PR 2bp d c max 2 c max [D.57]
bp d
Inserting(Eqn.[D.57])into(Eqn.[D.52])givesanexpressionforPsRintermsofPR:
hi
PsR 2bp hi c max PsR PR [D.58]
d
Introducing (Eqn. [D.55]) and (Eqn. [D.58]) into (Eqn. [D.51]) gives the critical tensile load PR crit
underwhichthepottingresinunderneaththeinsertfails(expressedintermsofPnR crit):
1

PRcrit 2PnRcrit 1 2 [D.59]
1 h
i
1 2 d
where:
PnRcrit bR2 Rcrit [D.510]
and:
Rcrit =Tensilestrengthofpottingresin.
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D.5.1.2 High-density non-metallic core
InD.4,apartiallypottedinsertinanonmetallichoneycombcoreisdescribed,e.g.NomexorGFRP.
Aconservativeestimateofthestaticloadcarryingcapability Pp non-metallicofsuchaninsertisgiven
in(Eqn.[D.412])and(Eqn.[D.413]),[2919];[2920].
Pottingfailureunderneaththeinsertinanonmetalliccoreisconsideredtooccurwhen:
PRnon metallic bR2 Rcrit [D.511]
Where:
bR =Realpottingradius,[See:7.4].
Rcrit =Tensilestrengthofpottingresin.
D.6 Compressive load: Additional criteria
D.6.1 Introduction
The upper face sheet does not contribute to the loadcarrying capability under compressive outof
planeload,ifthethicknessofthe(aluminium)facesheetexceeds0.6mm,[2919];[2920].
The reason for this is that tensile rupture of the bond between the core and the upper face sheet
adjacenttotheinsertisinduced.
Thus, in estimating the static loadcarrying capability it is necessary to neglect the loadcarrying
contributionoftheupperfacesheet,[2919];[2920].
NOTE This applies to inserts in sandwich plates with thick face sheets
subjectedtocompressiveoutofplaneloading.
D.6.2 Aluminium core
D.6.2.1 Fully potted insert

InviewofthecommentinD.6.1forafullypottedinsertinanaluminiumcore,thestaticloadcarrying
capabilityisreducedto:
Pcritc Pf crit Pscrit

P 2bp c ccrit

crit
2bp c ccrit
2
Pcrit
Pcritc bp c ccrit [D.61]
2
where:
Pf crit and Ps crit (with full core height) are introduced according to (Eqn.
[D.4-7]) and (Eqn. [D.4-8]).
Pcrit is given by (Eqn. [D.3-2]).
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D.6.2.2 Partially potted insert
Inasimilarmanner,thestaticloadcarryingcapabilityforapartiallypottedinsertisreducedto:
Ppcritc Pscrit Pncrit
[D.62]
Ppcritc 2bp hp ccrit bp ccrit
2
where:
PscritandPncrit arefrom(Eqn.[D.48])and(Eqn.[D.49]).
D.6.3 Non-metallic core
D.6.3.1 Fully potted insert

Thestaticloadcarryingcapabilitycanbeestimatedaccordingto(Eqn.[D.61]),[2919];[2920].
D.6.3.2 Partially potted insert

Thestaticloadcarryingcapabilityisreducedto,[2919];[2920]:
P 1
Pcrit c crit bp c ccrit [D.63]
2 K tpp
Where:
KtppStressconcentrationfactorforpartialpotting;asgivenby(Eqn.[D.413]).
D.7 Reliability considerations
D.7.1 Correlation coefficient

Comparisonofthetheoreticalwithtestresults,[2919];[2920],givesthecorrelationcoefficient,CC:
Pcrit test
CC [D.71]
Pcrit theory
Table D1 gives CC values for the various insert configurations.The correlation between test results
andtheoryisverygoodfor:
Fullypottedinsertsundertensileandcompressiveloading;
Partiallypottedinsertsundercompressiveloading.
However, the correlation with respect partially potted inserts under tensile loading is considerably
lessfavourable,asseenbythestandarddeviationonthecomparativeresults,[See:TableD1].
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TableD1:Correlationcoefficients
Correlation Standard
Insert Load
coefficient(CC) deviation(G)
Tensile
Fullypotted(1) 0.993 0.059
Compressive
Tensile 1.043 0.52
Partiallypotted
Compressive 0.998 0.072
NOTE(1)Includingthroughthethicknessandinsertsbehavinglikefullypottedinserts,
[Seealso:D.1fordeterminingpotting].
D.7.2 Reliability coefficient

To ensure a reliability of 99%, the theoreticallypredicted static loadcarrying capabilities are
multipliedbythereliabilitycoefficientRC,asgiveninTableD2,[2919];[2920].
TableD2:Reliabilitycoefficients
Reliabilitycoefficient(RC)
Core
Minimumvalue (2) Averagevalue(3)

RC 1.172 0.0063 c 0.2641 f RC 1.207 0.00544 c 0.2088 f
Aluminium,
Tensile(1)
Outofplaneloading
perforated [D.72] [D.73]

RC 0.91 RC 1.00
Others(4)
[D.74] [D.75]
Aluminium,
Compressive
perforated RC 0.89 RC 1.00

[D.76] [D.77]
Others(4)
NOTE(1) Assumingfacesheetsofidenticalthickness,i.e.f1=f2=f.
NOTE(2) Exceededbyaprobabilityof90%
NOTE(3) Exceededbyaprobabilityof50%
NOTE(4) e.g.unperforatedaluminium,NomexandGFRP.
D.7.2.2 Non-metallic cores

The analyticallypredicted, static loadcarrying capabilities of partially potted inserts in nonmetallic
coreshavebeensubjecttofarlesstestingthanthoseinmetalliccores,[2919];[2920].
Therefore,thepredictedstrengthsofpartiallypottedinsertsinnonmetalliccoresareonlytobeused
withcaution,andpreferablyforpreliminarydesignpurposesonly.
[Seealso:12.3forminimumandaveragevalues;12.4forsafetyfactors]
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D.8 Design graphs

Thesetofdesigngraphs,presentedinB.2,arebasedontheanalyticalexpressionsfor,[Seealso:B.1]:
Predictingstaticloadcarryingcapabilityofinsertssubjectedtooutofplaneloading,[See:D.1].
ReliabilitycoefficientsRC,[See:D.7;TableD2]
D.8.1 Static load-carrying capability

Thedesigngraphsprovidethestaticloadcarryingcapability Pssofinsertsinlargesandwichplates
subjectedtotensileorcompressiveoutofplaneloading,wherethestaticloadcarryingcapability Pss
is:
Pcritforthroughthethicknessandfullypottedinserts
[D.81]
Pss=RC
Ppcritforpartiallypottedinserts
Where:
PcritandPpcritaredeterminedaccordingtoD.1.
D.8.1.2 Core types

Fordifferentcoretypes,Pssisplottedasafunctionofthe:
Corethickness,c ;
Facesheetthickness,f;
Insertdiameter,di = 2bi.
NOTE Only sandwich configurations with face sheets of identical thickness
areincluded,i.e.(f1=f2=f).
D.8.1.3 Insert height

The insert capability design graphs have been established for a fixed insert height hi = 9 mm.
Although,theyarealsoapplicableforotherhivalues.
Amodificationofhishiftsthebreakinthecurvestowardslowerorhighercvaluesaccordingto,[29
19];[2920]:
C C hi hi [D.82]
where:
hi Basicinsertheight,i.e.hi=9mm.
hi* Newinsertheight.
C Coreheightatcurvebreakforbasicinsertheighthi.
C Newcvalueatcurvebreakcorrespondingtothenewinsertheighthi*.
*
NOTE The curve break in the design graph signifies a change of failure
modefromeither:
coresheartocorefailureunderneaththepotting,or
coresheartopottingfailureunderneaththeinsert.
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[Seealso:D.4;D.5and12.6formoreinformationonthisfailuremode
change]
Anincreaseinhi(fromhi =9mminthedesigngraphs)increasesthestaticloadcarryingcapabilityPss
forthosecaseswherefailureoccursinthe:
Coreunderneaththepotting,or
Pottingunderneaththeinsert.
NOTE Anincreaseinhi isespeciallyadvisedifapottingfailureunderneath
theinsertisexpected.
D.8.1.4 Average and minimum values

Pssaverageandminimumvaluesaregivenondesigngraphs,where:
Averagevalues: Pss andPss avarebasedonaverageproperties(exceededbyaprobabilityof

50%)ofthe:
coreshearstrength;
pottingdimensions;
modelcorrelationcoefficient,RC.
Minimum(lowerbound)values:Pss and Pss mincanberegardedasdesignAvalues(P=99%;

CL=95%)forallcaseswhere:
incominginspectionisperformed,[See:26.1];
mounting of the inserts: in accordance with manufacturing, [See: 23.1] and QA
procedures,[See:28.1].
NOTE See also: 12.3 for further details on average and minimum values of
Pss.
D.9 Other external loads

ThetheoreticaltreatmentofsandwichplateswithinsertsinAnnexDisbasedonclassicalantiplane
sandwich theory, [[2915], [2916], [2917], [2918]], i.e. the simplest possible sandwich plate theory,
extended with the assumption that the correct location for the peakshear stress isat the pottingto
honeycombinterface,i.e.r = bp.
[Seealso:Section8forthemechanicsofsandwichstructures]
The derived equations give a sensible approximation for the case of sandwich plates with inserts
subjectedtooutofplaneloading.
NOTE The validity of the equations is independent of the boundary
conditions specified along the outer radius of the considered
sandwich plate, provided that the sandwich plate radius is large
enough.
Usually,theresultsobtainedareofsufficientaccuracyiftheradiusoftheanalysedsandwichplateis
twicethepottingradius,i.e.ifa>2bp,[2919];[2920].
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D.9.1 Non-axisymmetric and twisting loads

Classical antiplane sandwich theory cannot be used for predicting either the load response or the
staticloadcarryingcapabilityformorecomplicatedloadingcases,i.e.casesofsandwichpanels with
insertssubjectedto:
Nonaxisymmetricloads,suchasinplaneorbendingmoments;
Twistingloads.
For such cases it is necessary to adoptmore refined modelling. This can be done by elaborate finite
element modelling, which is very costly, or alternatively by use of a higherorder sandwich plate
theory.
D.9.1.1 'Higher-order' theory

Higherorder sandwich plate theory has been specially developed and adapted for analysing
sandwichplateswithhardpointsintheformofinserts,[2921][2922][2924].
Unfortunately,theapplicationofthehigherordersandwichplatetheoryisrathercomplicateddueto
themathematicalcomplexityofthetheory,[Seealso:8.5].
To provide design engineers and stress analysts with access to the analysis model, modules for the
analysis of sandwich plates with throughthethickness, fully potted and partially potted inserts
undergeneralloadconditions,couldbeaddedtothesoftwarepackageESAComp.
NOTE ESAComp is a software package for the analysis and design of
composite laminates and structural elements, developed for the
European Space Agency and available from Componeering Inc., [29
23];[2925].
D.10 References
D.10.1 General
[2914] O.T.ThomsenCompConsult;Estimationoftheloadcarrying
capabilityofaninsertinalargesandwichpanel;ESTECContractNo.
10.983/94/NL/PPWorkOrderNo.6(March1996)
[2915] Plantema,F.J.SandwichConstructionJohnWiley&Sons,NewYork,
USA,1966
[2916] Allen,H.G. AnalysisandDesignofStructuralSandwichPanels
PergamonPress,Oxford,UK,1969
[2917] Stamm,K.andWitte,H. Sandwichkonstruktionen(inGerman);
SpringerVerlag,Wien,Austria,1974
[2918] Zenkert,D. AnIntroductiontoSandwichConstructionEMAS
Publishing,WestMidlands,UK,1995
StructuresDepartment,Bremen,Germany. StandardisationProgramme
forDesignandTestingofInserts;ESACR(P)1498.ESAContractNo.
3442/77/NL/PP(1981)
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[2920] W.PaulandD.WagnerERNORaumfahrttechnikGmbH,Structures
Department,Bremen,Germany.StandardisationProgrammeforDesign
andTestingofInserts,RiderII;ESACR(P)1665.ESAContractNo.
3442/77/NL/PP)(1981)
[2921] Thomsen,O.T.AnalysisofSandwichPlateswithThroughthe
ThicknessInsertsUsingaHigherOrderSandwichPlateTheory
ESA/ESTECReportEWP1807(1994)
[2922] Thomsen,O.T.AnalysisofSandwichPlateswithFullyPottedInserts
UsingaHigherOrderSandwichPlateTheory;ESA/ESTECReportEWP
1827(1995)
[2923] Saarela,O.,PalanterM,.Hberle,J.andKlein,M.ESACOMP:A
PowerfulToolfortheAnalysisandDesignofCompositeMaterials;
ProceedingsoftheInternationalSymposiumonAdvancedMaterialsfor
LightweightStructures(ESAWPP070),ESTEC,Noordwijk,(March
1994),p.161169
[2924] Section8Referencesformorerecentworkonsandwichplatemechanics
byO.T.Thomsen,AalborgUniversity,DK.
[2925] M.Palanter:ComponeeringInc,Finland
ESACompprivatecommunication(2004)
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Annex E
IATP
E.1 Introduction
A summary is presented of test data generated under the ESTECfunded IATP insert allowable test
programme,conductedbetween1995and1997.
TheaimoftheprogrammewastoprovideinputforanESTECevaluationofthereliabilitycoefficient,
RCforselectedCFRPsandwichpanelconstructionsandinsertconfigurations,[2926];[2927].
Thesummarydescribes:
Materials,[See:E.2];
Testing,[See:E.3];
Data,[See:E.4].
NOTE Noanalysisofthereliabilitycoefficient,RCisgiven.
E.2 Materials
TableE1liststhevariousmaterialsusedinIATP2,[2927].
NOTE IATP2usedfullyqualifiedmaterialsfortheENVISATPolarPlatform
Program.
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TableE1:IATP:Materials
Item Type Specification
Fibre:60%2%
Resin:69%3%
Voids:<2%
Arealweight(g/m2):
prepreg:29515%
dryfabric:1958%
VICOTEX Volatile:2%(weight)
FIBREDUX914/34%/G829 ILSS: 40N/mm2(min)
Fabric NOTE:ContainsM40andT300carbon 45N/mm2(average)
fibres. 4POINTFLEXURAL
Strength:
480MPa(min)
600MPa(average)
Stiffness:
155GPa(min)
160GPa(average)
Compressivestrength:
HEXCELCRIII50563/16.0015 Stabilised:
Honeycomb Perf.Thickness45mm 3.38MN/m2(min)[490psi]
Perf.Thickness80mm Density:
70.48kg/m3[4.4lb/ft3]
Filmadhesive REDUX319L
Primer REDUX109
Potting Compressivestrength(average):
STYCAST1090/Catalyst9
compound 73MPa
StandardEquipmentUnitInsert: Singlesideinsert.
TypeEM6 Dia.:17.5mm;Length:15mm
Inserts(1) Throughspool
TypeFF6 Dia.:21.3mm;
Length=panelthickness
NOTE(1)AsdefinedinPPFMMS.
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E.3 Testing
IATPusedinhousetestmethods.FigureE1showsthetestjigfor:
sheartesting,[2926];
pullouttesting:testspeed1.5mm/min,[2926];[2927].
FigureE1:Manufacturecontrol:Inserttensilepullouttestfixture
[Seealso:27.3fortextfixturesandsamplesizes]
E.3.2 Shear test configurations

TableE2showsthevariousinsertsandwichpanelconfigurationscoveredinIATP1.
[Seealso:E.2formaterials;E.4;TableE4fortestdata]
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TableE2:IATP:Sheartestpanelconfigurations
Core Skin Insert
IATP/Case Height Thickness Dia.
Layup Type
(mm)(1) (mm) (mm)
1/7 20 1.08 (0,+60,60)s TypeF2thruspool 21.3
1/8 20 1.08 (0,+60,60)s TypeEM6 17.5
1/13 20(2) 2.47 notstated TypeF4thruspool 25/17.5
1/11 20(2) 4.32 notstated TypeF3thruspool 21.3

1/3 45 1.08 (0,+60,60)s TypeEM6 17.5
Type30mm
1/1 45 2.16 (0,+60,60)s2 17.5
counterbore
Fabriconly:
1/16 45 3.24 TypeEM6 17.5
(0,+60,60)s3
Fabriconly:
1/17 45 3.24 TypeF3thruspool 21.3
(0,+60,60)s3
Fabriconly:
1/4 45 4.86 TypeEM6 17.5
(0,+60,60)s4,(0,+60,60)
Fabriconly:
(0,+60,60)s4,(0,+60,60)
NOTE(1) Aluminium5056PType3/160.0015
E.3.3 Pull-out test configurations

TableE3showsthevariousinsertsandwichpanelconfigurationscoveredinIATP1and2.
[See:E.2formaterials;E.4;TableE5fortestdata]
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TableE3:IATP:Pullouttestpanelconfigurations
Core Skin Insert
IATP/Case Height Thickness Dia.
Layup Type
(mm) (1)
(mm) (mm)
1/10 20(2) 4.32 notstated TypeF3thruspool 21.3
1/2 45 1.08 (0,+60,60)s TypeEM6 17.5

1/Envi(3) 45 1.08 (0,+60,60)s TypeF1thruspool 21.3
1/Envi(3) 45 2.16 (0,+60,60)s2 TypeEM6 17.5
1/Envi(3) 45 2.16 (0,+60,60)s2 TypeF2thruspool 21.3
Fabriconly:
2/5 45 4.86 TypeEM6 17.5
(0,+60,60)s4,(0,+60,60)
Fabriconly:
(0,+60,60)s4,(0,+60,60)
2/3 80 1.08 (0,+60,60)s TypeEM6 17.5

Fabriconly:
2/1 80 4.86 TypeEM6 17.5
(0,+60,60)s4,(0,+60,60)
Fabriconly:
(0,+60,60)s4,(0,+60,60)
NOTE(3) FromKongsbergsENVISATvalidation.NodatagiveninTableE5.
E.4 Test data
E.4.1 Shear test data

TableE4summarisessheartestdata,[2926].
Inhousetestmethods;
Testspeed:0.5mm/min,[2926].

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TableE4:IATP:Sheartestdata
Core Skin Insert ShearLoadTestData(N)(4)
IATP/
Height Thickness Dia.
Case Layup Type Rm MeanRm SD
(mm)(1) (mm) (mm)
12250
15875
TypeF2
1/7 20 1.08 (0,+60,60)s 21.3 16000 15455 2000
thruspool
15400
17750
8625
6575
1/8 20 1.08 (0,+60,60)s TypeEM6 17.5 6600 7645 980
8250
8175
Def.load:
25200
22400
35200
28000 Def.load: Def.load:
TypeF3 24000 26960 5040
1/9(5) 20 1.08 (0,+60,60)s 21.3
thruspool Peakload: Peakload: Peakload:
46600 47575 2021
n/a
45200
49400
49100
36100
33900
TypeF4 25/
1/13 20(2) 2.47 notstated 32600 34180 1256
thruspool 17.5
34000
34300
Def.load:
27000
26000
25000
TypeF3 24000 25480 1119
1/11
(5) 20
(2) 4.32 notstated 21.3
48200 48880 482
49400
48600
49200
49000
Def.load:
29250
27400
30000
1/15 TypeF5 25/ 31000 29130 1461
(5)
20(2) 4.94 notstated
thruspool 17.5 Peakload: Peakload: Peakload:
46500 47400 3460
42700
48700
46900
52200
1/3 45 1.08 (0,+60,60)s TypeEM6 17.5 8250 8588 640
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IATP/
Case Layup Type Rm MeanRm SD
(mm)(1) (mm) (mm)
9613
8425
7725
8925
13900
13125
Type30mm
13550
1/1 45 2.16 (0,+60,60)s2 counterbore 17.5 13300 657
12300
M4std.
14200
12725
14250
13150
Fabriconly:
1/16 45 3.24 TypeEM6 17.5 13750 14500 1148
(0,+60,60)s3
15500
15850
48800
51600
Fabriconly: TypeF3
1/17 45 3.24 21.3 47900 48120 2244
(0,+60,60)s3 thruspool
47700
44600
14000
Fabriconly: 16550
1/4 45 4.86 (0,+60,60)s4, TypeEM6 17.5 14725 14750 1040
(0,+60,60) 14250
14255
Def.load:
n/a
44000
41750
Fabriconly:
TypeF1 40000 41138 2260
1/5(5) 45 4.86 (0,+60,60)s4, 21.3
(0,+60,60)
80375 74850 7593
77750
61500
78125
76500
NOTE(1)Aluminium5056PType3/160.0015
NOTE(3)FromKongsbergsENVISATvalidation
NOTE(4)Deflectionload:pointwhereloaddeflectioncurveisnolongerlinear(Rp).
Peakload:Max.load+clippingofbolts.
NOTE(5)Greyedconfigurationsdidnotmeetcalculatedallowable,[2926]
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E.4.2 Pull-out test data

TableE5summarisespullouttestdata,[2926];[2927].
Inhousetestmethods;
Testspeed1.0mm/min,[2926].
TableE5:IATP:Pullouttestdata
Core Skin Insert Pull-out Test Data (N) (4)
IATP/
Case Lay-up Type Mean Rm SD
(mm) (1) (mm) (mm)
Rm
6400
6375
Type F2
1/6 20 1.08 (0, +60, -60)s 21.3 6575 6625 270
thru'spool
7025
6750
16600
16925
Type F4 25 /
1/12 20 (2) 2.47 not stated 17075 16860 176
thru'spool 17.5
16900
16800
1st peak:
16000
n/a
18600
14300 1st peak: 1st peak:
1/10 Type F3 17500 16600 1867
20 (2) 4.32 not stated 21.3
(5) thru'spool Peak: Peak: Peak:
17300 19130 1980
20800
21250
16900
19400
22250(4)
30200
Type F4 25 /
1/14 20 (2) 4.94 not stated 28600 29400 655
thru'spool 17.5
29400
29400
6580
5560
Type E M6
1/2 45 1.08 (0, +60, -60)s 17.5 5970 6090 359
Single sided
5950
6390
1/Envi Type F1
45 1.08 (0, +60, -60)s 21.3 not stated
(3) thru'spool
1/Envi Type E M6
45 2.16 (0, +60, -60)s 2 17.5 not stated
(3) Single sided
1/Envi Type F2
45 2.16 (0, +60, -60)s 2 21.3 not stated
(3) thru'spool
5650
Fabric only: 6275
Type E M6
2/5 45 4.86 (0, +60, -60)s 17.5 6450 6055 330
Single sided
4, (0,+60,-60) 5800
6100
16425
Fabric only: 16350
Type F6
2/6 45 4.86 (0, +60, -60)s 21.3 16225 16295 330
thru'spool
4, (0,+60,-60) 16125
16350
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Core Skin Insert Pull-out Test Data (N) (4)

IATP/
Case Lay-up Type Mean Rm SD
(mm) (1) (mm) (mm)
Rm
7275
5850
Type E M6
2/3 80 1.08 (0, +60, -60)s 17.5 6925 6310 1176
Single sided
7050
4450
15550
11450
Type F6
2/4 80 1.08 (0, +60, -60)s 21.3 15100 13670 2107
thru'spool
11300
14950
6675
Fabric only: 6575
2/1 80 4.86 (0, +60, -60)s Type E M6 17.5 8550 6940 911
4, (0,+60,-60) 6300
6600
16800
Fabric only: 16350
Type F6
2/2 80 4.86 (0, +60, -60)s 21.3 15625 16345 477
thru'spool
4, (0,+60,-60) 16750
16200
NOTE(3)FromKongsbergsENVISATvalidation
NOTE(4)Aluminiumtestrigdeformedduringfirsttest;earlyfractureoftestsample.Newsteeltestrigusedforremaining
samples.
NOTE(5)Greyedconfigurationsdidnotmeetcalculatedallowable,[2926]
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E.4.3 Design allowables
E.4.3.1 Shear test

TableE6comparesIATP1sheartestdatawithdesignallowables,[2926],[2928].
TableE6:IATP:Sheartestresultsversusdesignallowables
IATP/
Height Thickness Dia. Design
Case Layup Type MeanRm SD
(mm)(1) (mm) (mm) Allowable
TypeF2
1/7 20 1.08 (0,+60,60)s 21.3 15455 2000 10560
thruspool
1/8 20 1.08 (0,+60,60)s TypeEM6 17.5 7645 980 3816
Def.load: Def.load:
1/9 TypeF3 26960 5040
(4)
20 1.08 (0,+60,60)s 21.3 42224
thruspool Peakload: Peakload:
47575 2021
TypeF4
1/13 20(2) 2.47 notstated 25/17.5 34180 1256 25000
thruspool
Def.load: Def.load:
1/11 TypeF3 25480 1119
(4)
20(2) 4.32 notstated 21.3 42224
48880 482
Def.load: Def.load:
1/15 TypeF5 29130 1461
(4)
20(2) 4.94 notstated 25/17.5 50000
47400 3460
1/3 45 1.08 (0,+60,60)s TypeEM6 17.5 8588 640 3818
Type30mm
1/1 45 2.16 (0,+60,60)s2 counterbore 17.5 13300 657 6311
M4std.
Fabriconly:
1/16 45 3.24 TypeEM6 17.5 14500 1148 8810
(0,+60,60)s3
Fabriconly: TypeF3
1/17 45 3.24 21.3 48120 2244 31668
(0,+60,60)sx3 thruspool
Fabriconly:
1/4 45 4.86 (0,+60,60)s4, TypeEM6 17.5 14750 1040 12553
(0,+60,60)
Def.load: Def.load:
Fabriconly:
1/5 TypeF1 41138 2260
(4)
45 4.86 (0,+60,60)s4, 21.3 48283
(0,+60,60)
74850 7593
NOTE(3) Deflectionload:pointwhereloaddeflectioncurveisnolongerlinear(Rp).
Peakload:Max.load+clippingofbolts.
NOTE(4) Greyedconfigurationsdidnotmeetcalculatedallowable,[2926]
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E.4.3.2 Pull-out test
TableE7comparesIATP1pullouttestdatawithdesignallowables,[2926],[2928].
TableE7:IATP:Pullouttestresultsversusdesignallowables
IATP/
Height Thickness Dia. Design
Case Layup Type MeanRm SD
(mm)(1) (mm) (mm) Allowable
TypeF2
1/6 20 1.08 (0,+60,60)s 21.3 6625 270 3408
thruspool
TypeF4
1/12 20(2) 2.47 notstated 25/17.5 16860 176 6270
thruspool
1stpeak: 1stpeak:
1/10 TypeF3 16600 1867
(5)
20(2) 4.32 notstated 21.3 20000
thruspool Peak: Peak:
19130 1980
TypeF4
1/14 20(2) 4.94 notstated 25/17.5 29400(4) 655 15100
thruspool
TypeEM6
1/2 45 1.08 (0,+60,60)s 17.5 6090 359 4770
Singlesided
Fabriconly:
TypeEM6
2/5 45 4.86 (0,+60,60)s4, 17.5 6055 330 notstated
Singlesided
(0,+60,60)
Fabriconly:
TypeF6
2/6 45 4.86 (0,+60,60)s4, 21.3 16295 330 notstated
thruspool
(0,+60,60)
TypeEM6
2/3 80 1.08 (0,+60,60)s 17.5 6310 1176 notstated
Singlesided
TypeF6
2/4 80 1.08 (0,+60,60)s 21.3 13670 2107 notstated
thruspool
Fabriconly:
2/1 80 4.86 (0,+60,60)s4, TypeEM6 17.5 6940 911 notstated
(0,+60,60)
Fabriconly:
TypeF6
2/2 80 4.86 (0,+60,60)s4, 21.3 16345 477 notstated
thruspool
(0,+60,60)
Def.load: Def.load:
Fabriconly:
TypeF1 41138 2260
1/5 45 4.86 (0,+60,60)s4, 21.3 48283
(0,+60,60)
74850 7593
NOTE(3) NodatafromKongsbergsENVISATvalidationstated,[2927].
NOTE(4) Aluminiumtestrigdeformedduringfirsttest;earlyfractureoftestsample.Newsteeltestrigusedfor
remainingsamples.
NOTE(5) Greyedconfigurationsdidnotmeetcalculatedallowable,[2926]
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E.4.4 General comments on IATP-2 pull-out test data

AlthoughnodetailedanalysisoftestdatawasmadeinIATP2,anumberofgeneralcommentswere
provided,[2927].
Loaddeflectioncurvesshowthatfacesheetbendingcorrespondswiththe70mmopeninginthepull
outtestrig.
E.4.4.1 Standard equipment unit inserts

Thegeneralcommentsprovidedwere,[2927]:
Loaddeflectioncurvesshowalinearrelationship.
Tensile failure occurs in the (Stycast) potting compound before a certain level of face sheet
bending.
Higherstiffnessprepregmayimprovethefacesheetstiffnesscontributiontotheoverallinsert
capability.
Facesheetthicknesshasaneffect,althoughtheSDvaluesmakeitdifficulttoquantify:
80 mm core thickness, showed a strength increase of ~10% max. Between a face sheet
thicknessof1.08mmand4.86mm.
45 mm core thickness, showed no apparent strength increase between a face sheet
thicknessof1.08mmand4.86mm.
Effectofcorethickness:Athickercore,i.e.80mmcomparedwith45mmprovidedonlyasmall
strengthincrease;afew%.
E.4.4.2 Through spool inserts

Thegeneralcommentsprovidedwere,[2927]:
Loaddeflectioncurvesaremorenonlinear,duetofacesheetbending.
Facesheetbendingoccursduetocompressiveloadsinthepottingcompound.
Facesheetthicknesshasaneffect,althoughtheSDvaluesmakeitdifficulttoquantify.
E.5 References
E.5.1 General
KongsbergGruppenReportNo.01TR68040906
(May1995)
KongsbergGruppenReportNo.02TR68040906
(October1997)
[2928] CommunicationfromMMStoKongsberg
PPFMMBTFX509(13thOctober,1994)
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Annex F
Case studies
F.1 Introduction
ThisclauseprovidesasummaryofinsertapplicationsthathavebeenappliedinsomeEuropeanspace
projects,ispresented,[2929],[2933].Thecasestudiesgiveinformationabout:
Materialsandconfiguration:
insert(s);
sandwichpanel(facesheets,core);
potting.
Testing:
methodandsample;
data.
NOTE Only axisymmetrical inserts subsequently installed in honeycomb
sandwichpanelsarecovered,i.e.cocuringofpanelsisexcluded.
Edge inserts and metallic fittings integrated within sandwich panels
arenotincluded.
ThecasestudyconcerningROSETTALanderalsoincludesmoregeneralaspectsofthenoveldesign
carbonfibretubeinsertsfrommorerecentevaluationstudies,[2933].
[Seealso:A.3]
F.1.1 European projects

TheEuropeanprojects,withtheircontractor,describedare:
ARIANE1equipmentbay(CASA):Sandwichpanels,withaluminiumalloyfacesheetsandan
aluminiumhoneycombcore,withstandardpottedShurlokinserts,[See:F.2];
ARIANE4equipmentbay(CASA):Sandwichpanels,withaluminiumalloyfacesheetsandan
aluminium honeycomb core, with standard Shurlok steel or special aluminium alloy potted
inserts,[See:F.3];
ASAP4(UTAIndustrie):Sandwichpanels,withaluminiumalloyfacesheetsandanaluminium
honeycombcore,withstandardShurloksteelorspecialaluminiumalloypottedinserts,[See:
F.4];
ASAP 5 (MMSUK): Sandwich panels, with aluminium alloy face sheets and an aluminium
honeycombcore,withspecialaluminiumalloypottedinserts,[See:F.5];
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ROSETTA Lander (DLR Braunschweig): Sandwich panels, with CFRP composite face sheets
andaluminiumhoneycombcorewithadhesivelybonded,novelcarbonfibretubeinserts,[See:
F.6;A.3].
SPOT5equipmentbay(SONACA):Sandwichpanels,withCFRPcompositefacesheetsanda
thick aluminium honeycomb core with standard Shurlok aluminium alloy or special
aluminiumalloypottedinserts,[See:F.7];
UMS (Arospatiale): Sandwich panels, with CFRP composite face sheets and an aluminium
honeycomb core, with standardShurlok aluminium alloy orspecialaluminium alloy potted
inserts,[See:F.8];
SILEX structure (MAN Technologie): Both standard, Shurlok and special aluminium alloy
potted inserts were used in composite CFRP sandwich panels with aluminium alloy
honeycombcores,[See:F.9];
HRG (MATRA Defense): Special aluminium alloy inserts were potted into sandwich panels
havingCFRPcompositefaceskinsandanaluminiumalloyhoneycombcore,[See:F.10];
NILESAT battery (BTS): Standard Shurlok and special aluminium alloy inserts potted into
sandwichpanelswithaluminiumalloyfacesheetsandhoneycombcore,[See:F.11].
Aworkedexampleoftheinsertverificationprocessisgivenforaboxmountedonasandwichpanel
usingpottedinsertsatthefourcorners,[See:F.12].
F.1.2 Information sources

TheinformationpresentedinAnnexForiginatesfrom:
MatraMarconiSpace,(MMSToulouseUnitmcaniquethermiqueetmatriaux):Limitedto
structuresthatMMShadchargeofthedefinitionfile,associatedjustificationdatapackageand
followupofmanufacturers,[2929].
NOTE EngineeringdrawingsreproducedcourtesyofMMS,[2929].Someof
theoriginalssuppliedareofapoorquality.
DLRBraunschweigledconsortium,includingDaimlerBenzAerospace(RSTRostock),Helsinki
University of Technology, Patria Finavicomp for ROSETTA Lander and subsequent ESA
fundedstudiesoncarbonfibretubeinserts,[[2930],[2931],[2932],[2933]].
Theworkedexampleistakenfromthepreviouseditionofthishandbook,[2934].
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F.2 ARIANE 1 Equipment Bay

Designconsistsofsandwichpanels,withaluminiumalloyfacesheetsandanaluminiumhoneycomb
core,withstandardpottedShurlokinsertsandtestedunderaxialload.
NOTE AlsoappliestoASAP4,[Seealso:F.4].
F.2.1 Materials and configuration

[See:TableF1]
TableF1:Casestudy:ARIANE1equipmentbay/ASAP4Allowabletensileload
F.2.2 Testing
F.2.2.1 Methods
Aschematicofthetensiletest(insertpullout)isshowninFigureF1.
FigureF1:Casestudy:ARIANE1equipmentbay/ASAP4tensile
(pullout)testmethod
F.2.2.2 Allowable tensile load

FigureF1summarisesthetestresults.
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F.3 ARIANE 4 Equipment Bay

The Design consists of sandwich panels, with aluminium alloy face sheets and an aluminium
honeycombcore,andusingstandardShurloksteelorspecialaluminiumalloypottedinserts.
Insertswerespeciallydesignedtowithstandtheloads.Axialloadsareoftenthemorecritical.Inserts,
inparticularfullypottedtypes,areusedtotransmitshearloads.

TableF2listsmaterialsandconfigurationexamples.
F.3.2 Testing
Testsamplescorrespondtothestructure.
F.3.2.1 Methods
Testingincluded:
Tensiletest(insertpullout),asshowninFigureF4.
Sheartest,asshowninFigureF5.
TableF2:Casestudy:ARIANE4materialsandconfiguration
Project ARIANE4Case1 ARIANE4Case2
Application Equipment Structure;handling
Insert: [See:FigureF2] [See:FigureF3]
Standard Special
Type
Partiallypotted Partiallypottedwithcollar
Ref. ShurlokSL607
Position(1) +0.1/0 +0.1/0
Material Steel Aluminium2024T4
Surfacetreatment Cadmiumplated Chromicanodised,notsealed
Thread Locking Stainless,locking
Lubrication Molicote(titaniumfixings) Molicote(titaniumfixings)
Potting: SLE3010LVC SLE3010LVC
Sandwichpanel:
Aluminium2014T6 Aluminium2014T6
Facesheets
Thickness:0.5mm Thickness:0.5mm
5056440perforated 5056440perforated
Core
Height:23mm Height:notstated
NOTE(1)Withrespecttosurface.
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FigureF2:Casestudy:ARIANE4Case1
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FigureF3:Casestudy:ARIANE4Case2
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FigureF4:Casestudy:ARIANE4tensile(pullout)testmethod
FigureF5:Casestudy:ARIANE4sheartestmethod
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TableF3summarisestensile(insertpullout)testresults.
TableF3:Casestudy:ARIANE4equipmentbayAllowabletensileload
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F.3.2.3 Allowable shear load
Table F-4 summarises shear test data.
TableF4:Casestudy:ARIANE4equipmentbayAllowableshearload
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F.4 ASAP 4
The design consists of sandwich panels, with aluminium alloy face sheets and an aluminium
honeycombcore,andusingstandardShurloksteelorspecialaluminiumalloypottedinserts.

F.4.2 Testing
F.4.2.1 Methods
Tensiletests(insertpullout)wereconductedon:
Singleinsert;asshowninFigureF1;
Group;asshowninFigureF8andFigureF9.
TableF5:Casestudy:ASAP4materialsandconfiguration
Project ASAP4(Ariane4)1 ASAP4(Ariane4)2
Application Structure;Equipment;I/FMicrosatellite. Structure

Standard Special
Type
Partiallypotted Fullypotted
Ref. ShurlokSL601M615.9S
Position(1) +0.1/0
Material Steel Aluminium2024T6
Surfacetreatment Cadmiumplated Chromicanodised,notsealed.
Thread Locking
Lubrication
Potting: SLE3010LVC SLE3010LVC+primer
Sandwichpanel:
Aluminium7075T6 Aluminium7075T6
Facesheets
Thickness:1mm Thickness:1mm
AG5440perforated AG5440perforated
Core
Height:40mm Height:40mm
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:Casestudy:ASAP4
(AR4)1
FigureF7:Casestudy:ASAP4(AR4)2
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FigureF8:Casestudy:ASAP4(AR4)tensile(pullout)methodA
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FigureF9:Casestudy:ASAP4(AR4)tensile(pullout)methodB

[See:F.2;TableF1]
F.4.2.3 Insert groups and edge effects

Hand calculation of interference and edge effects are often very difficult and can reduce insert
capabilitiessignificantlysuchthatsafetyfactorsbecomenegative.
During the ASAP 4 structure optimisation, margins of safety were evaluated by measurement of
interferenceandedgecoefficients.
NOTE The calculated reduction factor, using the design procedures in this
handbook,ispessimisticcomparedwiththetestresults;asshownin
TableF6.
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TableF6:Casestudy:ASAP4interferenceandedgeeffects
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F.5 ASAP 5
Design consisting of sandwich panels, with aluminium alloy face sheets and an aluminium
honeycombcore,usingspecialaluminiumalloypottedinserts.
Special throughthethickness (fully potted) inserts were used in thick sandwich structures, i.e. core
height=60mm.

TableF7listsmaterialsandaconfigurationexample.
F.5.2 Testing
Special throughthethickness (fully potted) inserts were used in thick sandwich structures, i.e. core
height=60mm.
Theeffectofpottingfromoneorbothsidesofthesandwichwasexamined.
Testresults,whencomparedwithanalysismethodsinthishandbook,showthattheminimum
valueexceedsthecalculatedtypicalvalue.
Insertproximityeffectswereinvestigated.
F.5.2.1 Method
Nodetailsgiven,[2929].
TableF7:Casestudy:ASAP5materialsandconfiguration
Project ASAP5
Structure:
Application
Separationsystemminiandmicrosatellites
Insert: [See:TableF10]
Specialthroughthethickness
Type
(Fullypotted)
Ref.
Position(1)
Material 7175T7351
Chromicanodised,notsealed.Alodine1200(contact
Surfacetreatment
surface).
Thread Nonlocking,phosphorbronzeCdfree.
Lubrication Molicote106
Potting: SLE3010LVC+primer
Sandwichpanel:
Facesheets Aluminium2024T81Thickness:0.8mm
Core 5056440perforatedHeight:60mm
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FigureF10:Casestudy:ASAP5
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Table F-8 summarises the test results.
TableF8:Casestudy:ASAP5Allowabletensileload
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F.5.2.3 Insert groups and edge effects

Someinserts,testedindividually[See:TableF8],werealsotestedinagroup,asgiveninTableF9.
Thedistancebetweeninserts,d=33.8mm.
NOTE Thecalculatedreductionfactor,usingthedesignproceduresinthishandbook,arepessimisticcomparedwiththetestresults;
asshowninTableF9.
TableF9:Casestudy:ASAP5interferenceandedgeeffects
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F.6 ROSETTA Lander
F.6.1 Carbon fibre tube inserts

Designconsistingofsandwichpanels,withCFRPcompositefacesheetsandaluminiumhoneycomb
core,usingadhesivelybonded,novel,carbonfibretubeinserts,[Seealso:A.3].
F.6.2 Development history

The development of the comet Lander Philae for the ESA cornerstone mission ROSETTA was
performedbyaEuropeanconsortiumledbyDLR.InthisDLRBraunschweigdevelopedandbuilta
complexlightweightstructurebasedoncarbonfibresandwichplateswithseveralhundredsofinserts.
Manyoftheseinsertswereneededforthroughthethicknessfasteners.
FigureF11showstwooftheLandersstructuralcomponents.
FigureF11:ROSETTALander:Twostructuralcomponents
Thetightconstraintsofthemassbudget,thegiventhicknessofthesandwichplates,andthenumber
ofinsertsperunitareamadeitinevitablethatconventionalpottedinsertdesignhadtobereplacedby
anoveldesign,[2930];knownasacarbonfibretubeinsert,[Seealso:A.3fordetails].
The concept is based onan extremelystiff, thinwalled carbonfibre tube which fits exactlybetween
the face sheets and is bonded to the honeycomb core only by a thin layer of epoxy adhesive. The
pottingradiusisthereforenotmuchlargerthantheinsertradiusitself.
Thefulllengthoftheextremelystiffcarbonfibretubeactivelycontributestotheshearloadtransfer
into the much softer honeycomb core, because the tube always passes through the whole sandwich
thickness.Theformlockingcontactunderbothfacesheetsmakesthesandwichinthevicinityofthe
insertpracticallyincompressible.
In the course of the verification process of theROSETTA Lander,the qualification of the new insert
design was performed with regard to the specific mission requirements and the specific structural
configuration.
A preliminary test campaign was performed, [[2931], [2932]], and the final flight readiness was
proven by successful mechanical tests at Lander level (spacecraft level). However, a qualification of
theinsertdesignundermoregeneralconditionsremainedtobedone.
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F.6.3 Qualification
BasedontheexperiencefromtheROSETTALanderproject,thepotentialofcarbonfibretubeinserts
was investigated more thoroughly by DLR and two Finnish partners, PATRIA Finavicomp Oy and
HelsinkiUniversityofTechnology,duringanESAfundedstudy,[2933].
The influence of the sandwich parameters on the static and dynamic strength of the inserts under
different load cases was systematically investigated. The influence of thermal conditioning before
testing,edgeeffectsandtheeffectoftheinsertsizewerealsoconsidered.Alltestsweremadeonboth
typesofmetallicinsertcaps;asdescribedinA.3.
The experimental investigations were performed with the test fixtures; shown in Figure F12, [See
also:AnnexH].
Parallel, analytical investigations and numerical calculations based on a detailed FE model were
carriedout.
Bendingandtensioncompressiontests(toprow)
Torsionandsheartests(bottomrow)
FigureF12:ROSETTALander:Tensioncompression,shear,bending
andtorsiontests
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F.6.4 Preliminary results

AsofJuly2004,theevaluationstageofthestudyisnotyetcomplete,[2933].
Inparalleltothetests,insertstrengthvaluesweredetermined:
analytically,usingtheformulaegiveninthishandbook;
numerically,usingFEMcalculations.
Theresultsareinthesameorderof magnitudeasthetestresults,but the congruitybetweenanalysis
and testing still needs further evaluation. Likewise, special effects, e.g. edge effects, size effects,
thermal influences and the fatigue behaviour need further consideration. More results can be
incorporatedintothishandbookwhenthedataareavailable.
ThepreliminaryresultsaresummarisedinTableF10toTableF12,inclusive.Theseare restricted to
the basic static load cases and the influence of fundamental sandwich parameters on the insert
strength.
Theresultsgivenareforasandwichpanelconstructioncomprisingof:
face sheets (top and bottom) made of orthotropic carbon fibre fabric plies, fabric style 887
(manufacturedbyC.Cramer& Co),basedonTORAYCAM40JB600050Bcarbonfibres,with
anepoxymatrix(ScheuflerResinL160/HardenerH163)andafibrevolumefractionof50%,
intwodifferentthicknesses(0.5mmand1.5mm).
honeycombcore,madefromaluminiumalloybyHEXCELin2corethicknesses(20mmand50
mm)andin3materialspecifications,namely:
AerowebCRIII1/450520007P
This enables 2 different cell sizes (1/4 inch 6 mm and 1/8 inch 3 mm) and 2 different cell wall
thicknesses(0.0015inchand0.0007inch)tobecompared.
NOTE1 The face sheets each consisted of six orthotropic layers (0/90), in
order to investigate the influence of face sheet thickness. In realistic
applications, however, a six layer face sheet would certainly contain
45 fibres in addition to the 0/90. This leads to a much higher
bearing strength, and thus to higher critical insert shear loads than
thoselistedinTableF12.
NOTE2 Large outofplane forces (tension / compression) tend to crush the
honeycombcoreparalleltooneofthe facesheets.Usuallythis isthe
face sheet pressed against the test fixture. This tensioncompression
test fixture for 80 mm 80 mm sandwich specimens had a central
hole of 70 mm diameter [See: Figure F12]. The support area was
clearlytoosmalltoavoidthis. Otherwisethe measuredcriticaloutof
planeloadswould beevenhigherthanthoselistedin TableF10and
TableF11.
Onlythetestresultsobtainedwithinsertcapsforunilateralfixing,showninFigureF13,arelisted,
buttheresultsobtainedwiththealternativeinsertcaptypeforthroughthicknessfastenersaresimilar.
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TableF10:Carbonfibretubeinserts:Outofplanetension
facesheetthickness
criticalinsertload
criticalinsertload
meanvalue(of8)
honeycombcore
honeycombcore
honeycombcore
onA,B,Clevel
insert12mm (95%confidence)
thickness
cellsize
density

TensionTest
outofplane
A B C
1mm/min
99% 95% 90%
c f s
[mm] [mm] [kg/m3] [mm] [kN] [kN] [kN] [kN]
standardcase 50 1.5 50 6 4.22 5.22 5.73 7.60
smallcellsize 50 1.5 50 3 3.00 3.53 3.82 4.82
thinfacesheet 50 0.5 50 6 4.66 5.32 5.63 6.74
lightweightcore 50 0.5 25 6 1.21 1.37 1.46 1.76
smallthickness 20 0.5 50 6 1.10 1.34 1.45 1.90
smallandlight 20 0.5 25 6 0.83 0.88 0.91 0.98
TableF11:Carbonfibretubeinserts:Outofplanecompression
critical insert load

mean value (of 8)
on A-, B-, C-level
honeycomb core
honeycomb core
honeycomb core
Compression Test
(95% confidence)
insert 12 mm
face sheet
thickness
thickness
cell size
out-of-plane
density
1 mm / min
A B C
99% 95% 90%
c f s
[mm] [mm] [kg/m3 ] [mm] [kN] [kN] [kN] [kN]
standard case 50 1.5 50 6 6.41 7.08 7.37 8.38
small cell size 50 1.5 50 3 3.44 4.12 4.45 5.68
thin face sheet 50 0.5 50 6 5.01 5.58 5.84 6.74
lightweight core 50 0.5 25 6 1.23 1.40 1.49 1.78
small thickness 20 0.5 50 6 1.00 1.27 1.40 1.93
small and light 20 0.5 25 6 0.75 0.83 0.86 0.98
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TableF12:Carbonfibretubeinserts:Inplaneshearload

mean value (of 8)
on A-, B-, C-level
honeycomb core
honeycomb core
honeycomb core
(95% confidence)
insert 12 mm
face sheet
thickness
thickness
cell size
density
1 mm / min
Shear Test
A B C
in-plane
99% 95% 90%
c f s
[mm] [mm] [kg/m3 ] [mm] [kN] [kN] [kN] [kN]
standard case 50 1.5 50 6 2.74 3.96 4.61 7.40
small cell size 50 1.5 50 3 4.12 4.98 5.41 6.98
thin face sheet 50 0.5 50 6 1.32 1.88 2.19 3.56
lightweight core 50 0.5 25 6 1.08 1.47 1.69 2.63
small thickness 20 0.5 50 6 1.41 1.81 2.03 2.83
small and light 20 0.5 25 6 0.53 0.96 1.22 2.62
FigureF13:Carbonfibretubeinsert(type2):Withcapforunilateral
fixing
The critical insert failure load Fc was determined from each individual load curve; where Fc is a
generaltermforthecriticalstaticstrengthinthedifferentloadcases,e.g.PSSfortensioncompression;
QSSforinplaneshear;TSSfortorsion;MSSforbending.
Inallcases,Fcwasdefinedastheloaduponwhichthefirstfailureorplasticdeformationoccurs.Itis
observable as the first maximum of the curve or as the obvious end of the linear elastic range; as
showninFigureF14.InmanycasestheloadincreasedevenbeyondFcuptoamaximumvalueFmax.
However, Fc was regarded as the only relevant parameter; in line with a conservative design
philosophy.
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FigureF14:Carbonfibretubeinserts:Definitionofthecriticalinsert
failureload,Fc
Normally there were 8 experimentally determined critical load values per test scenario, i.e. per
combinationofsandwichtype,insertcaptype,andloadcase.
NOTE MeanvaluesarelistedintherighthandcolumnofTableF10toTable
F12,inclusive.
The data were processed by the Weibull ++5.0 computer program from Relia Soft. For each test
scenarioaWeibulldistributionwasgenerated,whichindicatessurvivablecriticalloadlevelswithout
anyinsertfailuresorplasticdeformation.ThesecriteriaaresummarisedinTableF13.
TableF13:Carbonfibreinserts:Weibullanalysiscriteria
99%probabilityof
1%probabilityoffailure socalledAlevel
survival
95%probabilityof
5%probabilityoffailure socalledBlevel
survival
90%probabilityof
10%probabilityoffailure socalledClevel
survival
All three levels were determined on a statistical confidence level of 95%. They are, of course, lower
thanthemeanvalue;thedifferencedependsonthescatterwithinthedistribution.
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F.7 SPOT 5
Design consisting of sandwich panels, with CFRP composite face sheets and a thick aluminium
honeycomb core (height of 80 mm), and using standard Shurlok aluminium alloy or special
aluminiumalloypottedinserts.

F.7.2 Testing
Nodetailsgivenin[2929].
TableF14:Casestudy:SPOT5materialsandconfiguration
Project SPOT5CASE SPOT5
Application Equipment StructureI/Fplatform

Type Standard Special
ShurlokSL100530M4Partially
Ref. Fullypotted
potted
Position(1) +0.1/0
Material Aluminium2024T4 Aluminium7175T7351
Chromicanodise,notsealed. Chromicanodise,notsealed.
Surfacetreatment
Alodine1200contactface. Alodine1200remachinedface.
M12,nonlocking.Phospher
Thread M4
bronze,Cdfree.
Lubrication Molicote106 Molicote106
Potting: SLE3010LVC+primer SLE3010LVC+primer
Sandwichpanel:
CFRP CFRP
Facesheets
Thickness:1mm Thickness:1mm
5056316perforated 5056316perforated
Core
Height:80mm Height:80mm
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:Casestudy:
SPOT5Case
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FigureF16:Casestudy:SPOT5StructureI/Fplatform
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F.8 UMS
Design consisting of sandwich panels, with CFRP composite face sheets and an aluminium
honeycomb core, and using standard Shurlok aluminium alloy or special aluminium alloy potted
inserts.

F.8.2 Testing
TableF15:Nodetailsgiven,[2929].Casestudy:UMSMaterialsandconfiguration
Project UMSSST UMSSST
Application Structure(radiator) Structure(platform/case)

Type Standard Special
ShurlokSL601M49.5APartially
Ref. Fullypotted
potted
Position(1)
Material Aluminium2024T4 AluminiumAU4G1T351
Surfacetreatment Anodised. Chromicanodise,notsealed.
Thread M4,locking. Stainless,nonlocking.
Lubrication Molicote106(titaniumfixings) Molicote106(titaniumfixings)
Potting:
Sandwichpanel:
CFRP CFRP
Facesheets
Thickness:0.8mm Thickness:0.8mm
AG5 AG5
420 420
Core 440 440
358 358
Height:notstated. Height:notstated.
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FigureF17:Casestudy:UMSSST1
FigureF18:Casestudy:UMSSST2
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F.9 SILEX
Both standard, Shurlok and special aluminium alloy potted inserts were used in composite CFRP
sandwichpanelswithaluminiumalloyhoneycombcores.

TableF16showsmaterialsandconfigurationexamples.
F.9.2 Testing
NOTE Nodetailsoftestmethodsgivenin[2929].
TableF16:Casestudy:SILEXMaterialsandconfiguration
Project SILEX SILEXGEOMPCS
Structure
Application Structure
Equipment
Standard Special
Type
Ref. ShurlokSL10068
Position(1) 00.05
Material Aluminium2024T4 Aluminium7075T73
Surfacetreatment AnodisedMILA8625 Chromicanodised,notsealed
Thread Nonlocking Stainless,nonlocking
Lubrication Nuflon(onbolt) Nuflon
Potting: ShurlokSLE3010LVC ShurlokSLE3010LVC
Sandwichpanel:
CFRP: CFRP:
Facesheets
Thickness:0.8mm1.6mm Thickness:0.8mm1.6mm
5056: 5056:
420 420
Core 320 320
328 328
345 345
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FigureF19:Casestudy:SILEXinsert
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FigureF20:Casestudy:SILEXGEOMPCSinsert
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TestresultsarefortransversetensileloadingaresummarisedinTableF17.
TableF17:Casestudy:SILEXAllowabletensileload
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F.9.2.3 Allowable shear load
The results of in-plane shear testing are summarised in Table F-18.
TableF18:Casestudy:SILEXAllowableshearload
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F.9.2.4 Allowable bending moment

The results for bending tests are summarised in Table F-19.
TableF19:Casestudy:SILEXAllowablebendingmoment
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F.9.2.5 Allowable torsion moment

The results for torsion tests on a standard insert are summarised in Table F-20. Torque is applied to the insert with a screw.
NOTE Onlyaminimumvalueisgiven.
TableF20:Casestudy:SILEXAllowabletorsionmoment
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F.10 HRG
HRG HauteRsolution Gomtrique is the main payload ofSPOT5. The structure is similar to HRV
andHRVIRonSPOT3andSPOT4,respectively.
SpecialaluminiumalloyinsertswerepottedintosandwichpanelshavingCFRPcompositefaceskins
andanaluminiumalloyhoneycombcore.

TableF21listsmaterialsandaconfigurationexample.
F.10.2 Testing
F.10.2.1 Tensile load

TableF22summarisesresultsofinsertpullouttestsusingthetestmethodshowninFigureF22.
NOTE TestdataisfromtheHRVproject(1983).
TableF21:Casestudy:HRGMaterialsandconfiguration
Project HRGCL
Application Electronicequipment
Insert: [See:FigureF21]
Special
Type
Partiallypotted,withcollar
Ref.
Position(1) +0.10
Material Aluminium2024T351
Surfacetreatment Alodine1200
Thread Stainless,nonlocking
Lubrication Nuflon(titaniumfixings)
Potting: SLE3010LVC
Bonding:(2) EC2216
Sandwichpanel:
CFRP
Facesheets
Thickness:2mmor3mm
5056440perforated.
Core
Height:43mm
NOTE(2)Collaradhesivelybondedtosandwichpanelfacesheet.
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FigureF21:Casestudy:HRGInsert
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TableF22:Casestudy:HRGTensileload
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FigureF22:Casestudy:HRGTestmethod
F.11 NILESAT
StandardShurlokandspecialaluminiumalloyinsertspottedintosandwichpanelswithaluminium
alloyfacesheetsandhoneycombcore.

F.11.2 Testing
Nodetailsgiven,[2929].
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TableF23:Casestudy:NILESATmaterialsandconfiguration
Project NILSATBattery1 NILSATBattery2
Structure;panelassembly;
Application Structure;handling.
satelliteI/F.
Standard Special(2)
Type
Ref. ShurlokSL10068
Position(1) +0.1/0
Aluminium7075T7351
Material Aluminium2024T4
Aluminium7175T7351
Surfacetreatment AnodisedMILA8625 Alodine1200
Thread Stainless,locking Nonlocking
Lubrication Molicote(titaniumfixings) None(titaniumfixings)
Potting: SLE3010LVC SLE3010LVC
Sandwichpanel:
Aluminium6061Thickness:0.3 Aluminium6061Thickness:0.3
Facesheets
mm mm
5056428perforatedHeight:not 5056428perforatedHeight:25
Core
stated mm
NOTE(2)FromTELECOM2
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FigureF23:Casestudy:NILESATbattery1
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FigureF24:Casestudy:NILESATbattery2
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F.12 EXAMPLE: Insert verification
F.12.1 Mounting
Aboxismountedonasandwichpanelusinginsertsatthefourcorners,asshowninFigureF25.
FigureF25:Example:Insertverificationdimensions

Thetypeofsandwichpanel,boxmassandloadingconditionsare:
Sandwichpanel:
core:aluminiumalloytype3/165052.0007;
coreheight,c:30mm;
facesheet:0.3mmaluminiumalloy.
Massofthebox:11kg
Acceleration(1):20ginallaxes
Temperature:ambient
NOTE(1) For simplification, the acceleration is assumed to act in the centre of
planeofthefacesheet.
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F.12.3 Loads
F.12.3.1 Total load

Fr=m209.81=2200N
F.12.3.2 Ultimate load on each box corner

Ft 1.5
Pult 4 4bolts [See:12.4]
Pult 22001.5
4
=825N
F.12.4 Insert selection

NOTE Seealso:AnnexB.
F.12.4.1 Tension
PSS(bi=11)=1090N [See:12.5;B.1]
PSS(bi=14)=1220N [See:12.5;B.1]
F.12.4.2 Compression
PSS(di=11)=900N [See:13.2;B.1]
PSS(di=14)=1050N [See:13.2;B.1]
NOTE Where the compressive strength is insufficient, increasing the foot
diameter to exceed the potting element 2bp can avoid using a larger
insert.
F.12.5 In-plane loads

QSS = 8bp2 wcrit +2bp f fy Eqn.[14.21]
With:
bpmin =0.93192bi+0.874SC0.66151 Eqn.[7.31]

bpmin (di =11)=8.63mm [See:Table122]
bpmin (di=14)=10.03mm
And:
w=0.32N/mm2 [See:Table63]
f = 0.3 mm
fy =270N/mm2 [See:6.6]
For(di=11): QSS =88.63 0.32+20.38.63270
2
=1589N
For(di=14): QSS =810.0320.32+20.310.03270
=1882N
NOTE Theallowablesexceedbyfartherequirements.
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F.12.6 Grouping effects

Seealso:Clause19.
F.12.6.1 Potting radius

Thepottingradius bpminwasidentifiedas:
For(di=11mm): 8.63mm
For(di=14mm): 10.03mm
with: bp1 bp 2 bp1 bp 2 1
F.12.6.2 Interference coefficient

Theinterferencecoefficientisbecomes:
For(di=11):
is is a
b p1
1 ; b p1 b p 2 1 =10.4
For(di=14):
is is a
bp1
0.9 ; b p1 b p 2 1 =0.95
where:
a=90mm(inaccordancewithFigure191)
NOTE Thedistanceinthelongitudinaldirectionexceeds10bp1,sothereisno
interferenceeffecthere.
F.12.7 Edge influence

NOTE Seealso:Clause18.Thesmallestdistanceoftheouterinserttothefree
edgeis:
l=40mm.
Thisresultsinaratio,[See:Clause18]:
For(di=11): l
bp 40 8.63 4.6
For(di=14): l
bp 4010.03 4.0
and:
For(di=11): EN=0.95
For(di=14): EN=0.90
F.12.7.1 Total tensile load capability

Totalloadcapabilityundertension:
For(di=11): Pmax(11)=109010.951035N
For(di=14): Pmax(14)=12200.850.91043N
NOTE Bothareacceptable.
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F.12.8 Life of inserts

NOTE di=11mm,[See:21.1]Themaximumloadduringoperationis:
Fworst 2200 4 =550N(amplitude)
Themeanratio,with FA F :
F 2 FA F 2 F
R F
F
1
Thecorrectionsfortheactualgeometryare:
hc=30mm,
f=0.3.
FEF 1.2766
} Fc f Fpp =1.411
Fpp 1.1052
F.12.8.1 Peak load

Assumingthesinusoidalvibrationtestatqualificationashavingasafetyfactorof1.33,thiscanresult
inapeakload:
F Fcc 1.33 2200 4 1.33 =722N

Thetolerableloadsare1.411timeshigherthanthatshownin21.5(herebi=11mm),whichgives:
Fplot N
Ftol=(Fplot1.411)
[N] [Cycle]
600 846 1200
500 705 6500
400 565 50000
Consideringthesweeprate,thenumberofcyclesoccurringduringsweepthroughtheeigenfrequency
isdeterminedby:
N0=fet
Where:
t=timetopassthroughthebandwidth,BW.
Withascatterfactorof4,ithastobeshownthat:
N4N0
NOTE Baseduponthetestconditions,theoptionsaretoeither:
acceptaninsertdiameterof2bi=11mm;
repeatthefatiguecheckusinganinsertdiameterof14mm.
420
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F.13 References
F.13.1 General
MMSRef.NT/102/BG/355013.96(Dec.1996)
[2930] ROSETTALanderSubsystemSpecificationStructure
ROLSTSP3601,Issue4/0,para.2.2.4(2001)
[2931] TestProcedureInsertQualificationTestsfortheROSETTALander.
DASAdocumentQTINRSTTPR0001(1998)
[2932] TestReportInsertQualificationTestsfortheROSETTALander.DASA
documentQTINRSTTR0001(1998)
StudyonCarbonFibreTubeInserts
ESTECContractNo.16822/02/NL/PA,2004
handbook
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Annex G
Formulae
G.1 Introduction
ExcludingthoseinAnnexes,alistofallthemathematicalformulaeandexpressionsstatedthroughout
thehandbookaregivenhere.Theseareprovidedwithoutexplanationandareintendedforhandbook
userscreatingtheirowncalculationsoftware.[Seealso:G.2fornomenclature].
Each equation is referenced by the equation number used in the handbook and hyperlinked to the
relevantsection,e.g.:
a=bc (Eqn.22.11)
Clause
Topic
Sequentialnumber
G.2 Nomenclature
a centretocentredistancebetweeninserts
A onesixthofhexagonalcellcircumference
AA AmericanAluminiumAssociation
av averagevalue
B bendingstiffness
bi insertradius
bp pottingradius
bpmin minimumpottingradius
bptyp averageortypicalpottingradius
bR realpottingradius
bRtyp averageortypicalrealpottingradius
c coreheight
422
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C correctionfactorforstrengthcapabilitieswithheightsofcore,c>9mm
D footdiameterofanattachedstructuralpart
di insertdiameter(also=2bi)
dp pottingdiameter
e distanceofinsertfromthesandwichpaneledge
E Youngsmodulus
Ef Youngsmodulusofisotropicfacesheetmaterial
ER tensilemodulusofpottingcompound
Exy Youngsmodulusofanisotropicfacesheetmaterial
F appliedinclinedload
f facesheetthicknesswhenf1=f2
f1 thicknessofupperfacingsheet
f2 thicknessoflowerfacingsheet
FSS staticstrengthcapabilityunderloadsinclinedtoplaneoffacing
GC effectivecoreshearmodulus
GL shearmodulusofcoreinLdirection
guar guaranteedvalue
GW shearmodulusofcoreinWdirection
hi insertheight
hp pottingheight
hpmin minimumallowablepottingheight
hptyp typicalpottingheight
Kt magnificationfactorduetofatigue
Ktpp stress concentration factor due to partially potted inserts in nonmetallic
cores
L longitudinaldirectionofahoneycombcore
LN LuftfahrtNorm(aeronauticalstandard)
MSS allowablebendingmomentrelatedtostaticinsertstrength
M bendingmoment
min minimumvalue
N newton
n numberofinsertsinaninsertgroup
NPC numberofcorecellsfilledwithpottingresin
p loadnormaltoplaneoffacing
P*SS reducedstaticstrengthcapabilityofaninsertduetoedgeeffects
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pcritmin insert load capability due to minimum properties of the components (core,
facing,resin)
pcrittyp insertloadcapabilityduetothetypicalpropertiesofthecomponents
PSS staticstrengthcapabilityofaninsertunderloadsnormaltoplane
Psscmin minimuminsertloadcarryingcapabilityincompression
Psstav averageinsertloadcarryingcapabilityintension
Psstmin minimuminsertloadcarryingcapabilityintension
Q resultingshearload
Q*SS reducedshearloadforinsertsnearpaneledges
QC portionofQtakenbythecore
QSS allowableshearload
R rearstressrate
RC reliabilitycoefficient
RT roomtemperature
Sc corecellsize
to corefoilthickness
Tss allowabletorsionalload
typ typicalvalue
W transversedirectionofahoneycombcore
x distancebetweenfacingsheetuppersurfaceandinsertupperflangesurface
anglebetweeninsertloaddirectionandfacingplane
c densityoftheexpandedcore
o densityofthematerial
R densityofthepottingresin
EN edgecoefficientofinsertsloadedintensionorcompression
EQ edgecoefficientofshearloadedinserts
hG interferencecoefficientofagroupofequidistantinserts
IC interferencecoefficientofinsertsloadedinoppositedirections
IS interferencecoefficientoftwoneighbouringinsertsloadcapabilityreduction
coefficientoftwoneighbouringinserts
T coefficientofthermaldegradation
TA loadcapabilityreductioncoefficientofinsertexposedtoelevatedtemperature
TC loadcapabilityreductioncoefficientofinsertsexposedtothermalcycling
Tb loadcapabilityreductioncoefficientofinsertatRTafter20hoursexposureto
elevatedtemperature
TR reductioncoefficientofpottingresinstrengthatelevatedtemperatures
f Poissonsratioofisotropicfacingsheetmaterial
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x,y Poissonsratioofanisotropicfacingsheetmaterial
ccritc corestrengthincompression
ccritt corestrengthintension
ccritcmin minimumcompressionstrengthofcore
ccritctyp typicalcompressionstrengthofcore
fy yieldstrengthoffacingsheetmaterial
Rcrit tensilestrengthofpottingresin
c coreshearstrength
ccrit coreshearstrengtheffectivetoinsertstrength(circular)
ccritmin minimumallowablecoreshearstrength
ccrittyp typicaloraveragecoreshearstrength
Lcrit criticalshearstrengthofcoreinLdirection
Rcrit shearstrengthofpottingresin
Wcrit criticalshearstrengthofcoreinWdirection
G.3 List of mathematical formulae

[See: G.1 for links; G.2 for nomenclature]
G.3.1 Clause 6 Sandwich panels

E f3
B 12 (1f 2 ) [6.21]
f
E x E y 1 Al
2
f Al
f an
4
E Al 1 x y
[6.22]
G G C
W
3
[6.41]
c crit 1.36 w crit [6.51]
c crit t 0 crit t c
0 [6.61]
c crit t min 0.9 0 crit t c

0 [6.62]
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c crit t min 0.9 0 crit c typ [6.63]
G.3.2 Clause 7 Embedding of inserts
1
bp
n bn
[7.31]
b p min 0.93192 bi 0.874 S c 0.66151 [7.32]
b p min 0.9bi 0.7 S c [7.33]
b p typ 1.002064 bi 0.940375 S c 0.7113 [7.34]
b p typ bi 0.8 S c [7.35]
F N F
b R

R
PC

C
[7.41]
Fc 0.95 0.75 S C cos

2
[7.42]
bR bi 0.35 S C [7.43]
bR typ bi 0.5 S C [7.44]
hp c for c hi c 7 mm [7.51]
hp min hi 7 mm [7.52]

h p typ h p min A tgh c h p min h p min [7.53]
426
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Massoffacesheethole= f bi
2
p [7.61]
G.3.3 Clause 8 Mechanics of sandwich structures
w wb ws [8.11]
d 2w M
2

dx D [8.12]
M
wb dxdx C1 x C 2
D
f 3 f (c f ) 2 c3
D b E f E c [8.13]
6 2 12
bf (c f ) 2
D Ef Forf<<candEf>>Ec [8.14]
2
uupper ulower
0 [8.15]
c
dws c
( 0 )
c f
[8.16]
dx
c Q
[8.17]
Gc Gc (c f )
dws Q c
0
dx S (c f )
[8.18]
M 0 cx
ws C3
S (c f )
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(c f ) 2
S Gc [8.19]
c
c c
Mz f z
xf E f where 2 2
D c c
z ( f )
2 2
[8.110]
Mz c c
xc Ec where z
D 2 2

Q
c
b(c f )
G.3.4 Clause 10 Design considerations
pallowable pult plimit jn [10.61]
Fy Flim SFadd J E [10.62]
Fu Flim SFadd J R [10.63]
Fall bearingall t [10.81]
Fadd all S bonding [10.82]
Fall 2 d t all [10.83]
Fall all h D [10.84]
G.3.5 Clause 12 Tensile strength
Pf Pss 2b p c [12.11]
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P Ip 1 I1 r b p K ( b p ) a K 1 ( a )
(r ) (
(h c) I r a b p I1 ( a ) K 1 ( b p ) I1 ( b p ) K 1 ( a )
[12.21]
K 1 ( r ) a I1 ( a ) b p I1 ( b p )
)
a b p I1 ( a ) K 1 ( b p ) I1 ( b p ) K 1 ( a )
t s1t s 2 (h c) 2
Ip [12.22]
4(h c)
3 3
t s1 t s 2
Is [12.23]
12
Gc (h c) I
[12.24]
E c t s1 t s 2 I s
Es
E [12.25]
1 s
2
RC=1.1720.0063c0.2641f [12.31]
RC=1.2070.00544c0.2088f [12.32]
*
C I* C I hi hi [12.61]
E Ex Ey [12.71]
xy yx [12.72]
G.3.6 Clause 13 Compressive strength
PSScmin=RCPcritmin [13.11]
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PSScav=RCPcritav [13.12]
G.3.7 Clause 14 Shear strength
D 2b p 2(bt 4 mm) [14.11]
Qc 8b p2 W crit [14.12]
QSS 8bp2 W crit 2 f b p fy for bp 11 mm [14.21]
QSttt _ symm. 2(2t s b p sy ) [14.31]
QSttt _ unsymm. 2t s b p sy [14.32]
Qc 8 b p2 Wcrit [14.33]
1
Qt ( w bi )t s t ,ult [14.35]
K e'
bi 1
Qs 2t s (e ) s [14.36]
2 cos
2
2 Es ts
Qd bp ts K D [14.37]
1 s2 Sc
2
Qb K b bi t s comp [14.38]

430
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*
Qcrit Qcrit EQ [14.39]
e e
EN 0.66 0.06 fore3bp [14.310]
bp bp
and: EN 1 for e 3bp
G.3.8 Clause 15 Bending strength
M ss PSSc bi [15.21]
M crit Pcrit bi [15.31]
G.3.9 Clause 16 Torsional strength
TSS 4 bR2 t 0 0 crit [16.21]
Tcrit 4 bR2 t0 0crit [16.31]
G.3.10 Clause 17 Combined loads

P 2
PSS
Q 2
QSS 1 [17.11]
FSS 2
PSS QSS
[17.12]
PSS cos 2 QSS
2
sin 2
431
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P 2
PSS
Q 2
QSS
M 2
M SS
T 2
TSS 1 [17.21]
G.3.11 Clause 18 Edge influence
P SS
*
P SS EN
[18.11]
EN 0.55 e
bp
0.05 e
bp fore 5bp
[18.12]
EN 1 fore >5bp

*
Q SS
Q
SS EQ
[18.21]
EQ 0.66 e
bp
0.06 e
bp fore3bp
[18.22]
EQ 1 fore>3bp
G.3.12 Clause 19 Insert groups

*
P SS 1 IS 1 P SS 1
[19.11]
a 5(bp1 bp 2 ) [19.12]
b p1

IS1 b p2 a 1
1 [19.13]
1 b p1 5b p1 1 b p1
b p 2 b p 2
IS 1 IS 2 1 for a 5(bp1 bp 2 ) [19.14]
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1
b p1
b p1

b p2
1 a bp2

IS 2 1 [19.15]
5b p1 1

b
1 p1
1 b p1

b p2 b p2

*
P SS 2 IS 2 P SS 2
[19.16]

I
1 1 P 2
* [19.17]
IS 1 IS 1
P SS 2
P SS
*
P SS IC
[19.21]
P
*
SSi
P SSi ISl ISr
1 [19.31]
a5(bpi+bpi2) [19.32]
P SS 1
*
P SS 1 IS 1 IC
[19.41]
P
*
SSi
P SSi ISl

ISr
1 IC
[19.42]
=0.9 fora5(bpi1+bpi2)
IC [19.43]
=1.0 fora>5(bpi1+bpi2)

G P SS
*
P SS
[19.51]
n 1 1
G
2
n
IS
0.5
n
[19.52]
IS=1/2(1+a/10bp) [19.53]
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G=IS=1 fora>10bp [19.54]
G.3.13 Clause 21 Fatigue
C2Kr
c
bc
max
F [21.21]
p
ccrit min
C Kr
*
max
[21.22]
P SS min 2b c p

ccrit min
F [21.23]
c
P SS min
0.57
cmin p
1290
[21.24]
1 4
4.4 10 2
p
mm
c local = c Kt [21.25]
K t
Ktj [21.26]
j 1
Determining Kt fatigue stress concentration factors for various local stress

effects, [See: Table 21-1]
mean 1a sin(t ) [21.31]
R
mean
A
[21.32]
mean
A
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F 2P a
[21.33]
1 R
2 a
[21.34]
1 R
1
a C N for mean A ccrit [21.51]
m
2
C N ccrit
1
for [21.52]
1 R K
a A
t
2
a [21.53]
1 R
m 1
2
C N
1
[21.54]

A
1 R
2b c

p
F * c
[21.55]
CK r max

[21.56]
c
K t
m 1
2b p c 2
C N
1
F [21.57]
K 1 R
* A
CK r max t
P
c
SS
crit
[21.58]
435
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m 1
1 2
F P SS
1
C N [21.59]
ccrit min K t 1 R
A
F PSS
c c
h p 0.8 2 m 1
1 R CA N
1
[21.510]
n
D i
k [21.61]
i
N i
G.3.14 Clause 22 Environmental effects
PTi P Ti [22.21]
G.3.15 Clause 23 Manufacturing procedures
N ges
n standard
1
100
[23.61]
N ges
n safetycrit
2
10
[23.62]
G.3.16 Clause 28 Quality control
actual cell size

Actual degree of (core) expansion nominal cell size
100 [%] [28.51]
N K ex act [28.52]
436
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Annex H
Insert test fixtures
H.1 Introduction
Thisannexcontainsthetechnicaldrawingsofthefourinserttestfixturesforthestandardisedtesting
of80mm80mmsandwichpanelspecimenswithacentralinsert;asdescribedin27.3.
Thefourdifferenttestfixturesenabletheapplicationof:
Outofplaneloads(intensionorcompression),[See:H.2];
Inplaneshearloads,[See:H.3];
Bendingmoments,[See:H.4];
Torsionalmoments,[See:H.5].
Thefixturesaresuitableforstatictestmachinesaswellasforservohydraulictestmachines,e.g.for
fatigueloading.
ThetestfixtureswereoriginallydevelopedbyDLRforthequalificationofcarbonfibretubeinserts,
[2935],butarealsosuitableforanyothertypeofinsert.
NOTE These DLR technical drawings are also provided in standard .DXF
(drawing exchange file) format on the Insert design handbook
CDROM,andcanbeimportedintomostcommerciallyavailableCAD
software.
[See:CDROMdirectoryTestFixtureDXFs]
Forinsert/sandwichconfigurationswithhigherloadbearingcapabilitiesasizeof80mm80mmfor
thesamplesandcorrespondingcoverplatescanbetoosmall.
Underhighoutofplaneforces,theremainingsmallsupportareaofthecoverplateoutsidethecentral
70mmdiameterholecanproducestressconcentrationshighenoughtocrushthehoneycombcore.In
thiscase,itisnecessarytoincreasethesampleandcoverplatesizesto100mm100mmormore.All
otherdesignfeaturescanremainunchanged.
H.2 Test fixture: Tension-Compression load

Thetensioncompressiontestfixtureisdescribedin27.3,[Seealso:Figure271andFigure272].
Thesetofengineeringdrawingsforthetestfixtureareshowndividedintoseveralparts:
Masterdrawing,inFigureH1
Part1,inFigureH2
Part2,inFigureH3
437
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Part3,inFigureH4
Part4,inFigureH5
Part5,inFigureH6
Part6,inFigureH7
Part7,inFigureH8
NOTE AllengineeringdrawingsreproducedcourtesyofDLR.
Master drawing
FigureH1:Testfixture:Tensioncompressionloadmasterdrawing
438
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H.2.1.2 Part 1
FigureH2:Testfixture:Tensioncompressionloadpart1
439
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H.2.1.3 Part 2
440
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H.2.1.4 Part 3
441
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H.2.1.5 Part 4
442
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H.2.1.6 Part 5
443
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H.2.1.7 Part 6
444
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H.2.1.8 Part 7
445
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H.3 Test fixture: In-plane shear load

Theinplanesheartestfixtureisdescribedin27.3,[Seealso:Figure273].
Part1,inFigureH10
Part2,inFigureH11
Part3,inFigureH12
Part4,inFigureH13
Part5,inFigureH14
Part6,inFigureH15
Part7,inFigureH16
Part8,inFigureH17
NOTE AllengineeringdrawingsreproducedcourtesyofDLR
H.3.1 Master drawing
FigureH9:Testfixture:Inplaneshearloadmasterdrawing
446
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H.3.1.2 Part 1
FigureH10:Testfixture:Inplaneshearloadpart1
447
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H.3.1.3 Part 2
448
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H.3.1.4 Part 3
449
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H.3.1.5 Part 4
450
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H.3.1.6 Part 5
451
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H.3.1.7 Part 6
452
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H.3.1.8 Part 7
453
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H.3.1.9 Part 8
454
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H.4 Test fixture: Bending

Thebendingtestfixtureisdescribedin27.3,[Seealso:Figure274].
Part1,inFigureH19
Part2,inFigureH20
Part3,inFigureH21
Part4,inFigureH22
Part5,inFigureH23
Part6,inFigureH24
Part7,inFigureH25
Part8,inFigureH26
Part9,inFigureH27
Part10,inFigureH28
Part11.12and13,inFigureH29
Part14,inFigureH30
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FigureH18:Testfixture:Bendingmasterdrawing
456
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H.4.1.2 Part 1
FigureH19:Testfixture:Bendingpart1
457
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H.4.1.3 Part 2
458
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H.4.1.4 Part 3
459
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H.4.1.5 Part 4
460
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H.4.1.6 Part 5
461
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H.4.1.7 Part 6
462
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H.4.1.8 Part 7
463
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H.4.1.9 Part 8
464
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H.4.1.10 Part 9
465
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H.4.1.11 Part 10
466
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H.4.1.12 Part 11. 12 and 13
FigureH29:Testfixture:Bendingparts11,12and13
467
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H.4.1.13 Part 14
468
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H.5 Test fixture: Torsion

Thetorsiontestfixtureisdescribedin27.3,[Seealso:Figure275].
Part1,inFigureH32
Part2,inFigureH33
Part3,inFigureH34
Part4,inFigureH35
Part5,inFigureH36
Part6,inFigureH37
Part7,inFigureH38
Part8,inFigureH39
Part9,inFigureH40
Part10,inFigureH41
Part11,inFigureH42
Part12,inFigureH43
Part13,inFigureH44
Part14,inFigureH45
Part15,inFigureH46
Part16,inFigureH47
Part17,inFigureH48
NOTE AllengineeringdrawingsreproducedcourtesyofDLR.
469
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FigureH31:Testfixture:Torsionmasterdrawing
470
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H.5.1.2 Part 1
FigureH32:Testfixture:Torsionpart1
471
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H.5.1.3 Part 2
472
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H.5.1.4 Part 3
473
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H.5.1.5 Part 4
474
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H.5.1.6 Part 5
475
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H.5.1.7 Part 6
476
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H.5.1.8 Part 7
477
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H.5.1.9 Part 8
478
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H.5.1.10 Part 9
479
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H.5.1.11 Part 10
480
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H.5.1.12 Part 11
481
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H.5.1.13 Part 12
482
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H.5.1.14 Part 13
483
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H.5.1.15 Part 14
484
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H.5.1.16 Part 15
485
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H.5.1.17 Part 16
486
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H.5.1.18 Part 17
487
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H.6 References
H.6.1 General
ESTECContractNo.16822/02/NL/PA(2004)
488

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ECSS-E-HB-32-22A

Change log .................................................................................................................3

3 Terms, definitions and abbreviated terms..........................................................29

4 Insert system ........................................................................................................66

6 Sandwich panels ..................................................................................................83

7 Embedding of inserts ...........................................................................................96

8 Mechanics of sandwich structures ...................................................................110

9 Design aspects ...................................................................................................134

10 Design considerations .....................................................................................139

11 Design flow chart..............................................................................................168

14 Shear strength ..................................................................................................190

16 Torsional strength ............................................................................................208

18 Edge influence ..................................................................................................214

22 Environmental effects ......................................................................................256

23 Manufacturing procedures ..............................................................................262

24 Sandwich panel machining..............................................................................278

27 Manufacture control .........................................................................................293

28 Quality control ..................................................................................................301

Annex A Inserts .....................................................................................................319

Annex B Permissible loads...................................................................................328

Annex C Analytical determination .......................................................................331

Annex D Estimation of static load-carrying capability .......................................344

Annex E IATP .........................................................................................................362

Annex H Insert test fixtures ..................................................................................437

Table A-1 : Commercially available inserts used in space ................................................... 320

References called in this clause

4.1 Insert systems and components

4.1.2 Insert system components

4.1.3 Loading modes

Type B: Potting (or equivalent non-standard procedure)

St Partially or Planes or ERNO No. R

St Partially or Planes or Only for very low loads.

[See also 10.3]

Type C: Mechanically clamped or screwed

5.2.5 Potting methods

5.3.4 Standardised diameters

5.3.5 Standardised heights

5.4.2 Aluminium alloys

5.4.3 Titanium alloys

5.4.4.1 Carbon steels

5.4.4.2 Stainless steels

5.4.5 Material selection

5.5 Surface protection

5.5.2 Aluminium alloy

heattreatedandaged QQA225/6 Anodised,e.g.LN9368

Carbonsteel AISI1137 Cadmiumplated(1)

5.5.2.2 Titanium alloys

5.6.2 ECSS standards

6.1 Sandwich properties

6.1.1 Insert load-bearing capability

6.1.2 Sandwich dimensions

6.2 Face sheet properties

6.2.1 Tensile and compressive loading

6.2.1.3 Isotropic face sheets

6.2.2 Shear loading

6.2.2.1 Isotropic face sheets

6.2.2.2 Anisotropic face sheets

228 2381 dimpling C

602 4163 bearing C

6.2.3 Other loads

6.3 Core properties

6.3.1 Types of cores

6.3.2 Hexagonal core

6.3.2.1 Core anisotropy