1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2013 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AMS4178E AEROSPACE MATERIAL SPECIFICATION AMS4178 REV. E Issued 1976-01 Revised 2
5、008-10 Reaffirmed 2013-12 Superseding AMS4178D Core, Flexible Honeycomb, Aluminum Alloy, Treated for Sandwich Construction 5052, 350 (177) RATIONALE AMS4178E has been reaffirmed to comply with the SAE five-year review policy. 1. SCOPE 1.1 Form This specification covers an aluminum alloy in the form
6、of honeycomb core in a non-hexagonal, flexible cell configuration, the core being treated for increased corrosion resistance and furnished only in the expanded form. 1.2 Application This honeycomb core has been used typically in contoured sandwich construction for short-term exposure up to 350 F (17
7、7 C) or for long-term exposure up to 200 F (93 C), but usage is not limited to such applications. 1.3 Safety - Hazardous Materials While the materials, methods, applications, and processes described or referenced in this specification may involve the use of hazardous materials, this specification do
8、es not address the hazards which may be involved in such use. It is the sole responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to take necessary precautionary measures to ensure the health and safety of all personnel involved. 2. APPLICABLE
9、DOCUMENTS The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The supplier may work to a subsequent revision of a document unless a specific document issue is specified. When the referenced document has b
10、een cancelled and no superseding document has been specified, the last published issue of that document shall apply. SAE INTERNATIONAL AMS4178E Page 2 of 12 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Can
11、ada) or 724-776-4970 (outside USA), www.sae.org. AMS4004 Aluminum Alloy Foil, 2.5Mg - 0.25Cr (5052-H191), Strain Hardened 2.2 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM B 117 Salt
12、Spray (Fog) Testing ASTM C 273 Shear Properties in Flatwise Plane of Flat Sandwich Constructions or Sandwich Cores ASTM C 365 Flatwise Compressive Strength of Sandwich Cores 2.3 U.S. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbi
13、ns Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-6257, http:/assist.daps.dla.mil/quicksearch/. FED-STD-595 Color 3. TECHNICAL REQUIREMENTS 3.1 Material 3.1.1 Metal Shall be AMS4004 aluminum alloy foil. 3.1.2 Adhesive The adhesive system used for node-to-node attachment shall be such that the res
14、ultant core meets the specified requirements. 3.2 Configuration The core material shall consist of strips of aluminum alloy foil, treated for corrosion protection, bonded together to form cells of approximately uniform shape as shown in Figure 1. 3.2.1 Designation Core shall be designated in accorda
15、nce with the following numbering system: Nominal density, pounds per cubic foot (kg/m3) Cell count, per linear foot (meter) of transverse direction Foil thickness in ten-thousandths inch (m) “N“ for nonperforated or “P“ for perforated “F“ for flexible “T” for treated for corrosion protection Adhesiv
16、e, option of supplier SAE INTERNATIONAL AMS4178E Page 3 of 12 Example in inch/pound units: Core with a nominal density of 2.1 pounds per cubic foot with a cell count of 40, 0.0013 inch foil thickness, nonperforated, flexible, treated, produced from AMS4004 (5052) alloy and bonded with required adhes
17、ive shall be numbered as follows: 2.1-40-13 NFT5052 (XXXX) Example in Sl units: Core with a nominal density of 34 kg/m3with a cell count of 131, 33 m foil thickness, nonperforated, flexible, treated, produced from AMS4004 (5052) alloy, and bonded with required adhesive shall be numbered as follows:
18、34-131-33 NFT5052 (XXXX) 3.2.2 Perforations When perforation is specified, the perforations shall be of such size and location that all cells are vented at least once for each 0.250 inch (6.35 mm) of core thickness. 3.3 Condition The core shall be supplied in the expanded form. 3.4 Properties Core s
19、hall conform to the following requirements; tests shall be conducted, on the core supplied in accordance with specified test methods: 3.4.1 Stabilized Flatwise Compressive Strength Shall be as specified in Table 1 and Table 2, determined in accordance with ASTM C 365 on five specimens 0.625 inch (15
20、.88 mm) in thickness. 3.4.1.1 At 77 F (25 C) TABLE 1 A - COMPRESSIVE STRENGTH, INCH/POUND UNITS Core Designation Minimum Individual Compressive Strength psi 2.1-40-13 N or PFT5052 3.1-40-19 N or PFT5052 4.1-40-25 N or PFT5052 5.7-40-37 N or PFT5052 4.3-80-13 N or PFT5052 6.5-80-19 N or PFT5052 8.0-8
21、0-25 N or PFT5052 157 280 420 700 455 735 1120 TABLE 1B - COMPRESSIVE STRENGTH, SI UNITS Core Designation Minimun Individual Compressive Strength MPa 34-131-33 N or PFT5052 50-131-48 N or PFT5052 66-131-64 N or PFT5052 91-131-94 N or PFT5052 69-262-33 N or PFT5052 104-262-48 N or PFT5052 128-262-64
22、N or PFT5052 1.08 1.93 2.90 4.83 3.14 5.07 7.72 SAE INTERNATIONAL AMS4178E Page 4 of 12 3.4.1.2 At 350 F (177 C) TABLE 2A - COMPRESSIVE STRENGTH, INCH/POUND UNITS Core Designation Minimum Individual Compressive Strength psi 2.1-40-13 N or PFT5052 3.1-40-19 N or PFT5052 4.1-40-25 N or PFT5052 5.7-40-
23、37 N or PFT5052 4.3-80-13 N or PFT5052 6.5-80-19 N or PFT5052 8.0-80-25 N or PFT5052 102 182 274 455 296 478 730 TABLE 2B - COMPRESSIVE STRENGTH, SI UNITS Core Designation Minimum Individual Compressive Strength MPa 34-131-33 N or PFT5052 50-131-48 N or PFT5052 66-131-64 N or PFT5052 91-131-94 N or
24、PFT5052 69-262-33 N or PFT5052 104-262-48 N or PFT5052 128-262-64 N or PFT5052 0.70 1.25 1.89 3.14 2.04 3.30 5.03 3.4.2 Shear Strength Shall be as specified in Table 3 and Table 4, determined in accordance with ASTM C 273 using five specimens 0.625 inch (15.88 mm) in thickness. 3.4.2.1 At 77 F (25 C
25、) TABLE 3A - SHEAR STRENGTH, INCH/POUND UNITS Core Designation Minimum Individual Shear Strength, psi Ribbon Direction Minimum Individual Shear Strength, psi Transverse Direction 2.1-40-13 N or PFT5052 3.1-40-19 N or PFT5052 4.1-40-25 N or PFT5052 5.7-40-37 N or PFT5052 4.3-80-13 N or PFT5052 6.5-80
26、-19 N or PFT5052 8.0-80-25 N or PFT5052 63 126 182 280 196 308 434 37 75 115 170 120 180 260 TABLE 3B - SHEAR STRENGTH, SL UNITS Core Designation Minimum Individual Shear Strength, MPa Ribbon Direction Minimum Individual Shear Strength, MPa Transverse Direction 34-131-33 N or PFT5052 50-131-48 N or
27、PFT5052 66-131-64 N or PFT5052 91-131-94 N or PFT5052 69-262-33 N or PFT5052 104-262-48 N or PFT5052 128-262-64 N or PFT5052 0.43 0.87 1.25 1.93 1.35 2.12 2.99 0.26 0.52 0.79 1.17 0.83 1.24 1.79 SAE INTERNATIONAL AMS4178E Page 5 of 12 3.4.2.2 At 350 F (177 C) TABLE 4A - SHEAR STRENGTH, INCH/POUND UN
28、ITS Core Designation Minimum Individual Shear Strength, psi Ribbon Direction Minimum Individual Shear Strength, psi Transverse Direction 2.1-40-13 N or PFT5052 3.1-40-19 N or PFT5052 4.1-40-25 N or PFT5052 5.7-40-37 N or PFT5052 4.3-80-13 N or PFT5052 6.5-80-19 N or PFT5052 8.0-80-25 N or PFT5052 41
29、 82 118 182 127 200 282 24 49 75 111 78 117 169 TABLE 4B - SHEAR STRENGTH, SL UNITS Core Designation Minimum Individual Shear Strength, psi Ribbon Direction Minimum Individual Shear Strength, psi Transverse Direction 34-131-33 N or PFT5052 50-131-48 N or PFT5052 66-131-64 N or PFT5052 91-131-94 N or
30、 PFT5052 69-262-33 N or PFT5052 104-262-48 N or PFT5052 128-262-64 N or PFT5052 0.28 0.57 0.81 1.25 0.88 1.38 1.94 0.17 0.34 0.52 0.77 0.54 0.81 1.17 3.4.3 Node Bond Strength Shall be as shown in Table 5, determined in accordance with 4.5.1. TABLE 5 - MINIMUM INDIVIDUAL NODE BOND STRENGTH Property C
31、ells per Linear Foot 40 Cells per Linear Foot 80 Cells per Linear Meter 131 Cells per Linear Meter 262 Node Bond Strength at room temperature 30 pounds force 35 pounds force 133N 156N 3.4.4 Flexibility A core slice shall lie flat without crimping, permanent distortion, or delamination when flexed as
32、 specified in 4.5.2. 3.4.5 Corrosion Resistance The core shall show a weight loss not greater than 125 milligrams per square foot (1345 mg/m2) of exposed foil area, determined in accordance with 4.5.3. 3.4.6 Cell Count Shall be within 10% of the specified cell count, determined in accordance with 4.
33、5.5. 3.4.7 Density Shall be within 10% of the specified density, determined in accordance with 4.5.4. SAE INTERNATIONAL AMS4178E Page 6 of 12 3.5 Quality The core, as received by purchaser, shall be free from imperfections detrimental to usage. Core shall be clean and free from grease, oil, trim scr
34、aps, and impurities. The foil edges of the core shall be free from notches, crush lines and rolled metal. The core shall have no more than three node bond breaks per square foot (32/m2) with no more than 2 connected node breaks per square foot (22/m2). The core shall have no more than 4 unexpanded c
35、ells per square foot of core (43/m2). The core shall not have more than 10 multiple laps per sheet 36 x 96 inch (914 x 2438 mm) of core. 3.6 Sizes and Tolerances 3.6.1 Sizes Length, width, and thickness of each panel shall be as ordered. 3.6.2 Tolerances Shall be as shown in Table 6. 3.6.2.1 Thickne
36、ss TABLE 6A - TOLERANCES, INCH/POUND UNITS Nominal Thickness Inches Tolerance, Inch plus and minus 0.250 to 4.000, incl 0.005 Over 4.000 to 10.500, incl 0.062 TABLE 6B - TOLERANCES, SI UNITS Nominal Thickness Millimeters Tolerance, Millimeters plus and minus 6.25 to 101.60, incl 0.13 Over 101.60 to
37、266.70, incl 0.062 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Inspection The manufacturer of core shall supply all samples and shall be responsible for all required tests. Purchaser reserves the right to sample and to perform any confirmatory testing deemed necessary to ensure that the c
38、ore conforms to specified requirements. 4.2 Classification of Tests 4.2.1 Acceptance Tests Composition (3.1.1), density (3.2.1), cell count (3.2.1), foil thickness (3.2.1), compressive strength (3.4.1), shear strength (3.4.2), node bond strength (3.4.3), flexibility (3.4.4), and quality (3.5) are ac
39、ceptance tests and shall be performed on each lot of foil or core as applicable. 4.2.2 Preproduction Tests All technical requirements are preproduction tests and shall be performed prior to or on the initial shipment of core by the manufacturer, when a change in ingredients and/or processing require
40、s reapproval as in 4.4.2, and when purchaser deems confirmatory testing to be required. SAE INTERNATIONAL AMS4178E Page 7 of 12 4.3 Sampling and Testing Shall be in accordance with the following schedule: Composition (3.1.1): Each lot of foil Density (3.2.1): Each lot of core Cell Count (3.2.1): Eac
41、h lot of core Foil Thickness (3.2.1): Each lot of core Compressive Strength (3.4.1): Each lot of core Shear Strength (3.4.2): Each lot of core Node Bond Strength (3.4.3): Each lot of core Flexibility (3.4.4): Each lot of core Corrosion Resistance (3.4.5): Acceptable to purchaser Quality (3.5) 4.3.1
42、A foil lot shall be all foil of one alloy, each lot of core and in a single shipment from the foil producer. 4.3.2 A core lot shall be each block or all slices cut from a single block. 4.3.3 For Acceptance Tests For composition, one sample from each lot of foil; for other tests each block or 2% of t
43、he slices from each lot shall be sampled at random to provide sufficient core to perform all required tests. The number of determinations for each requirement shall be as specified in the applicable test procedure or, if not specified therein, not less than three. 4.4 Approval 4.4.1 Sample core shal
44、l be approved by purchaser before core for production use is supplied, unless such approval be waived by purchaser. Results of tests on production core shall be essentially equivalent to those on the approved sample. 4.4.2 Manufacturer shall use ingredients, manufacturing procedures, processes, and
45、methods of inspection on production core which are essentially the same as those used on the approved sample. If necessary to make any change in ingredients, in type of equipment for processing, or in manufacturing procedures, manufacturer shall submit for reapproval a statement of the proposed chan
46、ges in ingredients and/or processing and, when requested, sample core. Production core made by the revised procedure shall not be shipped prior to receipt of reapproval. 4.5 Test Methods 4.5.1 Node Bond Strength A 0.625T x 5 x 10L inch (15.88T x 127L x 254W mm) core slice shall be tested in a suitab
47、le tension fixture by mounting, without causing cell distortion, at opposite ends of the “W“ dimension (See Figure 1) with round pins. Pins shall be as large as cell size permits and shall engage all cells of a continuous row. Opposite pins shall be in a mirror image alignment at a distance as near
48、to 8 inches (203 mm) as this mounting method permits. The fixture shall be slotted to allow horizontal pin movement. A steady loading rate of 1.00 inch 0.05 (25.4 mm 1.3) per minute shall be maintained. SAE INTERNATIONAL AMS4178E Page 8 of 12 4.5.2 Flexibility Test A 10-inch (254-mm) square specimen
49、 0.625 inch 0.005 (15.88 mm 0.13) thick, shall be wrapped around a 4-inch (102-mm) diameter cylindrical mandrel at room temperature, first perpendicular and then parallel to the L direction of the core. Representative specimens shall be 5 inches 1/16 (127 mm 1.6) (R) long (longitudinal direction “L“, See Figure 1), 6 inches 1/16 (152 mm 1.6) wide (transverse direction “W“), and 0.625 inch 0.010 (15.88 mm
