High-strength Corrosion-resistant Porous Sandwich Structure Stainless Steel Welded Honeycomb Core

High-strength Corrosion-resistant Porous Sandwich Structure Stainless Steel Welded Honeycomb Core

The High-strength Corrosion-resistant Porous Sandwich Structure Stainless Steel Welded Honeycomb Core is a high-strength, corrosion-resistant metal porous sandwich structure produced by advanced welding processes. It can be seen as the "core layer" of a sandwich panel. For the special shape and small quantity required, a wire cut process should be used to get a required purpose. Hexagonal cells for obtaining these strips are welded points between them. Spot welding device is three electrodes in the upper part, which carries five welding points across the width of the strip of corrugated sheet metal. Spot welding device filled with press and advance mechanisms. There are five welders in every unit area to make sure the strength is enough and uniformly distributed based on electrodes welding of stack and resistance. The honeycomb core generally requires a good precision of welding process, high equipment control on the product and strict quality control during process. Stainless steel honeycomb is mainly for aerospace, high industrial application and civil areas, with the structure comprised of special foils (plates). Instead of general widely used adhesive bonding, stainless steel honeycomb is welded between those joint areas of the hexagonal shapes.

Core Working Principle

To manufacture it, ultra-thin stainless-steel strips (0.05 mm to 0.5 mm thick) are continuously roll-formed into corrugated or trapezoidal strips. Three main welding techniques are used:

· Laser welding (mainstream) – Uses a high-energy laser beam for high-speed, precision welding, suitable for thin materials from 0.08 mm to 15 mm. Weld seams are tiny (approx. 0.2–2 mm), with a narrow heat-affected zone, minimal distortion, and excellent sealing.

· Vacuum brazing – Uses nickel-based filler metals such as BNi2 to achieve a metallurgical bond with high strength. The vacuum environment prevents contamination, ideal for 304 and 316L stainless steel.

· Precision resistance spot welding – Melts the contact surfaces using electrical current. Suitable for manufacturing honeycomb rings in confined spaces.

Specifications

Properties

Welded honeycomb core, no matter what material is, such as aluminum, stainless steel, steel, titanium etc, possesses better mechanical properties against regularly produced glued honeycomb core. So it performs significantly better again the common honeycomb bonded by adhesive on strength, modulus, corrosion resistance, dimensional stability etc. However, generally, these critical performance variables should be evaluated: material, airflow and attenuation.

1. Material Composition

Stainless steel grade should be considered according to the real application. Custom materials other than stainless steel are available upon request. Here are the parameters need to be evaluated:

Durability

Material type and grade is the first aspect to be evaluated then plating, discussed in depth later, can improve durability.

Weight

Material, structure and thickness of the material can affect the total part weight.

2. Corrosion resistance

Typically brass and stainless steel should be used in slashing environments. Plating or nonconductive surface coatings can improve corrosion resistance for all honeycomb types.

3. Shielding Performance

Different honeycomb core material offerings have different electrical performance, due to both inherent base material properties as well as the differing manufacturing processes used during honeycomb forming. Therefore, different EMI shielding performance may be realized. Shielding performance for different materials is ranked as brass, aluminum, steel and stainless steel. Plating can improve honeycomb shielding.

Specific attenuation requirements can be met through either plated or unplated alloys. Plating adds cost to the final product vent. Plating process for improving shielding is ranked as nickel, tin, tin-lead and zinc.

4. Airflow & Attenuation

Airflow and attenuation are inversely proportional. Infinitely large honeycomb cells result in infinitely small attenuation (and vice versa). Typically, as a design baseline, airflow performance requirements are calculated to meet thermal performance needs for the assembly that the vent is to be installed onto. Once airflow is determined, attenuation and other requirements can be evaluated. Standard cell sizes for honeycomb are 1/16", 1/8" and 1/4", with 1/8" being most common. Standard thicknesses are 1/4," 1/2" and 1," with 1/4" being most common.

Advantages

The product is non‑combustible (fire resistance up to A1 grade), offers effective heat dissipation, sound insulation, and due to its open‑cell structure, provides electromagnetic shielding. These properties enable wide use:

Industrial Applications:

· Construction & Transportation – fire‑resistant curtain walls for high‑rise buildings, interior partition panels for high‑speed trains.

· Industrial & Special Fields – wind tunnel rectifiers, chemical heat exchangers, hulls for ships and yachts, protective housings for precision instruments.

· Defense & Aerospace – aircraft wings, fairings, various shock‑absorbing components, and blast‑resistant sandwich structures.