Sandwich manufacturing with foam core and coversheets out of aluminum - a new process without rolling

The manufacturing processes for sandwiches made with aluminum or steel sheets are differentiated by their various melting ranges. Sandwiches with aluminum face sheets have recently been produced using to the so-called AFS technology, which includes a rolling process. However, if it is desirable to avoid rolling to reduce costs and allow for quick and flexible responses to the needs of the customer, the manufacturing process must be redesigned. This publication introduces a sandwich manufacturing approach that modifies the production of sandwiches with steel face sheets. The necessary process steps as well as the foaming and peeling test results are presented. Successful implementation of this approach has been demonstrated for sandwiches with surface dimensions of 1500 mm x 1000 mm.