Heat Shielding Lightweight Aramid Honeycomb Core for Exhaust Shrouds

The Heat Shielding Lightweight Aramid Honeycomb Core is a high-performance, non-metallic sandwich core material engineered specifically for exhaust shroud and thermal protection applications in aerospace, defense, automotive, and industrial sectors.

Manufactured from aramid fiber paper (meta-aramid or para-aramid, equivalent to Nomex® or Kevlar®) and coated with a heat-resistant phenolic resin, this honeycomb core delivers an exceptional combination of thermal insulation, structural strength, and fire safety—all at a fraction of the weight of metallic alternatives.

The hexagonal cell structure—nature's most efficient geometry—distributes thermal and mechanical loads evenly while maximizing material utilization. Whether protecting turbine exhaust ducts, engine bay shrouds, or high-temperature industrial piping, this core material provides the thermal barrier your application demands without the weight penalty of traditional solutions.

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2. Core Advantages

2.1 Superior Heat Shielding & Thermal Insulation

Parameter Value
Thermal conductivity 0.03–0.05 W/m·K (vs. aluminum 100–200 W/m·K)
Continuous service temperature -55°C to +180°C (up to +200°C with advanced resin systems)
Peak short-term exposure +260°C to +300°C
Thermal resistance vs. fiberglass 20% lighter than fiberglass alternatives

The trapped air within the honeycomb cells creates an effective insulating barrier. With thermal conductivity approximately 3,000–6,000 times lower than aluminum, this core dramatically reduces heat transfer from hot-side exhaust components to adjacent structures—protecting sensitive equipment, reducing cabin heat soak, and improving overall system efficiency.

2.2 Ultra-Lightweight Construction

Density Range 29 – 144 kg/m³ (1.8 – 9.0 lb/ft³)
Weight vs. solid materials Up to 60% lighter than equivalent metal structures
Weight vs. fiberglass 20% lighter

Every kilogram saved in exhaust shroud design translates directly into greater payload capacity, extended range, and lower fuel consumption. At densities as low as 29 kg/m³, this core enables engineers to achieve thermal protection without compromising weight targets.

2.3 Self-Extinguishing Fire Safety

Property Performance
Self-extinguishing time < 1 second (NOMEX® paper alone)
Flammability compliance FAR 25.853 Appendix F Parts I & V
Smoke emission Low smoke & low toxicity
Flame penetration Resistant in accordance with FAR Part 25 Appendix F

Unlike aluminum honeycomb, which melts and conducts heat, our aramid core is self-extinguishing and does not support combustion. The phenolic resin matrix triggers a char-forming reaction upon heating, creating a physical barrier that cuts off oxygen supply and quenches the flame. This active fire-interruption property provides critical protection in engine bays and exhaust zones where fuel lines, hydraulic fluids, and high temperatures create elevated fire risks.

2.4 Additional Performance Benefits

· Corrosion resistance – Inherently non-metallic; immune to galvanic corrosion, moisture, and chemical attack
· Dielectric properties – Excellent electrical insulator; no electromagnetic interference
· Impact resistance – High toughness with good fatigue and impact resistance
· Vibration damping – Effective acoustic and vibration insulation
· Formability – Good formability for curve forming

Mechanical Properties of the Nomex Honeycomb Core

Mechanical Properties of the Nomex Honeycomb Core 2

Application:

Extremely High Strength Para-Aramid Honeycomb Core For High End Application is a high performance non-metallic core which can replace fiberglass and Nomex® honeycomb core materials to achieve significant weight reductions without sacrificing performance in most applications. para-aramid fiber honeycomb uses include boat decks, aircraft galleys, flooring, partitions, aircraft leading and trailing edges, radomes, flaps, access panels and doors.