SEMCOMP2-09 Using resin transfer moulding techniques to produce composite mouldings

Transcription

1 Using resin transfer moulding techniques to produce composite Overview This standard identifies the competences you need to produce composite using resin transfer moulding techniques, in accordance with approved procedures. You will be required to use appropriate drawings, specifications and documentation to produce various, using the approved resin transfer moulding production techniques. You will be expected to produce a range of incorporating a variety of features. Mouldings produced will include laminates and sandwich structures, using a range of resin, fibre and core materials. Your responsibilities will require you to comply with organisational policy and procedures for the production activities undertaken and to report any problems with the equipment set up, production activities or materials that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work to instructions under supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying resin transfer moulding techniques and procedures. You will understand the production techniques used and their application, in adequate depth to provide a sound basis for carrying out the activities and ensuring that the work output is to the required specification. You will understand the safety precautions required when carrying out the moulding activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout and will understand the responsibility you owe to yourself and others in the workplace. SEMCOMP2-09 1

2 Performance criteria You must be able to: P1 work safely at all times, complying with health and safety and other relevant regulations and guidelines P2 confirm what has to be produced and how this will be achieved P3 confirm the equipment has been set up correctly for the resin transfer moulding operation P4 follow the correct component drawing or any other related specifications for the component to be produced P5 check that all safety mechanisms are in place and operate correctly P6 carry out any preparation activities required on the tooling, equipment and materials P7 check that the equipment is operating correctly P8 carry out the moulding activities using the correct methods and techniques P9 produce to the required specification P10 deal promptly and effectively with problems within your control and report those that cannot be solved SEMCOMP2-09 2

3 Knowledge and understanding You need to know and understand: K1 the health and safety precautions to be taken, and procedures used, when working with composite materials, consumables, tools and equipment in the specific work area K2 the hazards associated with carrying out resin transfer moulding techniques, and with the composite materials, consumables, tools and equipment used, and how to minimise these and reduce any risks in the work area K3 the protective equipment (PPE) that is needed for personal protection and, where required, the protection of others K4 the application of COSHH regulations in relation to the storage, use and disposal of composite materials and consumables K5 the specific environmental conditions the must be observed when producing composite (such as temperature, humidity, fume/dust extraction systems and equipment) K6 how to identify and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken K7 how to interpret drawings/lay up manuals, systems of measurement, workpiece reference points and system of tolerancing K8 the quality procedures used in the workplace to ensure production control (in relation to currency, issue, meeting specification) and the completion of such documents K9 the basic conventions and terminology used for resin transfer moulding techniques (such as material identification, lay-up specifications, resin viscosity, injection pressure, injection rate, resin/catalyst ratios, resin and fibre weights/volumes, gel times, exotherm) K10 the safety mechanisms on the machine and the procedure for checking that they function correctly K11 the operation of the machine controls and how to stop the machine in an emergency K12 the function of the main parts of the resin injection machines (such as injector heads, material delivery and flushing systems) K13 the common machine settings that may require adjusting to achieve the required specification K14 the effects that changes to theses settings will have on the quality of the components produced K15 the function resins, reinforcement, catalysts, accelerators and additives SEMCOMP2-09 3

4 play in the production of K16 the function fibre materials and preforms, their combinations play in the production of K17 the function core and insert materials play in the production of K18 how to visually identify raw and finished composite materials K19 the type of production tooling used for producing composite K20 the identification of common defects in production tooling K21 how to prepare moulds and tooling (including the correct selection and use of surface sealers and release agents) K22 the methods of handling, preparing, positioning the reinforcing fibres and fabrics K23 the importance of having the correct mixing ratios for gel coats, resins, accelerators and catalysts and the associated working times K24 the tools and equipment used in the resin transfer moulding activities and their care and safe handling K25 the common problems that can occur during the resin transfer moulding process (including defects such as contamination, incomplete saturation, pressure/vacuum leaks, flow restrictions) K26 the methods and techniques used to cure composite including cure cycles and the need to monitor them K27 the procedures and methods used for removing from production tooling K28 the identification of common defects in the composite (such as dry patches, print through, voids, contaminants) K29 the care and safe handling of production tooling and composite throughout the production cycle K30 the actions to be taken for any unaccounted items K31 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve K32 the documentation to be completed during and/or on completion of the moulding activity SEMCOMP2-09 4

5 Additional Information Scope/range related to performance criteria You must be able to: 1 carry out all of the following during the moulding activities: 1.1 use the appropriate documentation (such as job instructions, drawings, material data sheets, specifications, equipment setting-up documentation, planning and quality control documentation) 1.2 adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work 1.3 maintain a safe working environment for the setting and moulding activities 1.4 check that all tools and equipment to be used are correct for the operation to be carried out and are in a safe and usable condition 1.5 follow safe practice/approved setting and moulding techniques at all times 1.6 plug injection and vent holes on completion of resin injection where required 1.7 clean/flush mixing and injection equipment after use 1.8 return all tools and equipment to the correct location on completion of the moulding activities 1.9 segregate and dispose of waste materials using the correct procedure 1.10 leave the work area in a safe and appropriate condition on completion of the activities 1.11 complete relevant production documentation 2 confirm that the machine has been set up correctly to include all of the following: 2.1 all machine services are connected and operational (such as electrical, pneumatic, vacuum) 2.2 there are sufficient raw materials available and that they meet the component specification (such as resin, catalyst and flushing solvent) 2.3 the machine settings are appropriate for the moulding being SEMCOMP2-09 5

6 produced, including alarm conditions 2.4 the injector head and cleaning cycles function correctly 2.5 all the machine controls function correctly including pressure and vacuum sensors (where applicable) 2.6 the resin and/or mould tool heating arrangements have been set correctly (where applicable) 3 confirm the machine settings are correct for the moulding activity to include three of the following: 3.1 injection pressure 3.2 Injection flow rate 3.3 injection quantity 3.4 catalyst percentage 3.5 mould vacuum level 3.6 peripheral seal vacuum level 4 prepare the tooling for production, to include carrying out three of the following: 4.1 check that tooling is correct and complete 4.2 clean tooling and remove resin build-ups 4.3 check for surface defects 4.4 correctly apply sealers/release agents 4.5 clean and store tooling suitably after use 5 produce composite incorporating four of the following features: 5.1 internal corners 5.2 external corners 5.3 horizontal surface 5.4 vertical surface 5.5 double curvature 5.6 concave surface 5.7 convex surfaces 5.8 return surfaces 5.9 joggle details 5.10 nett edges 5.11 webs/ribs 5.12 inserts 5.13 fixtures 6 produce composite, using one type of resin from: 6.1 bio resin 6.2 acrylic 6.3 polyester 6.4 vinyl ester 6.5 epoxy SEMCOMP2-09 6

7 6.6 phenolic 6.7 other (to be specified) 7 produce composite, using one type of fibre from: 7.1 natural fibre 7.2 thermoplastic 7.3 glass 7.4 aramid 7.5 carbon 7.6 hybrid 7.7 other (to be specified) 8 produce composite, using three types of reinforcement/preform from: 8.1 uni-directional 8.2 chopped strand 8.3 tissues/veils 8.4 woven 8.5 braids 8.6 multi-axis/stitched 8.7 tapes 8.8 knitted 8.9 stitched perform D knitted perform 8.11 braided perform 8.12 RTM fabric 8.13 RTM fabric/core 8.14 other (to be specified) 9 produce composite, using one type of core materials from: 9.1 solid timber 9.2 end grain balsa 9.3 coremat 9.4 rigid foam 9.5 non-rigid foam 9.6 skinned honeycomb 9.7 other (to be specified) 10 produce composite, using one type of mould clamping system: 10.1 threaded fasteners 10.2 toggle clamps 10.3 latch clamps 10.4 vacuum clamping 10.5 hydraulic press 10.6 electric press SEMCOMP2-09 7

8 10.7 other (to be specified) 11 visually inspect a number of sample or trial and identify two of the following: 11.1 which meet the required specification 11.2 which have defects 11.3 that require further investigation 12 produce composite in compliance with one of the following: 12.1 BS, ISO or BSEN standards and procedures 12.2 customer standards and requirements 12.3 company standards and procedures 12.4 recognised compliance agency/body s standards SEMCOMP2-09 8

9 Developed by SEMTA Version number 1 Date approved February 2013 Indicative review date Validity Status Originating organisation Original URN Relevant occupations February 2016 Current Original SEMTA SEMCOMP2-09 Laminator; Composite Fitter; Composite Technician; Moulding Technician Suite Composite Engineering Suite 2 Key words Engineering; produce; composite; ; components; laminating; resin; fibre; resin transfer moulding SEMCOMP2-09 9