Course M-1/R-1 - Advanced Composite Structures: Fabrication & Damage Repair-Phase 1. Course Summary

Transcription

1 Course M-1/R-1 - Advanced Composite Structures: Fabrication & Damage Repair-Phase 1 Course Summary Our most popular class, Advanced Composite Structures: Fabrication & Damage Repair-Phase 1 is designed to meet the needs of a wide range of personnel; from the novice to the seasoned professional. This course is a prerequisite for both our repair and manufacturing programs and is highly recommended to anyone seeking a better understanding of advanced composite materials, processes, layup/lamination, vacuum bagging, adhesive bonding, tooling, repair, and inspection methods and techniques. Introduction Balanced with theoretical and practical presentations, the hands-on exercises in this course are extensive; they will work with prepreg carbon fiber unidirectional tape to explore the effects of orientation; balance and symmetry in a laminate. The students will also work with dry glass fabric and liquid epoxy resin in an exercise designed to teach fundamental vacuum bagging, bleeder & breather concepts. Mid-week, teams work with prepreg glass and aramid fiber harness-satin fabrics, along with Nomex honeycomb and polyurethane foam core materials, making sandwich panel structures, utilizing laminate nesting techniques. And finally, basic repair methods and techniques will be presented along with performing a wet layup repair in the lab. On the last day, the final repaired part will be cut in half for evaluation of the manufactured and repaired panel. Page 1

2 Topics Key Lecture Elements: History of composites, recent developments and terminology. Introduction to advanced composite materials/structures. Resin/adhesive systems: thermosets vs. thermoplastics, mix ratios, viscosity, service temperature limits, cold storage requirements/shelf life limits, pot life, etc. Material Forms: dry cloth and wet resins vs. prepregs, weave/styles, etc. Fundamentals of Fabrication: prepreg cloth handling, ply orientation, layup procedures, vacuum bagging. Fabrication Methods: wet layup, prepreg layup, filament winding, RTM, infusion, press molding, pultrusion as well as automated tape layup (ATL) and fiber placement (AFP). Curing methods: oven/autoclave/hot bonder cures. Viscoelastic properties. Health and Safety Issues: proper handling, personal protection, allergic reactions, waste disposal. Introduction to adhesive bonding technology: co-curing vs. secondary bonding, surface preparation, cleanliness, bond line thickness and clamping pressure requirements. Principles of Tooling: types of tools, thermal characteristics of various tooling materials. Drilling and fastening; proper speed and feed requirements, use of mechanical and adhesive bonded fasteners. Primer on repair design; permanent vs. temporary repairs, scarf vs. stepped vs. mechanical patch repair scenarios. Inspection methods & techniques: non-destructive inspection methods, defect detection, documentation, acceptable vs. unacceptable defects, defect prevention. Workshop Exercises: Panel layup using prepreg carbon uni-tape materials; symmetric and asymmetric laminates. Panel layup using dry glass cloth and liquid epoxy resin materials. Vacuum bagging with varied bleeder/breather sequences to evaluate resin bleed and flow characteristics. Sandwich panel layup, bagging and processing of nested glass and aramid fiber fabric foam and honeycomb core panels. Vacuum bagging using non-autoclave bleeder/breather schedules. Installation of pleats to minimize bridging in high-angle core transitions. Vacuum debulking, leak checking, and identification of other potential bagging problems. Oven curing; vacuum, ramp rate, soak, and cooling requirements. Composite repair; damage removal, scarf preparation, core and skin repair using wet layup materials and processes. Introduction to hot-bond repair equipment; demonstration of bonders, heat blankets and thermocouple placement. Page 2

3 Powered by TCPDF ( Course Benefits Students come away with a fundamental understanding of advanced composite materials & processes at a level sufficient to put learned skills into practice immediately upon entry or return to the workplace. Prerequisites None - This course is a prerequisite for subsequent manufacturing and repair courses. Teaching Method Active classroom lecture and workshop exercises CPD 3.6 Page 3

4 Course M-2 - Advanced Composite Manufacturing 2 Course Summary This course is designed as follow-on to the M-1/R-1 course and is intended for those wanting to further their knowledge of composite manufacturing, whether in preparation for employment in the advanced composite manufacturing industry, or as engineers or technicians desiring a further understanding of the practical skills involved in producing quality composite structures. Introduction At the end of Manufacturing 2 the student will have an intermediate level of understanding of composite layup and vacuum bagging techniques for complex shapes, fabrication of potted honeycomb core assemblies, manufacturing composite component parts using production type tooling, and a fundamental understanding of the documentation and record keeping required to support composite manufacturing. Topics Key Lecture Topics: Quality assurance in manufacturing; planning, in-process inspection, and record keeping systems. Mold preparation; using semi-permanent polymer release systems. Challenges in layup of complex geometries: maintaining ply orientation/symmetry. Vacuum bagging complex shapes for oven and autoclave processing. Introduction to tooling: component specific molds and fixtures. Overview of non-destructive inspection methods. Workshop Exercises: Mold preparation: clean, seal, and release molds for service. Cut and machine honeycomb core materials for use in layup. Cut and kit prepreg fabrics and adhesives for panel build. Layup, vacuum bag, and process complex sandwich core panels. Demold and inspect parts using non-destructive methods. Part marking, packaging, and storage of parts used for assembly. Course Benefits At the end of Manufacturing 2 the student will have an intermediate level of understanding of composite manufacturing practices using manual layup and vacuum bag/oven and autoclave processing. Page 1

5 Powered by TCPDF ( Prerequisites M-1/R-1 Advanced Composite Structures: Fabrication & Damage Repair-Phase 1 course, or *Equivalent (5-years min) experience with advanced composite materials and processes. (*Please contact Abaris for equivalency test criteria and evaluation.) Teaching Method Active classroom lecture and workshop exercises CPD 3.6 Page 2

6 Course M-3 - Advanced Composite Manufacturing 3 Course Summary This course is designed as follow-on to the M-2 (Manufacturing 2) course and is intended for those wanting to further their knowledge of composite manufacturing, whether in preparation for employment in the advanced composite manufacturing industry, or as engineers or technicians desiring a further understanding of the practical skills involved in producing quality composite structures. Introduction At the end of Manufacturing 3 the student will have an intermediate level knowledge of machining, trimming and drilling composite components using fixtures, surface preparation methods/secondary bonding of structures, component assembly methods and techniques, as well as a acquire a fundamental knowledge of the resin vacuum infusion manufacturing process. Topics Key Lecture Topics: Documentation of in-process and post-process operations. Rejection reports, cause and corrective actions. Machining, trimming, and drilling composite components. Surface preparation and adhesive bonding of composites Vs metals. Mechanical fastening methods and techniques. Composite structure assembly methods and procedures. Resin infusion processes: Vacuum Infusion Process (VIP), Resin Transfer Molding (RTM), Vacuum Assisted Resin Transfer Molding (VARTM), etc. Darcy s law/permeability discussion. Resin ingress vacuum egress plumbing design. Workshop Exercises: Trim and drill components for assembly using Trim and Drill Fixtures (TDF). Surface preparation and bond-assembly of components. Installation of bonded nutplates and inserts. Prepare mold for infusion layup process. Layup preforms, arrange inlet and vacuum plumbing, vacuum bag, and infuse panel. Inspect all panels and assemblies and document findings. Course Benefits At the end of Manufacturing 3 the student will have an intermediate level knowledge of machining, trimming,drilling and bonding composite components for assembly. Students will complete an assembled structure. Page 1

7 Powered by TCPDF ( Prerequisites M-2 Advanced Composite Manufacturing 2 Teaching Method Active classroom lecture and workshop exercises CPD 3.6 Page 2

8 Course M-4/R-7 - Adhesive Bonding of Composites & Metals Course Summary This course is designed for engineers, technicians, and anyone else looking to advance their knowledge in adhesive bonding technology, while gaining a deeper understanding of surface preparation and the fundamental adhesion principles necessary to achieve a good bond to both (polymeric) composite and metallic surfaces. Introduction The course contains a balance of theory and practical application, with much of the time spent in the lab constructing and testing various test specimens made from aluminum and composite substrates. A comparison of aluminum surface preparation methods are examined using wedge-crack testing per ASTM D-3762 methods and practices. Aluminum plates are prepared using several industry standard methods including phosphoric acid anodizing (PAA) and sol-gel treatments, as compared to typical abrasion techniques. The plates are bonded with structural film adhesives, cured, and then cut into wedge test specimens. Wedges are inserted into the bondline creating a crack. The crack length is then measured and the growth is monitored for each test specimen as they are exposed to various environmental conditions throughout the week. The data is collected daily, analyzed, and compared at week s end. In addition, a number of lap-shear coupons are prepared and bonded by the students using different surface preparation methods. The coupons will be bonded utilizing different film, liquid, and paste adhesives, and applicable processing methods. In some cases, deliberate contamination is introduced into the bondline to assess the effects. Specimens will also be made to evaluate bondline thickness control, utilizing media such as microbeads and knit or scrim carriers with both liquid and paste adhesives. Co-cured composite and secondary bonded aluminum sandwich panel structures will be fabricated and tested using a special flatwise-cleavage test developed by Abaris. This test allows the students to see the effects at the skin-to-core interface on both foam and Nomex honeycomb core materials. All of the test data is collected and compared in a spreadsheet format for each of the various tests with all of the results available to the students after each exercise. Page 1

9 Powered by TCPDF ( Topics Key Lecture Topics: Fundamentals of structural adhesive bonding Liquid, paste, and film adhesives; application and cure requirements Bondline control medias and methods Typical joint designs and forces on bonded joints Bondline integrity and durability considerations. Contamination issues; direct and indirect sources Moisture problems; laminates, adhesives and core materials Surface preparation of metals vs composites Overview of non-destructive inspection of bonded joints Destructive testing methods and practices Open-time considerations and environmental effects Workshop Exercises: Surface preparation of aluminum using grit blast, ScotchBrite, abrasives, PAA & Sol-Gel materials. Manufacture and testing of wedge specimens in accordance with ASTM D-3762 methods and practices. Surface preparation of composite substrates using various abrasive and non-abrasive methods, including blown-ion plasma surface treatment using Enercon equipment Manufacture and testing of CFRP lap-shear coupons. Bonded sandwich panel fabrication and testing. Vacuum bagging and curing of test specimens. Destructive testing and analysis of student-fabricated specimens. Course Benefits The student will have a good understanding of surface preparation and the fundamental adhesion principles necessary to achieve a good bond to both (polymeric) composite and metallic surfaces. Prerequisites None required - The M-1/R-1 course is suggested for basic subject knowledge if necessary. Teaching Method Active classroom lecture and workshop exercises CPD 3.4 Page 2

10 Course M-5 - Resin Infusion Technologies Course Summary This course is designed for the engineer, technician, laminator, fabricator, or anyone else wanting to learn about the fundamental principles and more complex concepts involved in resin infusion technology. Introduction Previous experience with composite materials, layup, and vacuum bag processing is required. For those who do not have a thorough background with advanced composite layup and processing, we recommend our M1/R-1 Composite Structures: Fabrication & Damage Repair-Phase 1 course as a prerequisite course prior to attending the resin infusion course. The fundamental science that drives vacuum infusion processing (VIP) is explained and tested in the workshop. Materials, tooling and application techniques are evaluated and applied with hands-on exercises and demonstrations. Students will gain a theoretical understanding and practical hands-on experience necessary to employ vacuum resin infusion in their own applications. This course will examine the pros and cons of infusion processing and define the usefulness and limitations related to the VIP process. The class includes a basic overview of the necessary facilities and equipment required to set up and perform VIP in a production setting. Page 1

11 Topics Key Lecture Topics: Overview of infusion techniques. Fiber forms and material types used for infusion. Specialty cores and fabrics. Resins used for infusion. Temperature, viscosity and permeability; Darcy's Law. Flow fronts; principles and designs. Race-tracking and other inherent problems. Resin feeder and vacuum systems. Resin/fiber calculations. Facilities, tools and equipment. Workshop Exercises: Fiber-pack/preform fabrication. Placing and securing fibers/fabrics in molds. Tool preparation and mold release application. Installation of resin and vacuum plumbing. Vacuum bagging for infusion. Infusion exercises involving various shapes. Solving infusion problems. Identifying leaks and dry areas. In-process repairs of dry areas. Curing infused panels and parts. Course Benefits The student will learn the fundamental principles of resin infusion processing with emphasis on vacuum infusion technologies. Prerequisites M-1/R-1 Composite Structures: Fabrication and Damage Repair - Phase 1, or Equivalent (5 year min) experience with advanced composite materials and processes. (*Please contact Abaris for equivalency test criteria and evaluation.) Teaching Method Active classroom lecture and workshop exercises CPD 3.4 Page 2 Powered by TCPDF (

12 Course M-6/R-8 - Mold Fabrication for Production and Repairs Course Summary This course is designed for the tooling engineer, tool designer, tool fabricator, or anyone else that has a desire to learn about designing and building molds and fixtures using advanced composite materials. Introduction In this course the students will learn about tool design techniques that contribute to both dimensional stability and tool longevity. After discussing basic concepts in the classroom, the students are encouraged to apply these lessons in the workshop to see for themselves how simple ideas can greatly improve tool quality. Molds and fixtures are fabricated in class off of existing master models, patterns, or parts using the latest materials and techniques; much emphasis is placed on using TenCate AmberTool low temp curing carbon prepreg materials for fabricating molds that can later be post-cured for use at elevated temperatures. Room temperature curing wet resins and dry fabrics are used for making intermediate transfer patterns and trim and drill type fixtures. AmberTool is a registered trademark of Royal TenCate. Page 1

13 Topics Key Lecture Topics: The tooling family; from master model to molded part. Tool codes/designations. Prototype vs. production tooling. Making tooling from existing parts. Complex vs. simple geometries. Indexing and part to tool coordination. Realistic part and tool design tolerances. Thermal properties; Coefficient of Thermal Expansion (CTE). Springback allowance. Integrated stiffening techniques. Backup structure materials and design. Damage prevention through design. Vacuum and pressure integrity issues. Lightweight tool-design concepts. Mold fabrication considerations: ply orientation and layup techniques. Tool repair materials and procedures. Permanent vacuum bags and semi-rigid caul tooling. Application of semi permanent seal and release systems. Workshop Exercises: Preparation of a master-model, permanent pattern, or an existing part for use in tool-laminate fabrication. Mock up fences and decks for molding flanges. Add indexes and other pertinent design features. Fabricating either a carbon fiber or fiberglass mold using the latest low-temperature curing tooling systems; includes bagging and (non-autoclave) cure processes and procedures. Fabricating glass-epoxy fixture laminates using wet-layup materials, methods and techniques. Course Benefits Upon completion of this course the attendee will have a better knowledge of composite tool design methods, as well as hands on experience with both wet and prepreg tooling systems in creating tool laminates for use in either composite production or repair scenarios. Page 2

14 Powered by TCPDF ( Prerequisites M-1/R-1 Composite Structures: Fabrication and Damage Repair - Phase 1 course, or Equivalent (5 year min) experience with advanced composite materials and processes. (*Please contact Abaris for equivalency test criteria and evaluation.) Teaching Method Active classroom lecture and workshop exercises CPD 3.6 Page 3

15 Course M-7/R-6 - Non Destructive Inspection Techniques for Technicians and Inspectors Course Summary This five-day course is designed for the repair technician, fabricator, or inspector tasked with identifying and quantifying defects in new or damaged composite panels using the latest equipment, methods, and techniques. The course is very hands-on in nature, and quite busy. The instruction is performed by an ASNT certified Level III engineer and is flexible to adapting to the students needs. Introduction Four of the most commonly used NDI techniques will be discussed and practiced in class. These techniques include Visual Inspection, Tap Testing (both manual and instrumented tap testing), Resonance Bond Testing, Acoustic Emission testing, Radiographic testing, and Ultrasonic Inspection. Some of the more sophisticated techniques, such as Pulsed Thermography, Fourier Transform Infrared (FTIR), Laser Shearography, and Laser Holographic Interferometry may be presented, but not actively used in the class. The students will inspect fiber-reinforced composite panels, of both solid laminate and sandwich construction. These panels will include deliberate defects in specified areas and will be inspected using different techniques to determine which methods or techniques work best for detecting the different types of defects. Through actual hands-on practice, the students will learn what methods work best and what may not work as well on different structures and with different types of defects. The goal is for the student to obtain a thorough understanding of why these differences exist, and which methods of inspection are most applicable to a specific structure. Training begins with a discussion of the basic elements of composite materials, and construction techniques. This leads into conversation about common flaws, defects, and typical damage scenarios, including hidden damage issues. Other topics include a review of damage types and causes, as well as damage from unexpected sources such as water, paint stripper, hydraulic fluid, and low-intensity impacts. The inherent Pros and Cons of all techniques and lessons learned will be discussed in detail; including a discussion about defects which cannot currently be detected with existing NDI methods or techniques. Page 1

16 Powered by TCPDF ( Topics Key Lecture Topics: Introduction to composite materials and processes. Fundamentals of solid laminate & sandwich panel construction. Types of defects and potential causes. Damage detection and assessment. Inspecting for hidden damage. Inspecting known damage. Overview of NDI methods and techniques. Classroom introduction to specific workshop exercises. Workshop Exercises: Students will perform visual inspection, manual tap testing, digital tap testing, ultrasonic and resonance bond testing on the composite panels to find flaws and defects on simulated and actual composite structures. The class will also inspect secondarily bonded composite specimens with intentional defects at the bond interface utilizing different methods and techniques to determine best practices applicable for bondline inspection. Course Benefits This course will give the attendees a good working knowledge of ultrasonic inspection techniques along with an overview of complimentary and comparative NDI/NDT techniques used in industry. Prerequisites M-1/R-1 or equivalent experience is preferred but not required. Teaching Method Active classroom lecture and workshop exercises CPD 3.4 Page 2

17 Course M-8/R-11 - Advanced Composite Drawing Interpretation Course Summary This three-day course is designed for engineers, technicians, mechanics, inspectors, or anyone else responsible for designing, fabricating, repairing or inspecting advanced composite structures. This course provides instruction in advanced composite drawing principles; reading and interpreting technical drawings used in manufacturing, production, and repair of advanced composite products. This course is only available onsite at customer locations only. Introduction Much emphasis is placed on the similarities of composite drawing standards used throughout the industry. Students will learn the basics of drawing layout, the importance of notes, parts lists, applications lists, and where to find other pertinent information related to panel layup and/or assembly information. Attendees will also learn to interpret cross sections, ply definition diagrams, ply tables, and basic orthographic projection principles that are essential to reading composite drawings. In addition to topic lectures, students will be provided actual composite drawings and participate in hands-on drawing interpretation exercises that are designed to progressively enhance their print reading abilities. Page 1

18 Topics Key Lecture Topics: Basic drawing format/layout; notes, material list symbols, title block. Geometric dimensioning and tolerance (G.D. & T.) in accordance with ASME Y14.5M Interpretation of drawing views: plan views, sections, details, tabulation, and orthographic projection. Material designation, material callouts, notes list. Ply definition diagrams and ply tables. Core ribbon direction, core callout, part numbering. Introduction to ply-shorthand code. Workshop Exercises: Drawing interpretation exercises using actual composite drawings. Exploration of parts lists, application lists, notes, and views on the field of the drawing. Interpreting 1st angle orthographic projection Vs. 3rd angle projection drawings. Course Benefits The student will learn fundamental drawing practices for constructing and interpreting advanced composite drawings used in design, manufacturing and repair. Prerequisites M-1/R-1 or equivalent is suggested but not required Teaching Method Active classroom lecture and print interpretation exercises CPD 2.0 Page 2 Powered by TCPDF (

19 Course M-10/R-12 - Certified Composite Instructor: Level I Course Summary The certificate program is offered to those persons who are currently teaching, or those that wish to teach subjects related to advanced composite materials, manufacturing, or repair. This course is designed as part of Abaris train-the-trainer (TTT) program that allows a dedicated student to become an Abaris Certified Composite Instructor: Level I. It is an opportunity to learn and grow with the best trainers in the world. Introduction This workshop will test and measure the student s level of knowledge in composite materials & processes, as well as their presentation and communication skills. Each attendee will be graded upon these abilities and certified to a list of training standards. The program is designed to train each person how to teach advanced composite subjects with the technical expertise and confidence necessary to engage their own students. Prerequisites: The Level I program requires the prospective trainer to graduate from the M-1/R-1 Composite Structures: Fabrication & Damage Repair-Phase I course, along with three other 5-day courses of their choice to qualify for this intensive 10 day certification workshop. *Note: If the student has graduated from any 5-day courses within the past 5-years, those courses will be credited towards the course requisites. They may attend additional courses, if necessary, at their own pace to qualify for certification. Abaris will offer at least one certification workshop annually as well as re-certification courses every two years. Page 1

20 Powered by TCPDF ( Topics Key Lecture Topics: Objectives Video Introductions Questions for the training expert Why People resist change 10 Principles of Learning Effective Training Focus on the Trainee Focus on the Trainer Systematic Approach to Training Developing a Lesson Plan Classroom Dynamics Review of topics; Composite Materials, Vacuum Bagging, Layup Techniques, Tooling, Adhesive Bonding, Tooling, NDI Techniques, etc. Workshop Exercises: 5-min Composite Pop Presentations Peer feedback sessions Class preparation exercises Lab Project Development 20 min final presentation Video presentation reviews with certifying instructor Course Benefits Attendees will receive Abaris Certified Composite Instructor: Level I certificate that designates that the attendee has proven competent to teach basic composite related subjects of choice. Prerequisites M-1/R-1 Composite Structures: Fabrication & Damage Repair-Phase I course, along with three other 5-day courses of choice. Teaching Method Active classroom lecture and workshop presentation and evaluation exercises CPD 7.2 Page 2

21 Course MQA-1 - Fundamentals of Advanced Composites for Auditors Course Summary This course is designed for the supplier quality auditor, internal auditor, quality engineer, or any other individuals wanting to gain knowledge in advanced composite manufacturing practices and procedures. The course is designed to provide an in-depth look at how composite products are fabricated and the quality controls that go along with each step in the process. Introduction The focus of the course is to provide the attendee with knowledge of the quality issues inherent to manufacturing advanced composite panels, components, and assemblies. This course also provides the student with a better understanding of advanced composite materials, processes, layup/lamination, vacuum bagging, adhesive bonding, tooling, repair, and inspection methods and techniques used in industry today. Balanced with theoretical lectures and practical workshop exercises, this course highlights many fundamental composite material control, layup, processing, and in-process inspection challenges as they might be experienced in an actual manufacturing environment. It provides the auditor a view of the details associated with each step in the composite manufacturing process and what to look for when conducting a site visit. During the course the students will actually work with composite materials, learning firsthand about material handling characteristics, the importance of ply orientation, vacuum bagging principles, curing, and a host of other important issues that influence the quality of the end product. Topics Key Lecture Elements Introduction to advanced composite manufacturing methods and techniques; wet layup, prepreg layup, filament winding, RTM, infusion, press molding, Pultrusion, automated tape layup (ATL) and fiber placement (AFP). Resin/adhesive systems: thermosets vs. thermoplastics, mix ratios, viscosity, service temperature limits, cold storage requirements/shelf life limits, pot life, etc. and auditing associated records, in-transit temperature recorders, material certificates, and product storage. Material Forms: unidirectional tape, fabric weave/styles, multi-axial forms, etc., and auditing material defects, storage & handling, and product traceability. Receiving Inspection: mechanical, physical, analytical, and flammability testing and auditing test laboratories, test methods, equipment, specimen traceability, and documentation. Core materials: Honeycomb and foam core; machining, splicing, potting forming, etc.; and auditing storage and handling procedures; dimensional inspection, environmental monitored areas. Fundamentals of Fabrication: prepreg cloth handling, ply orientation, layup Page 1

22 procedures, vacuum bagging, and auditing kit cutting, laminator techniques, knowledge of requirements, work instructions, proper use of expendable materials, and in-process inspection. Curing methods: oven/autoclave/hot bonder cures. Viscoelastic properties, and auditing associated cure records. Health and Safety Issues: proper handling, personal protection, allergic reactions, waste disposal. Facility requirements: controlled contamination areas (CCA); positive pressure systems, temperature and humidity recorders, particulate/dust controls, and auditing associated records, CCA maintenance, and verification of the enforcement of prohibited materials and practices in the CCA. Introduction to adhesive bonding technology: co-curing vs. secondary bonding, surface preparation, cleanliness, bond line thickness and clamping pressure requirements and auditing handling & storage of pre-cured details. Principles of Tooling: types of tools, thermal characteristics of various tooling materials. Auditing associated tooling, solvent double wipe cleaning, and application of mold release agents. Drilling and fastening; proper speed and feed requirements, use of mechanical and adhesively bonded fasteners. Digital Product Definition: firmware, software, part specific programs and auditing configuration & traceability of programs used for automated kit cutting machines, AFP/ATL machines, laser ply locators, cure, etc. Overview of repair design; permanent vs. temporary repairs, scarf vs. stepped vs. mechanical patch repair scenarios. Inspection methods & techniques: destructive and non-destructive inspection methods, defect detection, documentation, acceptable vs. unacceptable defects, defect prevention. Auditing test lab procedures. Workshop Exercises Panel layup using prepreg carbon uni-tape materials; symmetric and asymmetric laminate examples. Sandwich panel layup, bagging and processing of CFRP-honeycomb core sandwich panels. Vacuum bagging using non-autoclave bleeder/breather schedules. Installation of pleats to minimize bridging in high-angle core transitions. Vacuum debulking, leak checking, and identification of other potential bagging problems. Oven curing; vacuum, ramp rate, soak, and cooling requirements. Composite repair; damage removal, scarf preparation, core and skin repair using prepreg materials and processes. Use of hot-bond repair equipment; demonstration of bonders, heat blankets and thermocouple placement. Course Benefits The attendee will gain insight into composite materials and manufacturing practices as it relates to verification of practices and procedures used to ensure supplier quality. Page 2

23 Powered by TCPDF ( Prerequisites None Teaching Method Active classroom lecture and workshop exercises. CPD 3.4 Page 3