2. An introduction to
composites:
modern composites defined
matrix of resin +fiber
advanced composites
> strength : weight ratio
specific purpose design
composite history & evolution
60 yrs of accelerating advances
fiberglass
epoxy matrix
carbon fiber
aramid fibers
advanced composites
aircraft applications
ceramic & metal matrix materials
repair techniques
3. Composite applications
Transportation
Ground, air, marine, space
Military
armor, weapons, containers
Sporting goods
golf, tennis, fishing, helmets,
wheels, skis/snow boards, kite and
wind surfing, snow machines, gun
components
Building materials
pipes, beams, panels, bridges,
roofing, decking, signs, furniture
Medical
prosthetic devices, braces,
enclosures, body moving aids
4. Other industries
Electrical & electronics-
standoffs, circuit boards, junction
boxes, ladder rails, cherry picker
buckets
Corrosion resistant
systems- oil field pipes, pump
bodies, suction rods
Appliances & equipment-
compressor bases, washing
machine gears and parts, power
tool housings, computer housings
Renewable Energy
systems- wind, ocean, solar
5. Composite pros & cons
advantages
stiffness, TS/p, high fatigue life,
corrosion resistant,
complex shapes,
smooth skin, stealth,
multiple mfg methods
Disadvantages
high labor, material and capital
costs,
storage of materials
damage and repairs
safety concerns
6. Course Development
Industry needs
• workforce trained in composite usage
• work experience using composites
• design experience with composites
• repair experience with composites
Students needs
• hands on experience with composites
• Students who want to work in growing
advanced composite industries
• Design experience using composites
College needs
• New technologies for students
• New courses for program development
• New laboratory ideas & equipment
• Internships and industry partnerships
Lay-Up with splice
7. Industry connections
Training for new employees and
educational upgrades
Internships for students and
faculty
Research ideas for faculty and
students
Industry tours for processing
classes
Projects for capstone classes and
senior projects
Feedback from employed alumni
Development of training programs
Equipment and lab material
donations
Expertise for developing
programs and ideas
8. Industry ideas
Review product, processes.
Materials, inspection and repair
techniques
•Cessna
•Monaco and Country Coach
•ECS Case
•Bayliner
•Boeing
•Erickson Air Crane
Tooling
Lean
GD&T
Six sigma
CAD/CAM
Automated systems
Communication skills
Material conveyance
Repair
Testing and Inspection
9. Course Outline
Introduction to composites
Advanced composites ( high
temp/high performance)
Environmental effects on
composites
Fiber reinforcements
Composite design considerations
Tooling
Inspection and testing
Adhesive bonding
Advanced composite assembly
Liquid molding
Industries and processes using
advanced composites
Repair of composites
Nanocomposites
10. Laboratory Development
Laboratory experiments
• Wet lay up-flat
• Build a clip board
• Build a mold & mold prep
• Wet lay up with clocking in a
mold
• Prepreg layup with clocking in
mold
• De-bulking vac bag
• Make a product (skate board
or surf board)
• Resin transfer molding
experiment
12. Safety
• Identify safety hazards and
hazardous waste
• Illustrate use of safety
equipment
• Encourage compliance of
safety regulations
• List personal protective
equipment
• Post Material Safety Data
Sheets
• Location and use of fire
extinguishers
13. Lab Material
• Woven material –
fiberglass, carbon fiber &
aramid
• Resin fast and slow
• Vac bagging materials
• Mixing materials
16. • VISUAL INSPECTION DEFECTS
DEFECT LAY-UP
SEQUENCE
BAGGING FIBERS RESIN CURE TOOL
Bubbles
Wrinkles
Loose Fibers
Resin Starved Areas
Ply Orientation
Porosity
Surface Defects
Inclusions
Fiber Distortion
Voids
Contamination
FOD - FOE
Burned Resin
Burned Bag
Vacuum Leak
Delamination
Ply Gaps
TC Problems
Bridging
De-Bonds
Damaged Plies
Micro Cracking
Matrix (resin) Concerns
Uncured Resin
Blown Bag
Resin Rich Areas
Warped Laminate
X X X
X X X
X X
X X X
X X X
X X X
X X
X
X X X
X X X
X
X X
X X X
X X X
X X
X X X
X X
X X
X
X X X X
X
X X
X X X
X X
X X
X
X X X
X X
X
X X X
X X
X X
17. Course assessments
Testing & Homework
• Conventional testing but
with problems that are
specifically applicable to
composite industry
problems.
• Homework & research
based on composite
industry problems.
Ply orientations
18. IDENTIFY AND NAME THE COMPONENTS INDICATED BELOW
(A THROUGH E)
60. ____________________ (A)
61. ____________________ (B)
62. ____________________ (C)
63. ____________________ (D)
64. ____________________ (E)
66. Preimpregnated cloth may be warmed to provide greater flexibility when laying
up parts.
A. True B. False
65. The temperature hold period at 240 +/- 100F is intended to:
A. Cure the laminate.
B. Raise the viscosity of the resin so that it will no longer flow.
C. Allow for break time
D. None of the above
Test Panel or Test Cupon
Vacuum Hose
Vacuum Probes
Vacuum Gage
T.C. Wire
CIRCLE THE CORRECT ANSWER: (example B )
Page 10
C
D
E
B
20. Team Projects
Projects
• Develop drawing sets specific
to advanced composite parts
and assemblies
• Develop a composite product
through design and lay out its
manufacturing sequences and
then cost the product
• Graded via peer evaluations in
presentation
21. References
• ‘Manufacturing Processes for Advanced Composites’ by F. C. Campbell,
Elsevier
• ‘Advanced composite stuctures: fabrication and damage repair’ Abaris
Training Resources Inc.
• ‘Materials Science and Engineering an Introduction’ by William D. Callister,
Jr. 7th ed., Wiley
• Cessna Training program Bend, OR
• ‘Mechanics of Composite Materials’ by Autar K. Kaw 2nd Edition CRC Taylor
and Francis Group
• ‘Materials Selection In Mechanical Design’ by Michael F. Ashby 3rd ed.,
Elsevier
• CRC Practical Handbook of Materials Selection by James Shackelford,
William Alexander & Jun S. Park
• Abaris Training-’Advanced Composite Structures: Fabrication and Repair’
• Cerritos College ‘Composite Lay-Up Manual’
