1. Introduction to Advanced Composite Materials
Global Hawk UAV

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
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 Students needs College needs
Lay-Up with splice
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

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

11. Lab Equipment Benches Freezer Vacuum pump Hand tools Safety equipment
Furnace/autoclave
thermocouples

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

14. Lab
Wet hand lay up
Bagging/Debulking

15. Composite Inspection Methods
Visual
Delamination

16. VISUAL INSPECTION DEFECTS
LAY-UP
SEQUENCE
DEFECT
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

17. Course assessments Testing & Homework Ply orientations
Conventional testing but with problems that are specifically applicable to composite industry problems.
Homework & research based on composite industry problems.

18. B Test Panel or Test Cupon 60. ____________________ (A) Vacuum Hose
IDENTIFY AND NAME THE COMPONENTS INDICATED BELOW
(A THROUGH E) C D E B
Test Panel or Test Cupon
60. ____________________ (A)
61. ____________________ (B)
Vacuum Hose
Vacuum Probes
62. ____________________ (C)
Vacuum Gage
63. ____________________ (D)
T.C. Wire
64. ____________________ (E)
CIRCLE THE CORRECT ANSWER: (example B )
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
66. Preimpregnated cloth may be warmed to provide greater flexibility when laying
up parts.
A. True B. False
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19. (Figure 1) 72. From (Figure 1) below identify item #4. Nylon bag
#4. __________________________
Nylon bag
73. From (Figure 1) below identify item # 1.
#1. __________________________
Tool Plate
74. From (Figure 1) below identify item # 3.
#3. __________________________
Breather
75. From (Figure 1) below identify item # 7.
#7. __________________________
TC wire
(Figure 1) 6 4 3 5 7
Simulated Part 2
flash-breaker tape 1
(1)
(2) Simulated Project Part (use cardboard)
(3)
(4)
(5) Sealant Tape
(6) Vacuum Probe (through the bag)
(7)
© Robert N. Young
Rev. 1/21/06
All Rights Reserved
Page 12

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’