Composite Course outline AZAMI Boot Camp Composite Course outline Disclaimer and License information This workforce product was funded by a grant awarded by the U.S. Department of Labor’s Employment and Training Administration. The product was created by the grantee and does not necessarily reflect the official position of the U.S. Department of Labor. The U.S. Department of Labor makes no guarantees, warranties, or assurances of any kind, express or implied, with respect to such information, including any information on linked sites and including, but not limited to, accuracy of the information or its completeness, timeliness, usefulness, adequacy, continued availability, or ownership.   Unless otherwise noted, this work is licensed under the Creative Commons Attribution-NonCommercial 4.0 International (CC BY-NC 4.0). To view a copy of this license, go to https://creativecommons.org/licenses/by-nc/4.0/on your web browser.

Course outline Five days 6-7 hrs per day Lecture, demonstration, and lab project. Skills assessment and evaluation on a daily basis Daily testing over materials Prior knowledge based on entry assessment Composite

Composite Day 1 Six hours – lecture and demonstration Daily test Shop Safety Composite Structures What is Composite Bonded Structure, Cold Bonding, Hot Bonding, Cure Cycle, Matrix, Warp Tracers, Warp Clock Daily test Small team exercise and skill evaluation 1.5 hrs Composite

Composite Day 2 Six hours – lecture and project assignment Matrix System. Acts to bond and/or encapsulate the fibers enabling to transfer from fiber to fiber Thermosets Polyester Vinyl Ester Epoxy Phenolic Bismaleimide Cyanate Ester (CE) Polymide (PI) Thermoplastics Polyetherketoneketone (PEKK) Polyetherimide (PEI) Polyphenylenesulifide (PPS) Polyetheretherketone (PEEK) Daily test Small team exercise and daily evaluation test Polyimide (PI) Polyamideimide Others Metal Matrix Ceramic Matrix Carbon Matrix Composite

Composite Day 2 Continue Liquid Resin Pot Life- amount of time to gel Working Life- time you can work the resin-spread out, bag, etc. Open Time- time that a mixed resin or adhesive is open and exposed to air Mix Ratios: refer to the mixing instructions and determine if the mix is to be parts by weight (P.B.W.) or parts by volume (P.B.V) Storage and Shelf Life Consideration Ex: < 40°F/ 4.4°C- they must be kept moisture free Curing Considerations- it is misleading to think that a resin has fully cured just because it feels hard Prepregs- A “prepreg” is a reinforcement material that is pre-impregnated with resin Stages of Resin Systems A Stage- low viscousity and the ability to be diluted with solvents B Stage- viscous and tacky, but not flowing C Stage- insoluble and infusible Composite

Composite Day 3 Six hours - Lecture and project skills progress Prepreg Storage and Handling Tack and Drape Tack- refers to stickiness of prepreg at room temperature Drape- describes the ability of materials to conform to compound curves Prepreg Shelf Life- is defined as the time the materials can be stored and still be processed to desired conditions Required to be frozen storage (<0°F/ -18°C) Shelf life of a frozen prepreg is between six months to one year Prepreg out of limits Moisture Contamination Kit-cutting prepreg materials Recirtification- can be done for a short period of time Daily test Small group exercise and individual skills assessments Composite

Composite Day 4 Six hours – lecture and project review Daily test Curing thermoset prepregs Flow and gel Flow- resin as lowest viscosity Gel- from liquid to solid state Vitrification- a solid or glassy phase of material Cure cycle- most legacy cure cycles are simply recipes that define time/temp. and vacuum and pressure requirements at specific time intervals Too fast/too slow ramp rate problems Too fast- heated to quickly, the flow time is shortened and the viscosity will not stay low for a long enough period of time Too slowly- the viscosity may never get low enough to allow sufficient resin movement to take place Too long at soak problem: long soaks at upper temperatures may actually begin to degrade, rather than improve the Matrix Computer controlling processing Daily test Individual skill project and assessments Composite

Composite Day 5 Six hours – Lecture and Project Review Final test Fiber Reinforcement Glass (S and E) Carbon Aramid PE (polyethylene) PBO (polyphenylene benzobisoxazole) Others Boron Silicon Carbide Quartz Glass E glass S glass Carbon vs. Graphite Carbon Fiber is considerably different in form the true graphite, Graphite is very soft, but brittle (like pencil lead). Carbon Fiber Filament has an aligned crystalline structure making it stronger and more durable than Graphite. Quartz Fiber Boron Fiber Aramid Fiber- Kevlar Final test Final assessment and competency review Composite