1. Composite Course outline
AZAMI Boot Camp
Composite
Course outline
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2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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