AZAMI Boot Camp Composite Course outline Course outline

AZAMI Boot Camp Composite Course outline

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

�Day 1 �Six hours – lecture and demonstration ◦ Shop Safety ◦ Composite Structures ◦ What is Composite ◦ Bonded Structure, Cold Bonding, Hot Bonding, Cure Cycle, Matrix, Warp Tracers, Warp Clock �Daily test �Small team ◦ 1. 5 hrs exercise and skill evaluation 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 ◦ ◦ Polyetherketone (PEKK) Polyetherimide (PEI) Polyphenylenesulifide (PPS) Polyetherketone (PEEK) ◦ Daily test ◦ Small team exercise and daily evaluation test � Polyimide (PI) � Polyamideimide ◦ Others � Metal Matrix � Ceramic Matrix � Carbon Matrix 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

� Day 3 � Six hours - Lecture and project ◦ Prepreg Storage and Handling �Tack and Drape skills progress ◦ 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 assessments exercise and individual skills Composite

� Day 4 � Six hours – lecture and project review ◦ 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

� � Day 5 Six hours – Lecture and Project Review ◦ 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