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This five-day course is designed to those who desire to learn more about the fundamentals of

advanced composite materials manufacturing and repair techniques and have, for example, a
background in sheet metal with some exposure to composites technology.
The hands-on exercises are extensive, practical, and allow the trainees to work on advanced
composite material such as fiberglass in their individual projects. Students will have the
opportunity to work with honeycomb and high and low density foams. Fabricating a composite
panel using these materials to learn manufacturing techniques and elevated temperature curing
processes using an autoclave, thus making it an essential part of the training.
These composite panels will be damaged and afterwards repaired, using basic repair
techniques and various lay-up repair materials and processes. The final repaired parts will be
inspected to determine the quality of the repair.
Course Topics
a. Advantages and disadvantages of composite structures.
b. Fabrication Methods: wet lay-up, prepreg lay-up, filament winding, RTM, press molding,
and pultrusion.
c. Resin Matrix Systems properties: thermosets vs. thermoplastics, temperature ranges,
cold storage requirements/shelf life limits, adhesives.
d. Fabrication: prepreg cloth handling and ply orientation, lay-up procedures, vacuum
bagging.
e. Curing Methods: oven/autoclave cure alternatives
f. Inspection Criteria: non-destructive inspection methods, defect detection, galvanic
corrosion, documentation, acceptable vs. unacceptable defects, defect prevention.
g. Health and Safety Issues: proper handling, personal protection, allergic reactions, waste
disposal.
h. Principles of Tooling: types of tools, thermal characteristics.
i. Repair Methods: permanent vs. temporary repairs, scarf vs. stepped vs. mechanical
patch repair scenarios.
j. Damage assessment and classification.
k. Introduction to determining unknown lay-ups.
l. Drying moisture-contaminated honeycomb cores.
m. Introduction to bagging techniques for on and off-aircraft repairs.
n. Introduction to dealing with contaminated structures.
o. Heat management issues: Heat blanket and thermocouple problems.

Hands-On Exercises
p. Component lay-up using prepreg materials, including: sandwich panels in carbon fiber
unidirectional tape, fiberglass and aramid fiber cloth panels, ply orientation, warp
direction, stacking vs. nesting, material cutting and handling, honeycomb and foam core
installation.
q. Component lay-up using fiberglass dry cloth and liquid epoxy resin materials, including:
fiber orientation, lay-up, resin mixing procedures, health/safety concerns, controlling
fiber-resin ratios, vacuum bagging

r. Curing processes: ramp rates, vacuum schedule, oven cures, and potential problems.
s. Repairs: damage removal, scarf preparation, skin repair fabrication, use of wet resins
and cloth for repairs, core plug repairs.
t. Introduction to the use of manufacturers repair instructions.
u. Introduction to vacuum bagging (without crushing fragile structures).
v. Introduction to the inspection of repaired area.
Application
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Aircraft components such as: tails, wings, fuselage and propellers.


Boat hulls
Automobiles
Bicycles
Swimming pools
Storage tanks

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