Composites Technology & Applications Overview:
Plus Special Composites Repair Focus
Day 1
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Introduction
o Who are the attendees? Who is the Instructor?
o What is SAMPE – and other organizations
Composites “Market” – What does it entail?
o What are the 3 major markets?
o What does each market contain?
o How does tooling support each market?
o Where are the growth areas?
o What does the future look like in each?
Fiber materials across the industries
o What are the critical fibers today?
o What are their properties, typical costs, where used,
why used there, etc.?
o Fiber limitations – any known?
o What is “sizing”, “coupling agents”, and fiber
“interfaces”? Why are they important?
Textiles and fabrics – key material forms for
manufacturing
o What nomenclature defines these?
o What are the various forms?
o What is unique about each form (drape, strength,
cosmetics, knockdown factor, etc.)?
Resin materials – those important “glues”
o Thermosets vs. thermoplastics – differences
o Temperature ranges of interest and markets?
o Processing differences – and markets too!
o Discussion of all the key families – properties,
process methods, limits, costs, etc.
Manufacturing – traditional FRP methods
o FRP vs. Advanced Composites – overview of
differences
o Some basic processes – contact molding, filament
winding, pultrusion, chop & spray, SMC, BMC, etc.
o Process overviews – and – applications coverage with
examples
Composites Test Methods
o What tests are needed the most?
o What test data do material suppliers most often
provide – and why?
o Methods for tension, compression and shear
o Fracture mechanics tests for defects and damage
assessment
o Physical tests (DSC, Tg, fiber-resin-void content, and
other important parameters)
Tooling Technologies
o Where are metal tools used and why?
o While “heavier” than composites, what advantages do
metal tools still have?
o Where are composites used as tooling materials and
structures?
o What aspects need to be considered when using
composite tools?
o What other new materials are out there for “tooling” to
produce composites?
o What are their properties and what makes them
unique?
Manufacturing – introduction to Vacuum Bagging and
Hand Layup
o Coverage of vacuum bagging and hand layup
o What is the process – and the variables?
o Out-of-autoclave? Where is the fit – autoclaves?
DAY One – Summary, Wrap-up, Questions
Day 2
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Day 2 Start-up – Questions from the students
o Any questions from Day 1?
o Any topics you want clarified?
Design and analysis – at least a brief review of key
concepts
o Briefly – how does micromechanics, laminate plate
theory (LPT) and structural analysis all fit together?
o What is “quasi-isotropic”, or QI, behavior?
o What is “balance and symmetry” and why is it
important? What is the “potato chip” effect?
o Quick look at “failure criteria” and what it means for
test programs to establish design allowables
o Joints – bonded vs. bolted – what criteria to use?
o Some overall “Best Practices”
Composite Repair Technology – Special Focus Topic
o What are the typical in-plant, as-manufactured or inservice damage scenarios?
o How does one detect “damage”?
o What NDT methods work the best and often are
used?
o What is BVID and what does it imply?
o How does “damage” affect aerospace, commercial
(re: automotive and wind blade) and consumer
market products repair approaches?
o What “repair methods” are available?
o What processes and methodology are used to
actually repair structures?
o What about “lightning strike repairs”?
o Cosmetic repairs vs. structural repairs –
differences?
o Equipment necessary to complete repairs to
damaged composite structures?
o References to composites repair …
Manufacturing – Resin Infusion and Liquid Molding
processes
o This is a big area – how do the terminologies differ
internationally?
o What has changed with this technology over last
20+ years?
o Coverage of RTM, VARTM, SCRIMP and VIP
o Coverage of RFI and SQRTM
o Coverage of HP-RTM
o Comparison of the above methods, where they fit
into the industries and markets – numerous
examples … plus some variants (like TERTM,
RARTM. etc.)
Sandwich and Core Technologies – making things
lighter, yet stiffer in bending
o What are “sandwich construction and structures”?
o How are these unique to lightweighting and bending
stiffness improvements?
o What are the critical components (laminates,
adhesives, core materials, etc.)?
o Closeout and termination issues
Manufacturing – Automated Tape Laying, Fiber
Placement and Robotics – the growth areas!
o ATL, AFP, ATP and Robotics – what are these
processes?
o Videos of recent developments
o Manufacturing with fiber placement – advances in
technology – why this is important today
DAY Two – Summary, Wrap-up, Questions