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Level 1 Composites

Course description

Our Fabrication and Damage Repair Course is balanced with theoretical and practical elements. Students will work with dry glass fabric and liquid epoxy resin in an exercise designed to teach the fundamental vacuum bagging, bleeder and breather concepts and will work with pre-preg carbon fibre unidirectional tape to explore balance and symmetry requirements in a laminate.

Teams will work with pre-preg glass and aramid fibre harness-satin fabrics, along with Nomex (R) honeycomb and polyurethane foam core materials, where laminate nesting is practiced.

Basic repair methods and techniques will be presented along with performing a wet layup repair. The final repaired part will be cut in half for evaluation of the manufactured and repaired panel.

Course content

Theoretical 

  • Current state of composite technology: history, recent development and terminology
  • Characteristics of advanced composite materials
  • Material forms: dry cloth and wet resin vs. pre-preg, weave/styles, etc.
  • Fabrication methods: wet layup, pre-preg layup, filament winding, RTM, press moulding, pultrusion
  • Resin.matrix systems: thermosets vs. thermoplastics, temperature ranges, cold storage requirements/shelf life limits, adhesives
  • Fundamentals of fabrication: pre-preg cloth handling, ply orientation, lay-up procedures, vacuum bagging
  • Curing methods: oven/autoclave/hot bonder cures
  • Adhesive bonding technology: co-curing vs. secondary bonding, surface preparation, curing temperatures, cleanliness, pressure, blond line quality
  • Inspection methods and techniques: non-destructive inspection methods, defect detection, galvanic corrosion, documentation, acceptable vs. unacceptable defects, defect prevention
  • Principles of tooling: types of tools, thermal characteristics
  • Repair methods: permanent vs. temporary repairs, scarf vs. stepped vs. mechanical patch repair scenarios, demo of hot bonder field repair units
  • Fasteners: use of mechanical fasteners, adhesively bonded fasteners
  • Health and safety issues: proper handling, personal protection, allergic reactions, water disposal

Practical

  • Component lay-up using dry glass cloth and liquid epoxy resin materials. Vacuum bagging with varied bleeder/breather sequences to evaluate resin bleed and flow characteristics
  • Component lay-up using pre-preg materials, including: asymmetric laminate made from carbon fibre unidirectional taps. Layup and processing of nested glass and aramid fibre fabric sandwich panels.
  • Vacuum bagging using non-autoclave bleeder/breather schedules. Thermocouple placement. Pleating to minimize bridging in high-angle core transitions. Vacuum debulking, leak checking, other potential bagging problems. 
  • Over curing; ramp rate, soak, and cooling requirements. Introduction to hot-bond repair equipment.
  • Wet-layup repair: damage removal, scarf preparation, core and skin repair, use of wet resins and cloth for repairs, core plug repairs.

Course objectives

To gain an understanding of the fundamentals of advanced composite materials, manufacturing and repair techniques.

Course duration

5 days

Additional information

Booking your Level 1 Composites training

For individual bookings please contact our team on +44 (0) 1285 772669 for course dates and more information
For corporate bookings please click here 

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