a tool for making circular holes, consisting of a metal cylinder with a toothed edge 1. diamond abrasive hole saw •ideal for cutting fibre glass, boron, graphite 2. traditional hole saw (toothed hole saw) •used on aramid-reinforced •used in reverse cutting direction - 100 - 500rpm - Tool must be kept perpendicular and machined uniformly - Light feed pressure

A cutting a tool set tranversely to and revolving with the arbor of a lathe and acting upon work fed into it’s circular path 1. When using the part must be secured and square to the cutter

drilled hole flat

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a sander that uses a moving abrasive belt to smooth surfaces available grits: 60, 80, 120, etc

throatless shears are the ideal all purpose metal cutting tools 1. they permit any desired cut in heavy metal gauges, 2. handle lighter metals without distortion

red = cuts left green = cuts right yellow = cuts straight

a pointed instrument used for “making marks” on wood, bricks, aluminum and composite

1. footpowered, mechanically or hydraulically powered 2. clamps metal with a ram 3. moving blade comes down across fixed blade to shear the material like a guillotine

a tool usually of hardened steel with cutting ridges for forming or smoothing surfaces especially of metal single cut; one set of parallel teeth double cut; a second set of cuts forming the diamond shaped cutting surfaces

composed of a ruler and one or more interchangeable heads that may be affixed to it. “most common head is STANDARD/ square head used to check 90 degree angles or 45 degree angles

a straight strip or cylinder of plastic, wood, metal or other rigid material. typically marked at regular intervals “to draw straight lines or measure distance”

1. drawing circles and arcs 2. measuring distance between points 3. consists of two arms, one arm carrying the pencil while the other has a sharp point

1. A downdraft table draws contaminants like dust and fibres away from operators material 2. a downdraft table is an efficient and economical device for protecting workers from harmful dust caused by sanding / grinding

1. Is any pressure sensitive tape that is coated with adhesive on both sides 2. Design is to stick two surfaces together in a way which is “NOT visible in the end product”. due to it being in between objects rather than overlapping them

1. quick change retractable blades 2. increases productivity and safety

1. hand held portable instrument, for cutting / trimming composite prepreg & other hard to cut material 2. provides pattern shape versatility and produces a precise cut

1. portable high speed cutting tool 2. equipped with a base and a guide 3. ideal for cutting machined cores 4. used with a template for smooth accurate cuts

1. abrasive mineral bonded to a paper or fibre backing 2. aluminum oxide and silicone carbide are most common 3. “80-150” (rough sanding) 4. “150-240” (finish sanding)

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1. ideal to trim composite parts and to cut all materials necessary for production and tooling 2. use high speed low pressure 3. toothless diamond cutting blade should be used

1. a block used to hold sandpaper 2. block of wood or cork with one smooth flat side

1. steel wheel with diamond coated edge • higher cost, longer lasting, safer 2. fibre reinforced •wear rapidly if it binds in a cut it will fracture / break

vision: watering, redness, swelling, burning, itching. protection “glasses with shield, chemical goggles, full respirator skin: redness, itching, burning, rash, dry / cracking skin. protection “tyvek suit, gloves, barrier cream” respiratory: headache, nausea, tightness in chest, trouble breathing, short breath, dizziness. protection “respirator, dust mask, supplied air mask”

1. Room Temperature (75-80 degrees F) 2. Refrigeration (40 degrees F) 3. Freezer Storage (0 degrees F or less)

1. Discard all materials that exceed their storage life 2. Discard properly, consult the MSDS Many materials can't be thrown away 3. They may have to be mixed and cured “BEFORE disposal” 4. Handle materials with gloves Do not use brushes contaminated with another material

1. store dry fabric and bagging materials in a clean dry area 2. care should be taken not to distort the fabric weave

a chemical additive that quickens cure or chemical reaction

materials that are mixed into a two part resin system to improve the property of the system

a substance that is applied between two mating surfaces to bond them together

pre-mixed adhesives cast onto a thin plastic film

the resin mixture AFTER it has been mixed with a catalyst or hardener “it may still be in a workable state”

an impurity or foreign substance present in a material or environmental that affects one or more properties of that material

used to promote or control the curing action

the amount of time prepreg is exposed to ambient temperatures

the length of time that the resins, mixed with a catalyst will be in the “workable state”

1. the time span that a product will remain useful 2. listed on label 3. temp during storage will affect shelf life

the period of time during which a liquid resin, packaged adhesive or prepreg can be stored under specified temperature conditions

the resistance to fluid flow

material such as water and alcohol in a resin formulation, that are capable of being vaporized at room temperature

the period of time during which a liquid resin or adhesive remains usable

fibreglass strands / pieces

1. the central member of a sandwhich part 2. lightweight, high strength component when laminated with face sheets

Most often epoxy resins filled with hollow glass, phenolic or plastic micro balloons, cotton, flox, or other materials use so repair damage to a sandwich honeycomb structure that is “smaller 0.5 inch or less”

a tube with a nozzle and a piston or bulb for sucking in and ejecting or withdrawing liquid in a thin stream

1. a tool with a flat, smooth edge / blade 2. used to remove or control the flow of a potting compound

manufactured in special reinforced plastic for precise tooling of sealants and adhesives

a tool or device used to apply a fluid or semi fluid substance to a surface

cartridges can be filled with potting compound for large areas

a tool that holds a cartridge / tube that’s filled with material used for sealing gaps, cracks, holes

1. Damage that is larger than half inch in diameter 2. ensure the structure is returned to its original strength & rigidity

1. Oven 2. AutoClave 3. Hot Bonder

a wire assembly used with a control device (hot bonder) to sense temperature readings 1. should be placed as close as possible to repair material 2. strategically placed in hot or cold areas 3. never use fewer than 3 thermocouples 4. placed 0.5” away from edge of adhesive line

1. is the process of creating a molecular bond between two compatible thermoplastics 2. welding offers superior strength and drastically reduced curing cycle

1. a heat blanket is a flexible heater 2. made of two layers of silicone rubber with metal resistance heater between the two layers of silicon 3. common method of applying heat for repairs on aircraft

store on original packaging box

1. store in freezer 2. sealed in moisture proof bag 3. keep record of time out 4. warm to room temperature before use 5. wear latex or nitiral gloves when handling prepregs

a substance that initiates a chemical reaction

1. downdraft tables should be sized and maintained to have an average face velocity between 100 and 150 cubic feet per minute 2. should be monitored and filters changed on a regular basis to provide max protection and particle collection

1. Composite materials can be cured using various pressure applications 2. vacuum bagging used to remove volatiles / trapped air 3. oven cure between 250-350 F 4. temperature sensor required 5. must have two thermocouples on part

1. A large vessel used to cure laminates and bonded parts using pressure, vacuum and heat in an inert atmosphere 2. Use a vacuum bag to provide a path for removal of volatiles

1. A portable device that automatically controls heating based on temperature feedback from the repair area 2. Controls the cure cycle with thermocouple that are placed near the repair 3. Some repairs require up to 10 thermocouples 4. Cure cycle data can be printed and downloaded