no, only approved AMO

drawings & manual

when transport Canada approves “aircraft type”

document for transport Canada, certifies type of design complies with TC

certificate for modification

illustrated parts catalogue

original equipment manufacturer

1. Supplemenatary type certificate 2. one off 3. technical standing order

a minimum performance standard issued by TC for specified parts, processes and appliances on civil aircraft

for an aeronautical product identified in the document by a single serial number. process to certify one aircraft is easier.

design approval representative “delegated individual”

design approval organization “delegated company”

deligated engineer “delegated individual within a company”

airworthiness engineer organization “delegated company with limited delegation to the aircraft they operate”

1. Fit 2. Form 3. Function

6 possible views of an object; one, two or three view drawings most common to show object

obtained by cutting away part of an object to show shape and construction at the cutting plane. cross hatch lines show parts cut away

shows an object as it appears to the eye. useful in showing general appearance of object. not good for showing complex forms and shapes.

a note added to the drawing describing the type of composite laminate and fibre form used

specified ply orientation and sequence of the layup

the place where two or more parts of the mould meet

are where the parts are to be trimmed after manufacture and before fitting them.

a light mould that serves as a temporary duplicate. the splash mould serves as a guide to make a model of the part

1. wood 2. plaster 3. fibre reinforced plastic 4. styrofoam 5. reinforcement

ensure to water proof wood moulds. best wood = “Medium Density Fibre Board”

•can be moulded to complex shapes •ensure no “undercuts” on finished shape

•waterproof and smooth •smooth surfaces allows mould to seperate from cast

•for large or more hand crafted moulds •styrofoam density must be considered •needs waterproofing, same as wood

•needs to be strong enough to support the part when being manufacturered. •won’t break when removing the part •made of “steel, wood, fibreglass, MDF

1. split moulds 2. parting boards 3. joint lines 4. taper 5. trim flanges

• closed moulding process • ideal for efficient fabrication of parts at medium and high volumes of production •little waste

•fibres are placed into single-sided or open mold. resin is added to the fibres until fully wetted and resin is cured •low volume production

the point where the mould pieces join together.

enables the part to be removed from the mould more easily. without taper it will be tough to remove the part

trim flange incorporated into the tool design. Allows a tool to be guided on

1. aerodynamic smoothness 2. gel coats 3. sanding surfacers

laminar airflow =increased fuel effienceny & max speed must have “external flush repair”

white pigment gel coat enables high degree of smoothness +protect from UV and water ingress “not fully UV and water resistant, will degrade over time”

high build epoxy primer is recommended for use as a sanding surfacer over properly sanded gel coat. fills imperfections in gel coat, made to fill, level and sand easily

tooling gel coat: gives mould surface a strong scratch resistance, wax free. general purpose gel coat: more flexible and softer and easier scratched. used for” high vibration parts” and will NOT crack if bent

small production quantities; lower cost tooling, higher labour costs at slower rate production. larger production quantities; with higher cost tooling, lower labour costs at faster rate production.

temporary moulds: 10 or less, wood, foam, clay or plaster permanent moulds: 10 year life, 1000+ cycles, fibre glass

moulds should provide basic shape of composite part being produced. composite tool design must be strong and torsion resistant during processing. normally made from same material as parent tool or dissimilar metals

the mould is a mirror image of part, most accurate and expensive are metal moulds. exact shape and finish of master will be transferred to part.

moulds known as “tools” are made of different material depending on a variety of factors. fibre glass used when less accuracy of dimensions is needed high rate production tools are made of robust metals for repeated cycles, good dimensional accuracy. carbon fibre, graphite or metals

heated by blankets, oven or autoclave depending on material being cured. glass fibre in an auto clave under high heat and pressure won’t work.

for multiple copies of parts with complex shape. inexpensive, easy to make and long lasting. produces hundreds of parts

used when moulds need highest strength and rigidity

metal, glass, carbon fibre and plastic moulds offers smooth non-pourous surface. wood and styrofoam have poor surface finish and wear resistance. coating with epoxy resin can solve moisture prevention.

general term for “resin based surface coating”. for cosmetic and protective coating

long production runs require a metal mould. negatives; metal is most expensive mould material. aluminum most common

ceramic tools are heavy and expensive but able to withstand many thousands of production cycles. less expensive than metal tools/ moulds

part cure pressure / thermal expansion moulding are wrapped around rubber blocks and placed in a metal mould. rubber expands more than metal as heat putting pressure on laminate. •makes complex shapes without later joining fastening operations.

atmospheric pressure is used to suck air from under vacuum bag, compacts the layers down and makes high quality laminate. used for variety of components including larger complex shapes

ribs and integral stiffeners help stabilize “large flat surfaces” without increasing mould thickness

egg crate the backing structure of a mould to add strength and allow for high tolerance parts to be produced. adds support and manageability to moulds with awkward shapes. made from wood, can be made from metal.

tubing can create shapes or a structural base that can hold the mould. rigid, corrosion resistant, can handle heat caused by curing.

microwave based curing for carbon fibre sandwhich parts. microwaves selectively penetrate material and heat product, oven chamber remains cool. moulds don’t need to be built for higher temp than oven or autoclave

isotropic = uniform properties in all directions. aluminum and titanium are isotropic

true

stacking sequences determine the stiffness, dimensional stability and strength of the part. orientation of plies determines this.

strength and stiffness depend on orientation sequence. proper selection of plies and orientation required to build part correctly

warp is the threads that run length of the tool. longitudinal fibres of fabric highest strength due to straightness of fibres

used for direction of fibres. if warp clock is not available, the fabric is oriented to zero as fabric comes off the roll

fill threads run width of the roll. strength lower than warp due to waviness in pattern. if extra strength in a different direction is required, ply can be angled 45 degrees.

true

majority of fibres run “1” direction. high strength only in 1 direction.

fabrics used for structural applications with both same weight or yield in warp and fill directions

symmetrical layup helps avoid thermal twisting of parts as they cool down. these effects are most pronounced in laminates that are cured at “higher temperature in an auto clave”.

symmetrical layups help avoid thermal twisting of parts when they cool after curing. consistent heat distribution from oven or autoclave much better than heating blankets

1. ply orientation 2. fabric type 3. fabric style 4. lay-up sequence 5. ply dimensions

1. woven fabrics 2. unidirectional 3. multi-axial-unidirectional 4. chopped strand mat

•ensure to work in clean area •don’t get pre-pregs dirty by dropping on floor •do not use contaminated pre pregs

don’t spend a lot of time on patterns. you can mark dimensional ply layup with sharpie marker then cut plies with scissors

when making several parts, you will want to makeup pattern templates to help quickly cut and trace out plies

mark cloth or pre preg using sharpie marker to know where to cut shapes of plies *biron said not to contaminate plies with sharpie marker, slides say otherwise**

paper and cardboard can be used as pattern templates for tracing composite ply parts

extremely strong polyester film. used to make patterns for plies, developed in 1950s. also used in magnetic audio and video tape, capacitor dielectrics, batteries.

the best material to make part tracing templates. ensure metal is debured as it can easily damage composite fabric

•used for secondary structure on aircraft “fairings, radomes, wing tips, helicopter rotor blades” •lower cost than other materials

•light weight and strong •high resistance to impact damage, used in “impact damage prone areas” •disadvantage is water absorption , tough to drill and cut

both carbon and graphite based on “hexigonal layers”. very stiff and strong, good corrosion resistance used for; floor beams, stabilizers, flight controls, primary fueselage and wing structure. high cost, poor lightning protection, needs protective mesh coating for lightning strikes

•very stiff and high tensile strength. used to repair cracked aluminum skins •does not flex well, very expensive •normally used in military applications

•incredible strength and heat resistance, used on turbine blades •used in high heat applications •made by super heating and spinning into strands

plain weave; consists of yarns one over and one under each yarn least pliable, least strong

similar to plain weave, except two or more filling yarns are alternatively interlaced over and under one another. more pliable and stronger, not as stable as plain weave

used where relatively low number of yarns are involved. used for light weight membrane applications “EIFS”

more pliable than plain weave, easier around compound curves

similar to 4 harness very pliable, good drape, good for forming curves more expensive due to higher yarn count

• more pliable than plain weave •used where tightly woven fabric with high density required

1. no dust 2. positive pressure room 3. clothing

1. clothing 2. skin protection “gloves” 3. eye protection “glasses” 4. respiratory protection “mask”

•resin rich “too much resin used” •resin starved ratio “too much resin bled off during the curing process, shown by fibres that show to the surface

A: resin base mixed, chemical reaction not started B: resin chemical reaction starts C: resin is fully cured

A, B, C

stored below 0 degrees

operator must keep temperature records of the time in and out of freezer

used to accurately monitor the maximum “out life” of pre preg and film adhesives

shelf life: uncured prepreg and fil. adhesives have time limits in storage and use. normally 6 month storage life. storage life can be extended by manufacturer after material is tested pre cut kits: many repair facilities cut material in smaller kits and store in moisture free bags. quicker thaw time, limits time out of freezer for big rolls that can be cut down. bench life: max time allowed for material at room temperature