Prevents cross contamination between the clean and dirty room. Ensures quality of composite while curing. Safety shoes and glasses, respiratory protection, lab coat, face shied.

Just as the name implies, this room is where the dirty part of composite manufacturing takes place. Tyvek suit respirator and face shield or eye protection required

Keeps the area organized, ensure quality of material and prevents injury

Contains 2 or more physically distinct and mechanically separable materials. Created by binding two materials together to achieve positive quality’s from both materials

Reinforcement (fibres) aramid, fibreglass, carbon fibre etc. Matrix (resin) epoxy

Strong, lightweight, thermal and corrosion resistance, bullet proof

Expensive, difficult to detect interior damage, exposed fibres wick up moisture.

Raydome, flight control surfaces, vertical and horizontal stabilizer

Thermoplastic; formed using heat, will change shape if significantly “reheated” Thermosetting; formed using heat or room temperature. Will not change shape if significantly heated

Most structural applications on an aircraft

Part A “Base” Part B “catalyst” / hardener

It needs to be measure in precise ratio in weight and volume as per manufactures instructions

Mix part A first then part B

White in colour, less weight and strength, low cost compared to aramid and carbon fibre. E-glass resistant to current flow S-glass for structural applications, high temperature and tensile strength

Thin string crystalline filament of black carbon, used as a strengthening material in with the matrix system. Known as carbon fibre composite. Promotes galvanic corrosion when bonded to other metals.

Yellow in colour, known also as Kevlar or NOMEX. High tensile strength and bullet proof, used on rotor blades and hub assembly’s.

Fire hazard, splash hazard, absorption hazard, inhalation hazard

Tyvek suit ,safety shoes and glasses, respirator, gloves and hearing protection

Uncontrolled exotherm, the release of excess heat, smoking and bubbling in matrix causing combustion. Also called “run away” or “hot batch” Sensitization, allergic reaction following contact with matrix resin system. Develops upon repeated exposure.

Exothermic, reaction followed by release of heat

Sensitization, can be cause by contact with matrix resin systems or other materials that follows by an allergic reaction, that develops upon repeated exposure to a chemical or material

MSDS (material safety data sheet)

Methyl ethyl ketone (MEK) Acetone Goggles, Tyvek suit, gloves, respirator

Isopropyl alcohol, used to clean bonding surfaces and clean tools or working surfaces

1. Room temperature, epoxy and art resins 2. Heat cure, pre pregs

The “pot life” dictates the time limit when working with the materials

Avoided using filler or tropic agent. Too hot = sagging Too cold = becomes thick and difficult to use

Small hallow phelonic resin plastic microspheres that are light weight “thickener/ additive”. They don’t add structural strength

Very fine microscopic droplets of fumes silica powder (dust) not for structural accommodations

A fuzzy material from fabric strands, used to thicken matrix and increase strength

Fibre glass, carbon fibre, aramid

Filament / thread

Kevlar

Stored in flat, warm, dry climate controlled, contaminate free area

A fabric previously impregnated with a mixed resin and then “B-staged” or partially cross-linked until it no longer flows at room temperature. Stored frozen and must be thawed. Requires heat and pressure to fully cure. Requires out time log

-Proper ratio of fibre to mixture -resin system already worked into fibres -less mess and eliminates need for weighing and mixing resins

Two or more layers of different reinforcing fibres bonded together. Used to create composite with the characteristics of both fibres.

Vacuum bagging

Removes excess resin, removes air between laminates, maintains contours and shape and compacts fibres

1. Peel ply 2. Perforated release film 3. Bleeder 4. Solid release film 5. Breather 6. Vacuum bag