Composites for Engineers 1 Design, Test and Manufacture

Course Code: AC009
Duration: 5 Days
Fees: £1250.00 (£1500.00 incl.VAT)
Course structure: 60% theory, 40% practical

Who is it for:

The course is intended for delegates with a good technical background in engineering, materials or mechanical design who require a comprehensive technical understanding of advanced materials, their use manufacture and test.

Course content:

Composites for Engineers 1 is designed to provide engineers and technicians with a comprehensive technical overview of the materials and processes and the affect the materials and process choices have upon composite material performance.

The course considers in detail good practice in design, orientation effects, use of cellular systems, finish considerations, wet and dry layup techniques, laminate performance analysis, causes of laminate distortion, Non-Destructive Testing (NDT) and other testing requirements in both components and tool design. Practical activities support the theory and are used to demonstrate the interaction between design, material and process choice along with the opportunity to practice NDT and analysis techniques. The course satisfies ATA 104 IV objectives

The course aims to: 

  • compare composite material their uses and application.
  • specify suitable material characteristics for a given application.
  • enable delegates to be able to describe the difference between traditional and advanced materials in relation to the appropriate design criteria.
  • give an appreciation of the use of composite materials and their effects upon component design and manufacture.
  • develop an appreciation the impact of mould design to maximise performance expectations of composites.
  • develop an understanding of mechanical testing and the use of NDT in the design and manufacture of composite components.

 The course covers:

  • Introduction to laminate theory, orientation effects, fibre and resin properties. Good practice in design and the impact of loading parameters considering the principle stresses and maximum shear that the component is subject to are considered along with the load paths and supporting structural needs to produce fit for purpose design. The impact of fibre orientation, curing schedules and hygrothermal effects and the influence of the tooling design and the manufacturing process will be taken into account.
  • The key weaknesses of component performance will be evaluated with regard to inter lamina shear and how these effects can be overcome by good design practice and the application of design centred criteria.
  • Consideration of tool design in terms of the impact of thermal expansion, surface finish and release surfaces influences will be explored in terms of component, mould design and component release influences.
  • Laminate performance analysis, causes of laminate distortion will be demonstrated through the use of physical testing.
  • Non-Destructive Testing (NDT) and other testing requirements in both components and tool design will be reviewed with simple NDT techniques being utilised through-out the practical activities.
  • Practical activities – manufacture laminates of different orientation to carry out mechanical testing to evaluate tensile, torsional and bending properties of laminates against laminate theory.
  • Delegates will have the opportunity to experience handling a variety of fabrics in the form of dry fabrics and pre-pregs used for manufacture. Delegates will have the opportunity to use wet lay-up and pre-pregs to produce their own parts, considering the theoretical elements discussed.
  • Delegates have the opportunity to produce a part using resin infusion techniques and compare this to the hand layup techniques previously used. 

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