4

Composites Processing

for the Complete Life Cycle

  

Introduction

Fibre reinforced polymer composites have gained substantial popularity over the recent years mainly due to their ability to combine the properties of different materials which allows them to manufacture products having very effective and versatile properties. This has led to the use and application of composite materials in several high performance industries like aerospace and automotive. The major disadvantages of these materials, however, are high processing and equipment costs and difficulty of manufacturing. These parameters are even now gaining prominence in aerospace and automotive industries.  

Learning Objectives:

On Completion of this Course, the participants will:

(1)   Be familiar with manufacturing processes involved in making Composite components

(2)   Understand aspects of qualification and inspection of Composite components-especially gaining knowledge of how composite materials are tested and inspected in both destructive and non-destructive fashion

(3)   Appreciate the challenges for entering composite components into service and understand the effects that various operating environments have on performance

(4)   Appreciate how the life of composite components can be extended or ended as appropriate 

Course Contents:

Unit I          Pre-processing  

  Introduction of Composites Materials 

o   What are composites?

o   Categorization of Composites

o   Reinforcing fibers, fabrics and pre-forms

o   Matrices and molding Compounds

o   Interfaces and inter-phases

o   Lightweight structural cores 

  Composites Tooling 

o   Tooling/mold design criteria

o   Methods of Making molds 

  Prepregs or Ply Cutting                                                        

o   Storage Conditions

o   Manual methods of cutting

o   Nesting, Kitting and Cutting

o   Automated options-  Benefits and limitations 

  Reliability of raw Materials 

o   Shelf life and checking of shelf life

o   Analytical and Mechanical tests required to check      reliability 

Unit II         Processing 

  Basic Steps in Composites Manufacturing Process 

o   Impregnation

o   Lay-up

o   Consolidation

o   Solidification 

 Manufacturing   Processes                                                                              

 

o   Prepreg lay-up/Wet lay up

o   Autoclave molding

o   Vacuum assisted Processing (VARI, VARTM, CRTM, RTM etc)

o   Filament Winding

o   Pultrusion

o   Compression Molding/Injection Molding

Unit III        Post-Processing 

  Inspection 

o   Non Destructive Testing

o   Visual Inspection

o   Tap Testing

o   Ultrasonics

o   Radiography/Tomography

o   Thermography 

  Assembly Considerations 

o   Optimization of structures for manufacturing

o   Reduced part methodology

o   Machining/Drilling

o   Testing 

  Quality Assurance and Documentation 

o   Traceability

    • Shelf life
    • Role of NDT/Qualifications
    • Defects type

Unit IV        Special Topics  

  A brief introduction on Composites design

  Physical and Mechanical Characterization of Composites

  Damage assessments

  Damage resistance and Tolerance

  Repair Techniques

Pre requisites

 Prior knowledge of Composites would be advantageous

Potential Participants/Organizations

(1)   All personnel working in composites

(2)   Those who wants to pursue their career in advanced materials

(3)  Students of material sciences

 

Starting From Timings Last Date of Registration Fee
30-05-13

1730-2030

(Thu-Fri-Sat)

28-05-13

Rs:9,500/--

Per Participant

Duration =         18 Hours (2 weeks)

 

 

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