AVM 262 - Aircraft Composite Repair III

3 Credits, 6 Contact Hours
1.5 lecture periods 4.5 lab periods
Intermediate level of composite layup and vacuum bagging techniques for complex shapes, fabrication of potted honeycomb core assemblies, manufacturing composite component parts, knowledge of machining, trimming, and drilling composite components, surface preparation methods/secondary bonding of structures, component assembly methods and techniques, as well as a fundamental understanding of the documentation and record keeping required to support composite manufacturing.

Prerequisite(s): AVM 260

Course Learning Outcomes

Recall proficient knowledge of quality assurance in the production of advanced composites, and structural design considerations.
Recall proficient knowledge of molding methods and practices, layup techniques, and the machining, trimming, and drilling of advanced composites.
Demonstrate common processes/procedures associated with following proper documentation and quality assurance procedures to fabricate and assemble an advanced composite structure.

Outline:

Quality Assurance in Manufacturing
1. Planning
2. In-Process Inspection
3. Documentation and Record Keeping Systems
Structural Design Considerations
1. Advantages/Disadvantages
2. Typical Sandwich Design
3. Solid Laminate and Monolithic Design
4. Joint Types
5. Core Materials
6. Impact Resistance
7. Ply Orientation, Balance, and Symmetry
8. Electromagnetic Effects (EME)
9. Conductive Layers
10. Sealants
11. Primers
12. Finishes
13. Acoustic Properties
14. Sonic Fatigue
15. Elevated Surface Temperature Requirements
16. Erosion Protection
17. Galvanic Compatibility
18. Transmissivity
Molding Methods and Practices
1. Semi Permanent Release Agents
2. Vacuum Bagging Complex Shapes and Geometries
3. Hot Drape Forming
4. Hand Layups - Prepreg
5. Automated Tape Laying and Automated Fiber Placements
6. Oven and Autoclave Equipment
7. Thermoforming
8. Compression Molding
9. Resin Transfer Molding
10. Bladder Molding
Tooling Types and Functions
1. Tool and Part Design
2. Metal Vs Composite Tooling
3. Elastomeric Mandrels, Bladders, and Cauls
4. Reusable Vacuum Bags
5. Jigs and Fixtures
Release Agents
1. Mold surface preparation
2. Tool Sealers
3. Releasing Agents
Layup Techniques
1. Applying heat
2. Interim Debulking
3. Ply Verification tabs
Machining, Trimming, and Drilling Composites
1. Overview of Machining Methods and Practices
2. Rotary Cutting
3. Waterjet
4. Laser
5. Drilling Tools and Techniques
6. Mechanical Fastening Considerations
7. Bonded Fasteners and Inserts

Effective Term:
Fall 2024