Engineering Professional Programs

Course Outline

1. Introduction

1.1 Introductory remarks

1.2 Processing of composites

1.3 Composite product fabrication

1.4 Design for manufacturing and design for assembly

1.5 Additional comments

2. Manufacturing Fundamentals

2.1 Part cycle vs. manufacturing cycle

2.2 Curing the material

2.3 Degree of cure

2.4 Viscosity

2.5 Gel time test

2.6 Resin flow

2.7 Shrinkage

2.8 Voids

3. Manufacturing Processes for Thermoset and Thermoplastic Composites

3.1 Hand lay-up (wet lay-up and prepreg methods)

3.2 Automated tow placement

3.3 Automated tape placement

3.4 Bag molding process

3.5 Compression molding

3.6 Pultrusion

3.7 Filament winding

3.8 Liquid composite molding processes (RTM, VARTM, SRIM, SCRIMP, CAPRI)

3.9 Elastic reservoir molding

3.10Tube rolling

3.11Manufacturing processes for thermoplastic composites

4. Manufacturing Defects

4.1 Typical Manufacturing Defects

5. Tooling Considerations

5.1 Tooling considerations ( matched die molding, vacuum bag molding, coefficient of thermal expansion, curing, autoclave moldings made out of metals, composites, metal coated composites, elastomeric materials).

6. Composite Fabrication and assembly

6.1 Cutting, drilling, and machining: Mechanical methods

6.2 Water-jet cutting

6.3 Laser cutting and drilling

6.4 Diamond wire cutting

6.5 Adhesive bonding

6.6 Mechanical joining

6.7 Sandwich construction

6.8 Painting and coating

7. Repair of Composites

7.1 Mechanical damage, Environmental damage, Manufacturing defects

7.2 Potential for damage in composite parts (summary)

7.3 Damage detection techniques: NDI methods

7.4 Repair considerations

7.5 Non-patch repairs

7.6 Patch repairs

7.7 Bolted repairs

7.8 Damage removal and site preparation

7.9 Bonded repairs

7.10 Sandwich repairs

8. Quality Control and Quality Inspection Methods

8.1 Quality inspection methods (Raw materials, Cure cycle monitoring, Cured composite parts)

8.2 Non-destructive inspection methods (Visual, Tap test, Radiography, Ultrasonics, Acoustic emission, Acousto-ultrasonic, Thermography, Optical holography, Shearography, Eddy current)

9. Appendix

9.1 Resin viscosity

9.2 Autoclave process objectives

9.3 Theory of porosity and void formation

9.4 Lay-up variables

9.5 De-bulking operations

9.6 Caul plates

9.7 Residual stresses

9.8 Design for manufacturing

9.9 Process models

Texts

Lecture notes

Instructors

Dr. K. B. Das

is currently an Affiliate Professor in the Department of Materials Science and Engineering at the University of Washington where he has been teaching since 1978. He worked for Boeing for nearly 40 years (24 years in Materials and Processes Engineering and 16 years in QA organizations) before retiring in February 2003. Dr. Das obtained three Masters degrees from Osmania University (India), Purdue University, and University of Illinois in Electronics and Modern Physics, Solid State Physics, and Metallurgical Engineering, respectively, and a Ph.D. in Metallurgical Engineering from the University of Washington (1971). Dr. Das has over 40 years of research and development experience in high vacuum technology, rapid solidification rate powder metallurgical (RSR/PM) alloys, hydrogen embrittlement and stress corrosion cracking, corrosion engineering, alloy development and characterization, atomic and molecular spectroscopy, defect structure and physics of metals, and advanced composites.

Douglas A. McCarville, TF, PE

is a Technical Fellow who works full time as a Manufacturing Research and Development Engineer in Boeing's Integrated Defense Systems division. He has a Bachelors in Chemical Engineering from Iowa State University, a Masters in Business Administration from Wichita State University, and a Masters in Systems Engineering from National Technology University. In addition, he is pursuing a Ph.D. in Engineering Management through Walden University. During his 25 years of industry experience he has specialized in composite manufacturing design, equipment and processing issues. He has worked on a variety of key products and components including: reinforced thermoplastics, 777 perforated nacelle cowlings, F-22 sine wave spars, reusable launch vehicle cryogenic tanks, and the Joint Strike Fighter inlet duct. Currently, he divides his time between 787 support and the Structurally Integrated X-Band Array Air Force contract.

Questions

If you have questions about this program, please call UW Educational Outreach Advising at 206-685-8936 in the greater Seattle area or 1-800-543-2320. If you have questions about registration for this program, please call the UW Educational Outreach Registration Department at 206-543-2310 or 1-800-543-2320.

For more information about Boeing initiatives in composites education,email Michael Richey, Boeing Learning Training and Development, Engineering & Operations Group.