WELCOME TO CMPST 121:
COMPOSITES CONSTRUCTION & REPAIR
This class is an introduction to fiberglass
reinforced plastics with an emphasis on chemical
safety applicable to poly and vinyl ester resins,
solvents, and epoxies. This course includes hands-
on training with molds, gel coats, release agents,
resins, cosmetic color matching and reinforcing
materials in hand layup and structural repair.
TEXTBOOK(S)
There is no required textbook for this class. For additional
information I recommend two reference books. You do not have
to purchase these books; they can be checked out of the college
library.
• Fundamentals of
Composites Manufacturing:
Materials, Methods and
Applications, Second
Edition by A. Brent Strong
• Fiberglass Repair: Polyester
or Epoxy by David & Zora
Aiken
OUTCOMES
After completing this course, the successful student will be able to:
Distinguish between and explain the overlapping areas of the composite
industry.
Demonstrate the knowledge of how resin systems work in practice.
Select several areas of interest in our composite industry that would be
attractive for employment.
Understand the safety precautions required when working with fiber
reinforced plastics.
Identify and perform the steps in fiber reinforced plastics repair.
List and calculate the quanity of materials required for a repair
along with the necessary tools and supplies.
COMPOSITES ARE
USED IN:
Aerospace
Transportation
Industry
Energy
Production
COMPOSITES ARE USED IN
RECREATIONAL PRODUCTS:
Snowboards
Skateboards
Bicycles
INTRODUCTION TO COMPOSITES
In this section you will acquire the following knowledge:
A definition of composites.
A brief history of
composites.
The difference between
composites and other
manufacturing materials.
The advantages of
composites.
The ability to recognize and
understand some composite
terminology.
WHAT IS COMPOSITES?
There is a broad range of definitions for composites, the
term can be used in a variety of ways.
A useful and broad definition of composites in our
industry refers to "Two or more dissimilar materials
which when combined are stronger than the individual
materials."
The materials in composites can be man-made
(synthetic) or come from natural sources.
Plywood is a good example
COMPOSITE HISTORY
The use of composite materials has been around for a long time. In
ancient history it was learned early on that by using multiple
materials, you could achieve a strength greater than the original
materials. Material choice was based on the desired characteristics
of the finished product. By combining the individual materials with
the desired characteristics, a product was achieved that was better,
stronger and more suited to its use.
ANCIENT COMPOSITES
The earliest and most simple composite material made was
the adobe brick.
The ancient Egyptians created composite materials when
they made bricks for the pyramids.
Ancient bows were made in the 12th century from multiple
materials.
CLASSIC COMPOSITES
Classic composites use both made and natural materials.
MODERN COMPOSITES
Advances in chemistry between 1870 and 1890 included the
development of synthetic resins. These resins could be converted
from a liquid state to a solid state by a process called
polymerization.
Polymerization is the cross linking, on a molecular level,
during the change from a liquid state to a solid state.
Another term for polymerization is esterification.
MODERN COMPOSITES
A rapid growth began in the
1940's and most of the
composite processing
methods used today were
developed by 1955. This
included open molding, hand
lay-up, contact molding,
chopped strand molding,
compression molding,
filament winding, resin
transfer molding, vacuum
bag molding and vacuum
infusion.
ADVANCED COMPOSITES
Advanced
composites are
replacing metal
components in
many uses,
particularly in the
aerospace
industry.
Composites are classified according to their matrix phase (the
resin) and the reinforcement (the fiber), advanced composites
are characterized by high-end resins and high-end fibers.
Primarily, epoxy resins and carbon fiber reinforcements.
The predominate method of construction in the Aerospace uses
pre-impregnated carbon fiber and oven cures and is growing in
the automotive manufacturing industries.
ADVANCED COMPOSITES
Working with advanced composites requires:
An understanding of the basic practices
and methods of working with different
Resin system
Reinforcements
Methods of construction
Methods of repair
ADVANCED COMPOSITES
Although composites are already in use in the aerospace
industry, the use of composites is growing rapidly in all
industries.
Lots of job opportunities!
A BETTER DEFINITION
In this course, a more accurate definition of composites is required.
The composites that this course covers is referred to as reinforced
plastics.
Our specific course of study is Fiber Reinforced Plastics (FRP).
Composites for Fiber Reinforced Plastics (FRP) is defined as "a
combination of fiber reinforcement in polymer matrix".
Another common, but less used term, is GRP (Glass Reinforced Plastic)
The glass fiber is the reinforcement, and the polyester resin is the
matrix or "glue" that transfers the load between fibers and protects
the fibers.
A BETTER DEFINITION
The most common polymer matrix resins are:
Polyester
Vinyl Ester
Epoxy
Common reinforcing fibers include:
Fiberglass
Carbon Fiber
Aramid
A BETTER DEFINITION
As we increase the quality level, the higher the price.
The final product, use of the product and aesthetic quality of the
product will determine
The engineering of the product.
The materials used
The method of production
INDUSTRY OVERVIEW
Manufacturers, engineers and designers all share in common an
appreciation of the ability of composite materials to produce
products that are:
Durable
High Quality
and Cost Effective
You will find composite materials throughout your day in almost
every aspect of your life.
INDUSTRY OVERVIEW
6,000 composite-related
plants and materials
distributors throughout the
United States.
More than 125,000 people are
employed.
230,000 people are employed
in related support of the
composite industry.
Composites that are composed of glass fiber and either
polyester or vinyl ester resin make up approximately 90% of
all composites manufactured.
65% are manufactured in the open molding/contact molding
method
35% are manufactured using closed molding or continuous
molding methods.
WHY ARE COMPOSITES DIFFERENT?
All materials have different properties and composites are no
different.
Isotropic materials.
Anisotropic materials
Composite are different that other materials in that they can be
tailor made for strength in a specific direction.
WHY ARE COMPOSITES DIFFERENT?
This wide array of choices is an advantage, but it is more difficult to
establish material sizes to match strength requirements.
Composites are more complicated due to the variety of choices in
resins and reinforcements.
Each specific material contributes to the unique properties and
attributes of every FRP product.
There is no common or mainstream FRP composite.
We have a long list of resins that can be used, polyester, vinyl ester,
WHY ARE COMPOSITES DIFFERENT?
The glass fiber we use for reinforcement also comes in a wide
variety of styles.
Depending on both the molding style and strength requirement,
many options in materials are available.
Fiber in random orientation exists in the form of chopped strand
mat.
Woven rovings, knitted fabrics, woven fabrics and unidirectional
fabrics are some alternate choices.
To maximize the benefits of composite products, while controlling
costs, the appropriate materials must be determined carefully, and
custom configured to match the application.
THE ADVANTAGES OF COMPOSITES
The advantages of composite materials over other traditional
engineered materials have allowed rapid growth and acceptance
throughout many industries and with many consumers. The
advantages include:
Composites have a higher specific strength than other materials.
Specific strength is a term that relates strength to weight.
As an example, a piece of 1/2" rebar and a piece of 1/2" composite
rod will not have the same strengths. The rebar will have higher
compressive and tensile strength but will weigh more than the
composite rod. If the composite rod were increased in diameter
to the same weight as the rebar, it would have greater strength.
Per unit of weight, the
composite rod is stronger
than the steel rod. When the
strength of the two are
equal, the composite
constructed product will be
lighter.
ADDITIONAL ADVANTAGES OF COMPOSITES
Composites can be formed into complex shapes that have more
constituent variables.
Composites, because of their physical properties, have more
durability.
1947 Coast Guard 40-foot patrol boats were used until the 1970's.
Composites require a lower initial startup investment as compared
to other manufacturing industries.
Many boat builders started with small facilities using simple hand
lay-up techniques and unsophisticated molding to produce their
first boats.
