unit 47 - Assignment 2 Composite repair processes include a very detailed description and examples of how a composite is repaired and the different types of repairs that can be carried out and how effective/ efficient are they. I submitted this assignment in 2022 and received a DISTINCTION grade
As also stated in the vocational scenario I must link my current research to the research I
have conducted for assignment one and use the two applications (Archery bow , F1 Rear
wing) to select the most suitable manufacturing process for it.
Wet Layup Process
Tools and equipment used for wet layup process:
• Flat surface (metal plate)
• A mould that is specially created for your design
• Release Agent which is the plastic sheeting
• A mixing Container and a stick which is required to mix the matrix
• Roller which distributes the matrix evenly
• Scissors which used to cut the fibres to size
• Epoxy resin
• Hardening agent which is mixed into the matrix
• The Fibre that is used e.g., carbon fibre or glass fibre
• Cleaning agents which are used to clean the mould and the tooling. The
cleaning agent used is Acetone
• Special trash container which abides by COSHH.
• Gloves and googles and a Smock which is used for your protection to
prevent the toxic materials coming into contact with your skin.
• Grey pencil without lead
• Ruler
• Standard tape
Before we do anything, we must create a mould based on our design. The mould can be
created by 3D printing(for the Bow), or it can be casted if its going to he heated to high
temperatures to avoid the mould from melting it can be cast out of aluminium.
Then we must select a fibre type, even tough both carbon fibre and glass fibre can be used
for wet layup it is easier to work with glass fibre for wet layup due to the fact that carbon
, fibre requires accuracy of matrix to fibre ratio which cannot be exactly done during wet
layup and wet layup process is more prompt to errors and due to the fact that even the
smallest error can scrap a part worth thousands of pounds. Due to this most companies and
engineering business choose to use glass fibre for Wet layup Process.
There are also many different types of matrixes such as epoxy, polyester, or vinyl ester. The
main difference between these types of matrixes is that they support the structures of the
fibres in different ways, so it affects the mechanical properties of the material in different
ways. The most common one to be used in industry is epoxy matrix due to the fact it takes
lest time for it to cure and it provides the best structural support for the fibres
How the process works:
1. Draw the ply pattern on a PE plastic
film(Vacuum bagging film).
2. Put the selected fibre into the PE plastic
film.
3. Weigh the resin and the hardener.
4. Degas the resin and hardener.
5. Mix them both together once you have
weighed and degassed them.
6. Cut the fibre along the pattern line.
7. Clean the surface of the Mould with
acetone and wipe off the excess with a
tissue
8. Place the fibres into the mould
9. Pour the mixture on the fibre and spread it evenly across the pattern and spread it
using a roller.
10. If required add extra resin and then layup another layer of fibre. Repeat this until
you achieve the desired thickness or layers of fibre
11. Depending on the resin used the composite part can cure in open air.
12. The Curing time can vary depending on the resin used however the average curing
time is 3 to 5 hours depending on the layers used
Dry Layup Process:
Tools used for Dry Layup Process:
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