Abaris Training Composite Repair

Competitors Required:

2

Description:

This skills event is based on an elevated high temperature, vacuum bagged, composite repair scenario.

References:

Essentials of Advanced Composite Fabrication and Repair

Tools, Equipment, and Materials Provided:

Each team will be provided with a work packet which includes the Job Card, Repair Ply Material and vacuum bag.  All tools & equipment needed to perform this skills event will be provided and reused by all teams including the following items: Vacuum source/hoses/ports, Heatcon Single Zone Bonder/ heat blanket/thermocouples, scissors, Stanley Knife, sharpie marker, volt ohm meter, 12-inch scale, circle template and calculator.

 Snap-on provided tooling (qty one in each of two pallets unless otherwise indicated): None

Procedures:

As soon as your team is in the competition area, they will be able to review the job card, not at any time before.  They need to write their team’s name, number & individual names clearly on the Job Card. This is important since Abaris Training is once again giving away two 5-day course Scholarships to the team with the fastest time.  The Scholarships are for the course titled, “Advanced Composite Structures:  Fabrication and Damage Repair, phase 1” (one 5-day course valued at $2795).  The two scholarships can be used by the participants or any personnel within their organization.

Side note: A beneficial observation by the judge is being organized throughout the 2-day competition.  Example: Arriving at the Composite Repair Skills Event early to better utilize the 5-minute reset window, allows for more time to review the Job Card & derive a plan of attack.

The Job Card can be accomplished in any order that is decided by the team, but all sign-off blocks must be completed.  Any missed steps, or any mistakes noted by judge, will be a one-minute deduction off final time.

Repair ply material, a rectangle piece of paper, will be used for the repair plies.  After drawing a 3”, 4” and 5” circles with the circle template provided, mark the “warp direction” within each circle.  The short side of the rectangle piece of paper/repair material is the warp direction.  Once cut out, follow Job Card for proper orientation of each repair ply…a cause of many deductions in the past, the Judge will be watching closely!!

Teams should be familiar with Ohm’s Law when given Voltage, Wattage & solving for Resistance ( R = V²  ÷ W ).  This will be used to calculate, measure & document both results on the Job Card. They also need to solve & calculate a resin mix ratio word problem…Example; Based on a given amount of total mixed epoxy resin needed, say 50 grams with a mix ratio 100:35, how many grams of Part A?  How many grams of Part B?  Teams will clearly write their answers on the Job Card…do not forget to sign off this block!  Another commonly missed step in the past.

Teams should also be familiar with vacuum bag processing.  Peel ply, Bleeder, solid film, Breather materials needed for this skills challenge will be pre-cut, clearly marked and reused for all other teams.  Once their repair area is vacuumed down, they can start the bonder.  Important note: this is a good time to ensure all sign off blocks are filled in because once the bonder’s printer starts, the time stops and any missed steps or missed sign off blocks are not complete are a one-minute deduction. Teams must follow job card precisely!

 All teams must understand that these instructions are a general overview of this skills challenge & that there is a lot of detail on the Job Card, that if not followed, can lead to problems and/or unexpected deductions.  Good Luck to all Competitors!!