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What material is known for its exceptional strength and resistance to cutting?
Kevlar®
What tool is primarily used to prevent composite materials from adhering to the working surface during the layup process?
Perforated Release Film
What is applied to the surface of a composite laminate during curing for a clean surface for bonding?
Peel Ply
What type of equipment removes air from a vacuum bag during composite layer consolidation?
Vacuum Pump
Which flexible material seals the repair area and creates a vacuum in composite manufacturing?
Vacuum Bag
What material requires a brush for application to dry fibers in the wet layup process?
Resin
Which tool supports composite parts during curing and ensures a smooth finish on the laminate?
Caul Plate
What material absorbs excess resin and allows air and volatiles to escape during curing?
Bleeder Ply
What is the primary purpose of vacuum bagging in composite manufacturing?
To apply uniform pressure to the composite material.
How does vacuum bagging work?
By applying a vacuum to remove air from the bag.
What is the typical pressure applied to a composite using vacuum bagging at sea level?
14.7 pounds per square inch.
Which methods can be used in combination with vacuum bagging?
All of the above.
Compared to metallic counterparts, composite structures fabricated using vacuum bagging are typically what?
Easier to fabricate.
What is the primary benefit of using filament winding in composite manufacturing?
Lightweight material.
What is a filament winding machine used for?
Winding the reinforcing fibers around a mandrel.
What is the typical method for curing filament wound parts?
Autoclave curing.
Why are repairs on filament wound parts often difficult?
The fibers are continuous and difficult to repair.
What is the major disadvantage of RTM?
The high cost of molds.
What is a one-party system in RTM?
A system that uses a pre-mixed resin and curing agent.
What is the primary advantage of pultrusion over other composite manufacturing methods?
Versatile shapes.
How does pultrusion work?
By pulling fibers through a heated die.
What is the die in pultrusion used for?
To shape the composite part.
Do pultruded parts require vacuum bagging or autoclave curing?
No, for all pultruded parts.
What is a common application of pultrusion?
Structural profiles.
What is the primary difference between hand lay-up and wet lay-up?
The use of a mold.
What is the typical curing process for hand lay-up parts?
Air drying.
What is the primary advantage of wet lay-up over other composite manufacturing methods?
Low cost.
Which of the following is NOT a common method for curing wet lay-up parts?
Oven curing.
Why is wet lay-up a popular method for home aircraft builders?
It is relatively inexpensive.
What is the main problem associated with using different materials for the mold and the part in composite manufacturing?
Different thermal expansion rates.
Why are steel and aluminum molds often used for composite manufacturing despite their CTE problems?
They are stronger.
What is the advantage of using composite tooling with built-in heating elements?
It eliminates the need for an oven.
What is the main disadvantage of building your own composite mold?
Time-consuming process.
Why is it important to make multiple parts from a composite mold to make it cost-effective?
To spread out the cost of the mold.
What is the first step in repairing a damaged composite part using a two-part molding compound?
Remove the damaged area.
Why is it important to clean the damaged area before applying the molding compound?
To ensure a strong bond between the molding compound and the part.
What is the purpose of a backup potting compound when the damage extends through the skin of the composite part?
To provide structural support.
Why is it important to apply a mold release agent to the entire structure before applying the molding compound?
To prevent the molding compound from sticking to the part.
What is the final step in the repair process after bonding the new piece to the existing component?
Sand the repaired area.
Which products are commonly made using filament winding?
Helicopter rotor blades.
What is the primary difference between RTM and other composite manufacturing methods?
The type of resin used.
How does resin transfer molding work?
By injecting resin into a mold containing fabric.
What is the major advantage of RTM over hand lay-up?
Faster production time.
Why are repairs on filament wound parts often difficult?
The fibers are continuous and difficult to repair.
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