The course is designed to introduce new technology to a wide range of composites personnel including material & process engineers, inspectors, technicians, QA personnel, and process equipment operators. This course has been designed to demonstrate engineering, certification, and manufacturing methods for implementation of available technologies both within limits of existing process specifications and to enable greater use of these technologies in future designs.
This course has been developed to provide engineers and technical managers with a broad, but comprehensive understanding of composite materials and manufacturing techniques used in component development, design, and “in-service” operation. The course covers the major considerations for the application of composite materials with an emphasis on the structural requirements, material usage, manufacturing techniques, vacuum bagging, and cure cycles. The E-1 course also covers the fundamentals of composite analysis. The course incorporates classroom lecture, and hands-on fabrication of wet layup, prepreg, solid laminate, foam core, and honeycomb core panels. These panels are then both bonded and bolted together then mechanically tested to evaluate their performance and failure to the classroom analysis. E-1 is a recommended prerequisite for all of the Engineering Structures courses to ensure that the students have a sufficient understanding of composite materials and processes before they begin the learning process on more in-depth composite analysis techniques. Only engineers with extensive composite materials and process experience from OJT, or other formal training, such as Abaris' Advanced Composite Structures: Fabrication & Damage Repair - Phase 1 (M-1/R-1) course should consider omitting this course as a prerequisite.
This course is designed for degree-qualified aerospace and mechanical engineers or persons having practical experience in strength of materials calculations who are responsible for the design analysis and substantiation of repairs to secondary structure and lightly loaded primary structures. This course is an entry level course and provides classroom lecture on composite materials, processes, and manufacturing with a focus on repair techniques and repair analysis. The hands-on shop work involves manufacturing test panels, damaging the panels, performing repairs, and mechanically testing coupons from both the original and repaired panels. The mechanical characteristics of the original and repaired panels are validated with analysis using an Excel spreadsheet, which has become one of the most recognized analysis training tool in the industry. Many students come from aircraft operators involved with commercial, business, general aviation, and military aviation, but the course is also applicable for engineers involved in original design who need to consider the design for maintainability and supportability of composite structures. The ER-1 course is also a mandatory prerequisite for the ER-2 Advanced Aerospace Repair Analysis and Substantiation course.
This course provides the backbone designing and analyzing composites with a thorough understand on classical laminate plate theory and failure criteria. The ES-2 course is perfect for engineers who did not take composite course during their university education, or who recognize that their university courses were too theoretical and did not provide enough practical understanding. ES-2 goes well beyond university level composite courses by using mechanical property data for modern composite materials that are currently available and evaluating these materials on existing composite configurations. The course is 80% analysis and 20% hands-on. The shop work involves manufacturing unidirectional and woven fabric panels at the lamina and laminate level as well as loading test coupons to failure. The course performs the analysis with a highly evolved Excel spreadsheet. Additionally, it introduces the students to composite analysis using FEA. ES-2 is a prerequisite for ES-3 and ES-4, unless the students have an extensive background with laminate analysis through their past work experience or university education. ES-2 is also recommended as an intermediate prerequisite between ER-1 and ER-2 for engineers performing repairs and modification who have access to load data.
This course has been developed specifically for engineers to provide a thorough understanding of the configuration of composite details and components to meet the design requirements for structural applications. ES-3 discusses the requirements for designing both assembled and co-cured/co-bonded structure using solid laminates, sandwich panels, stiffened structure, panel edge bands, ply drop-offs, and panel field areas. The course also addresses the requirements for assembling composite structures using both bonded and mechanically fastened joints, and utilizes the most robust bonded and bolted joint analysis available. Analysis is performed to evaluate panel buckling and vibration. Additionally, ES-3 provides an understanding of allowables, knockdown, and design values to meet the Damage Tolerance requirements for both primary and secondary structure. This courses performs analysis with both traditional hand calculations and FEA.
This course the most advanced course in the Abaris Engineering Structures (ES) curriculum, and is intended for engineers who need to understand composite structural analysis at the highest level. ES-4 evaluates how the laminate in-plane and flexural stiffness and compliance properties are applied to both FEA and traditional analysis, as well as modulus weighted cross sections using composite laminates in moment of inertia calculations. The course progresses from strength of materials analysis, through equilibrium, to Work and Energy calculations using strain energy and strain energy density. ES-4 addresses the fifteen field equations and field variables for static analysis from a strain-displacement aspect. The course looks at load distribution throughout the entire structure with both traditional analysis and FEA, to allow engineers to analyze a composite structure as a whole without having to rely solely on FEA software, but provides a means to validate FEA models.
This course is an advance level course designed for degree-qualified aerospace and mechanical engineers who are responsible for the design analysis and substantiation of repairs to both primary and secondary composite structures. This course provides analysis techniques for the bonded and bolted joint calculations for composite repairs, Damage Tolerance for composite repairs, and rapid Finite Element Analysis composite repairs. The joint analysis addresses precise solutions to the most advanced bonded and bolted joint analysis, covering both precured doubler and co-cured scarf joints. The Damage Tolerance portion addresses the latest industry guidance on threat assessment, damage types, the effects of damage severity, and the substantiation of damage resistance and residual strength. Both hand calculations and simplified FEA is used to determine the load redistribution for the damaged and repaired areas. All students are required to have completed the ER-1 Aerospace Repair Analysis and Substantiation course to be prepared to explore a more in depth analysis of repairs to global structures.