Carbon Fiber Applications Course

Lesson 1 • Mechanical and Physical Properties

Quantifies tensile strength, modulus, density, and thermal conductivity of standard fiber grades. Connects property data to material selection decisions in real applications.

Lesson 2 • Comparison with Competing Materials

Benchmarks carbon fiber against aluminum, steel, fiberglass, and aramid on key performance metrics. Enables evidence-based material substitution arguments.

Lesson 3 • Health, Safety, and Handling Basics

Introduces fiber inhalation risks, skin irritation, and static electricity hazards during raw material handling. Establishes safe practices required throughout all subsequent lab and shop work.

Lesson 4 • Carbon Fiber Chemistry and Structure

Covers atomic bonding, graphitic microstructure, and precursor types (PAN, pitch, rayon). Establishes the molecular basis for all mechanical and thermal properties discussed later.

Lesson 1 • Role of the Matrix in Composites

Explains load transfer, fiber protection, and shape retention functions of the matrix. Frames why resin selection is as critical as fiber selection for composite performance.

Lesson 2 • Epoxy Resin Systems

Covers epoxy chemistry, hardener types, pot life, and cure schedules for room-temperature and elevated-temperature systems. Epoxy is the dominant matrix in structural carbon fiber parts.

Lesson 3 • Thermoplastic Matrix Systems

Introduces PEEK, PEKK, nylon, and polypropylene matrices and their consolidation requirements. Highlights recyclability and impact toughness advantages over thermosets.

Lesson 4 • Alternative Thermoset Matrices

Surveys bismaleimide, cyanate ester, and polyimide resins for high-temperature and aerospace applications. Broadens resin selection knowledge beyond standard epoxy systems.

Lesson 1 • Prepreg Materials and Handling

Covers prepreg construction, tack, drape, and cold-storage requirements. Proper handling prevents contamination and ensures consistent fiber volume fraction in finished parts.

Lesson 2 • Ply Orientation and Laminate Design

Explains fiber angle notation, balanced and symmetric laminate rules, and quasi-isotropic stacking sequences. Correct ply orientation is the primary driver of structural performance.

Lesson 3 • Manual Prepreg Layup Procedures

Demonstrates ply cutting, debulking, and consolidation techniques on flat and contoured tooling. Hands-on practice builds the tactile skill needed for defect-free layups.

Lesson 4 • Dry Fabric Infusion Preparation

Covers binder-stabilized dry fabric handling, preform assembly, and fiber volume fraction control for infusion processes. Bridges manual layup skills to liquid composite molding methods.

Lesson 1 • Process Monitoring and Control

Introduces dielectric cure monitoring, fiber optic sensing, and statistical process control for cure verification. Real-time monitoring reduces scrap and supports process qualification.

Lesson 2 • Autoclave Processing

Covers autoclave pressure-temperature profiles, load configuration, and thermocouple placement for process control. Autoclave processing sets the benchmark for aerospace-grade laminate quality.

Lesson 3 • Out-of-Autoclave Cure Methods

Surveys oven cure, press cure, and heated-tool methods for cost-sensitive applications. Students evaluate when OOA methods can meet structural requirements without autoclave investment.

Lesson 4 • Cure Kinetics and Cycle Design

Explains exothermic reaction management, dwell temperatures, and ramp rates for thermoset cure. Proper cycle design prevents voids, residual stress, and incomplete cure.

Lesson 1 • Vacuum-Assisted Resin Infusion

Covers flow media selection, resin pot setup, and infusion sequence for large-area VARI parts. VARI reduces tooling cost while achieving fiber volumes comparable to prepreg layup.

Lesson 2 • Mold Design for Liquid Molding

Covers mold sealing, parting line design, and surface treatment for repeatable part release in liquid molding. Good mold design is the foundation of consistent part quality at volume.

Lesson 3 • Resin Infusion Process Variables

Analyzes permeability, viscosity, and vacuum level interactions that govern infusion speed and completeness. Understanding these variables enables troubleshooting of short shots and dry areas.

Lesson 4 • Resin Transfer Molding Fundamentals

Explains mold filling, gate and vent placement, and injection pressure control for closed-mold RTM. RTM enables high-volume production of structural parts with two finished surfaces.

Lesson 1 • AFP Programming and Path Optimization

Covers offline programming, collision avoidance, and fiber path optimization for structural efficiency. Optimized paths reduce material waste and improve part performance simultaneously.

Lesson 2 • Quality Assurance for Automated Processes

Teaches in-process inspection of gaps, overlaps, and tow drops using laser and vision systems. Automated inspection closes the quality loop without halting production.

Lesson 3 • Filament Winding Machine Operation

Covers machine axes, tension control, resin bath setup, and pattern programming for multi-layer windings. Consistent tension and speed are critical to uniform fiber volume and surface quality.

Lesson 4 • Automated Fiber Placement Fundamentals

Introduces AFP head mechanics, tow steering, cut-clamp-restart sequences, and compaction roller function. AFP enables complex contoured structures impossible to achieve with manual layup.

Lesson 1 • Inspection Standards and Disposition

Covers allowable defect size criteria, inspection documentation, and engineering disposition of nonconforming parts. Proper disposition prevents unsafe parts from entering service.

Lesson 2 • Defect Types in Carbon Fiber Laminates

Catalogs voids, delaminations, fiber waviness, inclusions, and impact damage as the primary defect classes. Knowing defect morphology is prerequisite to selecting the correct inspection method.

Lesson 3 • Radiographic and Computed Tomography

Explains X-ray radiography and industrial CT scanning for three-dimensional defect characterization. CT provides volumetric data unavailable from surface or single-plane inspection methods.

Lesson 4 • Ultrasonic Inspection Methods

Covers pulse-echo, through-transmission, and phased-array ultrasonic techniques for laminate inspection. Ultrasonic testing is the industry-standard method for detecting internal delaminations and voids.

Lesson 1 • Failure Criteria and Damage Tolerance

Applies Tsai-Wu, Hashin, and maximum strain criteria to predict first-ply and progressive failure. Damage tolerance analysis ensures structures survive impact and fatigue loading.

Lesson 2 • Finite Element Analysis for Composites

Covers shell and solid element modeling, material property input, and progressive damage simulation for carbon fiber structures. FEA reduces physical test iterations and accelerates design cycles.

Lesson 3 • Application Case Studies

Analyzes design decisions in aerospace primary structure, automotive chassis, wind turbine blades, and pressure vessels. Case studies integrate all prior chapter skills into complete engineering solutions.

Lesson 4 • Classical Laminate Theory

Derives ABD matrix relationships, in-plane and bending stiffness, and thermal residual stress for symmetric laminates. CLT is the analytical foundation for all laminate structural calculations.