HANDS-ON
GENERAL TRAINING COURSE
ON COMPOSITE
MATERIALS

Theoretical Content

- In this hands-on course we will study the most important thermosetting resins in the composite materials sector and their main properties. Applications of polyester, vinylester, urethane-acrylate and epoxy resins.

- We will analyse the resins reactivity: crosslinking monomer, catalysts, hardeners, accelerators and inhibitors.

- Low styrene resins: dicyclopentadiene (DCPD) and vinylester-dicyclopentadiene resins.

- Polyester, vinylester and epoxy gelcoats: types and application standards. Most frequent defects that can appear in gelcoat applications and how to avoid them. We will also studing Gelcoats for parts and moulds manufacturing.

- High mechanical performance and corrosion resistant resins: vinylester resins. Main properties and uses.

- Epoxy resins: main properties, chemistry and types. Glass transition temperature (Tg). Polymerisation of epoxy resins: gel time, hardening and curing.

- Urethane-acrylate resins (Crestapol): a new generation of high tenacity resins for carbon fibre applications, aramid and high impact resistant polypropylene fibres. High flame resistant resins.

- Adhesives: urethane-acrylate (Crestomer), methacrylates (Crestabond) and epoxy (Resoltech). We will study threaded T-joints for bulkheads. Composite-composite, composite-metal, etc. joints. Adhesives for materials with different expansion coefficients.

- Reinforcement fibres: glass, carbon, aramid (kevlar) and Innegra. Mechanical properties of composite laminates and individual fibres. As a novelty, we will present spread tow carbon fibres.

- Materials for sandwich structures manufacture (PVC cores, balsa wood, Sphere.tex y Sphere.cores, SAN, PMI, PET, Core Cork®, Millifoam®, honeycomb...) Compressive and shear strength.

- Release agents: Chemtrend and Mikon semi-permanent systems.

- Infusion/vacuum and RTM manufacturing processes will be studied with particular emphasis.

- Advantages and disadvantages of these processes and a comparison between them.

Practical Content

- Composite parts manufacture with polyester, urethane acrylate and epoxy resins.

- We will use high flame resistant resins: Crestafire (polyester) and Crestapol (urethane-acrylic).

- Mould construction by Rapid Tooling method using low shrinkage resins (low profile), low shrinkage vinylester-DCPD resin and vinylester gelcoat.

- We will also construct an epoxy mould or epoxy master with high Tg epoxy polyester suitable gelcoat and high performance epoxy resin, using the vacuum compaction technique, silionne and multi-axial glass fabrics.

- Adhesive practice: we will glue aluminium plates, resin/fibre laminates and plastics.

- We will manufacture an small piece composed by epoxy resin and exposed carbon fibre in a split mould (two halves), in which we will inject a high compressive strength and low density epoxy foam.

-Manufacture of a 4 m long wind blade shell by infusion/vacuum process, using isophthalic polyester gelcoat and Crestapol 1260 resin reinforced with glass fibre and Millifoam (PVC), Sphere.core and Spherecel cores.

- Manufacture of a 3-metre small boat deck by vacuum infusion technique, using Crystic U904LVK30 orthophthalic polyester resin. Typical materials for these applications will be used: Metycore, Polymat mat/fabric complex, multiaxial fabrics, sandwich cores (80 kg/m3 density PVC, Spherecore and balsa wood), peel plys, resin distribution meshes, vacuum bag, etc.

-Manufacture of a high flame resistant part with urethane-acrylic resin (Crestapol 1211A) injected by RTM Light for a machine cover casing.

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In our facilities of Resinas Castro, S.L.:
A Granxa Industrial Estate
Parallel 3. 190 Cíes Street
36400 Porriño (Pontevedra)
Spain
GPS coordinates:
N 42.11343° W 8.61786

On the first day we hand out theoretical and practical manuals to the students. If the student completes the course successfully, he/she is given a diploma certifying that he/she has passed the course and the student becomes a new "Super Composite", ready to help others in this type of applications with composite materials.

Accommodation is not included in the course fees. Students choose their own accommodation, although due to proximity and price almost everyone stays at the Hotal el Volante (https://www.elvolantehr.com/hostal/) or the Hotel Alfonso I (www.hotelalfonsoprimero.com).

1.445 € per student, but we offer a discount of 25% for unemployed people, who can prove it with the corresponding updated documentation. Spanish companies can also subsidise the training of their employees through FUNDAE. This means a saving of around €400 per student. More information at https://www.bonificatucurso.com/cursos/resinas-castro-general-materiales-compuestos.

We simply recommend that you bring a notebook and a pen. The student receives a full set of PPE to ensure that he/she works with all the necessary safety during the training. Professional mask with filters, FPP2 mask, nitrile gloves, safety goggles and overalls are provided.
Comfortable, sporty clothing is recommended. If you have comfortable safety boots, it is ideal to bring them. No branded suits or shoes, please! Resins stain!

Our face-to-face courses are intensive, and have a duration of more than 40 hours, spread over 5 days from Monday to Friday.