DOCUMENTATION OF ACTIVITIES IN HCCT

300L
(HEATCON COMPOSITE TRAINING SHOP)

SUBMITTED BY: 12B - B2 GROUP 1

BAUTISTA, VICTOR PAUL
JULIANO, SHEAN KEANU
LOBRAMONTEL, KYLE AUDREY
MERCADO, MERGEL
RAMOS, VINCE RENIER
 TABLE OF CONTENT

TITLE PAGE
Group Member ………………………………………………………… 1

Activity no. 1: Chamfering exercise ………………………………….. 2

Activity no. 1: Photo Documentation ………………………………… 3

Individual Reflection ………………………………………………….. 4-8

Activity no. 2: Fabrication of Honeycomb Structure ……………….. 9

Activity no. 2: Procedure ……………………………………………… 10

Activity no. 2: Photo Documentation ………………………………… 11 - 12

Individual Reflection ………………………………………………….. 13 - 17

Activity no. 3: Center and Edge Inspection ………………………….. 18

Activity no. 3: Materials and Procedure ……………………………... 19

Activity no. 3: Photo Documentation ………………………………… 20 - 21

Individual Reflection ………………………………………………….. 22 - 26

Activity no. 4: Center and Edge Repair ……………………………… 27

Activity no. 4: Materials and Procedure ……………………………... 28

Activity no. 4: Photo Documentation ………………………………… 29 - 30

Pictures With the Finish Product …………………………………….. 31

Individual Reflection ………………………………………………….. 32 - 36

 GROUP MEMBERS

JULIANO, SHEAN KEANU M. LOBRAMONTEL, KYLE AUDREY

BAUTISTA, VICTOR PAUL MERCADO, MERGEL

RAMOS, VINCE RENIER M.

1
ACTIVITY 1: CHAMFERING EXERCISE

OBJECTIVE:
To become familiar with procedures and process involved in the chamfering of honeycomb
sandwich structure.

EQUIPMENT:
 Cutter
 Chamfering tool
 Steel Ruler
 Marker (sharpie)

MATERIALS:
 Nomex Honeycomb

PROCEDURE:
1. Prepare and cut 12 in. x 12 in. Nomex Honeycomb
2. Layout 1 in. on both sides of the honeycomb for chamfering purpose
3. Chamfer the honeycomb materials on both sides
4. Prepare and cut (2) pcs. of 14 in. x 14 in. and (3) pcs. 15 in. x 15 in. Fiberglass

2
ILLUTRATION/ SPECIFICATION

Tools and materials

Chamfering and Cutting Exercise

3
Reflection:
First day in Heatcon Lab, we were tasked right after the groupings. First we need
to cut honeybomb by 12 x 12 using cutter, and after that we measure all the sides by 1
inch then cut it in 45 degree using chamfering tool and cutter.

BAUTISTA, VICTOR PAUL

Name/Signature

Checked by: Mr. Carlos Carpio

4
Date: March 18, 2023
Reflection:
During our first day, Sir Carpio grouped us into 4. Before we started our activities,
he made sure that we are familiar on the tools that we will use and he taught us all the
step by step process that we need to do on each meeting. On our first day, our activity is
to cut the honeycomb by using the chamfering tool. After that we cutted the fabrics that
we need for our next meeting.

JULIANO, SHEAN KEANU

Name/Signature

Checked by: Mr. Carlos Carpio

5
Date: March 18, 2023
Reflection:
Our first meeting in the HEATCON Laboratory was quite stressful but I learned a
lot. The class was first separated into several groups by the teacher; fortunately, most of
the classmates with whom I was paired were friends. We started by cutting the edges of
the honeycomb that we would be using with the help of a chamfering tool.

LOBRAMONTEL, KYLE AUDREY

Name/Signature

Checked by: Mr. Carlos Carpio

6
Date: March 18, 2023
Reflection:
During our first meeting we are grouped into 4 groups and the we have learned
how to cut a honeycomb. At first it is hard for us to cut it even though we had a 45-
degree chamfering tool there were many flaws at our first try but, as time pass by we
manage to cut a 12 by 12 sized honeycomb that we will be needed for our next meeting.

MERCADO, MERGEL
Name/Signature

Checked by: Mr. Carlos Carpio

7
Date: March 18, 2023
Reflection:
During first day of HEATCON laboratory, we were tasked is to be familiar to the
tools and materials like honeycomb. First thing that we need to do to honeycomb is to cut
by 12” by 12” using cutter to cut straight then next is we need to measure and mark the
all side of honeycomb in exact 1 inch. Then we need to cut the all sides from the 1inch.
measurement of honeycomb and cut in 45-degree using chamfering tool and cutter be
careful to using cutter and watch the instruction from the instructor.

RAMOS, VINCE RENIER M.

Name/Signature

Checked by: Mr. Carlos Carpio

8
Date: March 18, 2023
ACTIVITY 2: FABRICATION OF HONEYCOMB STRUCTURE

OBJECTIVE:
To become familiar with wet layup procedures and processes involved in the Fabrication of
honeycomb sandwich structure. tresses in the damaged area are reduced by the bonded composite repair.
It stops cracks from forming or expanding in the area. The use of composite materials is widespread.
applications in the automotive, surface transportation, aerospace, marine, and sporting goods industries.

EQUIPMENT:
 Squeegee
 Cutter
 Steel Ruler
 Marker (sharpie)

MATERIALS:
 Nomex Honeycomb
 Resin and Catalyst solvent
 Fiber

9
PROCEDURES:
1. Get the weight of the fiber and follow the standard computation of fabric to resin ratio.
2. Mix a laminating epoxy A (2/3 ratio) & B (1/3 ratio).
3. Wet layup procedures
4. Prepare the caul plate, and Place the caul plate
5. Place a non-perforated release ply on the caul plate
6. Place ply 1 and 2 (14” x 14”) fiber
7. Place the 12” x 12” honeycomb
8. Place ply 3,4, and 5 (15” x 15”) fiber
9. Vacuum the bag procedure
a) Place a peel ply if it is for repair and performed release ply if it is for wet layup only.
b) Place a bleeder cloth on the top of perforated release ply
c) Place a non-perforated release ply on the top of bleeder cloth
d) Place a breather cloth on the top of the non-perforated release ply.
e) Cut (2) pieces of bleeder cloth just enough for vacuum sniper foundation.
f) Place a vacuum bagging film on the top of the non-perforated release ply.
g) Install the vacuum sniffer assembly (22” Hg) recommended running time 2-3 hours.
h) Check for leaks

10
ILLUSTRATIONS/ SPECIFICATION
Measuring the Resin and Mixing

Fabrication of Sandwich Panel

11
Vacuum Bagging Process

12
Reflection:
Our second meeting in Heatcon Lab. Computation of the resin, first we compute
how many weight could it be in resin A and resin B, then we mix it together until we get
the standard resin that we need, then we pour it little by little in fabric, we spread until all
fabric will be obtained, right after We vacuum in order of the procedure, so that our
honeycomb is ready for our next meeting.

BAUTISTA, VICTOR PAUL

Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 22, 2023

13
Reflection:
During our 2 meeting, our instructor taught us how to compute the resin that we
nd

need to use for our next activity. He gave us some mask and gloves for us to be safe from
the chemicals. He told us that we need to mix the resin properly so we can get the
standard resin that we need. After mixing we putted it in our fabrics and honeycomb. Our
instructor taught us how to use the vacuum in order for us to put it on our product so that
our honeycomb is ready for our next meeting.

JULIANO, SHEAN KEANU

Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 22, 2023

14
Reflection:
the composite is built in layers, beginning with a resin mixture of 60% A and 40%
B. The amount of resin used and the amount of fiberglass utilized are determined using a
form. We then vacuum-addition more layers, beginning with a peel ply and progressing
to a perforated release ply. Breathing fabric, non-piercing releasing ply, and bleeding
fabric. I then used a vacuum to close the gap. After that, the seams are dried and checked
for leaks. This activity teaches the complexities, labor, and expertise required to build a
honeycomb structure, which is mirrored in the material's excellent resilience and light
weight.

LOBRAMONTEL, KYLE AUDREY

Name/Signature

Checked by: Mr. Carlos Carpio

Date:

15
Reflection:
In our second meeting we learned how to compute the amount of resin that we will
be needed for our next activity. Our instructor also thought us how to mix a resin
properly. The resins have a strong smell that it is required for us to use a 3M 8710 FFP1
Respirator Mask for us not to be grogy on the smell and also to protect our lungs. We
also learned how to spread the resin to our fiber and we also learned how to use a vacuum
to seal our final product on that day.

MERCADO, MERGEL
Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 22, 2023

16
Reflection:
.
In our second day in HEATCON laboratory our instructor introduce to us how to
compute the how many resin A and Resin B that we need to get, and he teach us how to
apply proper the mix resin A and resin B to the fiber, the whole task is needed a team
work. To mix the resin all the time until it’s finish, and to how to apply the resin to the
fiber. To make in faster because of the resin how long the time of mixing the resin is
getting harder that’s why we need to double time the work.

RAMOS, VINCE RENIER M.

Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 22, 2023

17
ACTIVITY 3: CENTER AND EDGE INSPECTION

OBJECTIVE:
Evaluate the condition of the composite structure and to understand the process and procedures
of inspecting a composite structure. The purpose of this inspection is to determine what tools,
materials, and labor are needed to repair it into a good condition. Composite structures are
inspected for delamination (separation of the various plies), debonding of the skin from the core,
and evidence of moisture and corrosion.

EQUIPMENT:
 Circle Templates Marker (Sharpie)
 Tap Hammer/Coin
 Pneumatic Grinder
 Step-ply Cutting Knife (with square head)
 Long Nose Plier
 Pneumatic Grinder

18
MATERIALS:
 Nomex Honeycomb
 Fiberglass (Dry)
 Peel Ply
 Non-Perforated Release Ply
 Perforated Release Ply
 Breather / Bleeder Cloth
 Laminating Epoxy

PROCEDURE:
1. Damage the honeycomb core panel through the top face sheet into the core.
2. Perform a tap test inspection using a tap hammer or tap coin. Use a marker to
mark and identify the damage area.
3. After identifying the location of the damage part. Use the smallest circle template
that can cover the entire damage part.
4. Layout the first circle for the replacement core.
5. Using a pneumatic grinder or hole saw, drill out the top face sheet.
6. After removing the top face sheet, cut the damage core material out using the
step-ply cutting knife with a square blade. Use pliers to remove the core material
7. Clean the surface with alcohol. Use circle templates to layout the three repair
plies
8. Using the pneumatic grinder, sand the top face sheet using the ½” overlap for
each repair ply to determine the taper sanded area.

19
ILLUSTRATIONS/ SPECIFICATION
DAMAGE INSPECTION

20
REMOVAL OF EXCESS PART & REMOVAL OF DAMAGE CORE PLUG

21
Reflection:
I was able to further develop my skills and knowledge in heatcon composite
training, the center damage inspection, Repair, Edge damage and inspection reapectively.
This tasked mostly focused on our analysis and familiarization with this lab program, it
showed the proper course of action to take in determining and fixing the damage inside
the composite material.

BAUTISTA, VICTOR PAUL

Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 29, 2023

22
Reflection:
In our third meeting, Sir Carpio gave our product a damage so that we can learn on
how to fix those damage in our honeycomb. We need to identify how to remove it to
repair it for another piece of honeycomb. We cutted the side part of our honeycomb to
make it smaller and remove the sharp parts. We grinded it so that we can have a smooth
honeycomb and to put our newly piece of honeycomb. We need to use gloves and
goggles to avoid those dusts and fiber.

JULIANO, SHEAN KEANU

Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 29, 2023

23
Reflection:
The structural center of the honeycomb was harmed by Activity Number 3's Center
and Inspection Repair. The next step is to use a tap mallet to evaluate the damage and
assess its seriousness or extent. You must pay carefully since the sounds produced by the
intact and damaged structures differ. The damaged core was pounded by the instructor,
therefore the first step is to peel back the layers of the circular boundary. The first layered
part can then be cut by your team or group. Use a pneumatic grinder to make cuts along
the edges of the center of the broken honeycomb structure. Long-nosed pliers are used to
remove the damaged portion, then the center is hollowed out. Another honeycomb is then
cut into the fiberglass to serve as a helper from that point on. After the new honeycomb
has been put in and dried, a separate combination is used to create the wet arrangement.
In the proper vacuum bag layers, the structure is cured after the fabrication of the wet
pattern or mixture. This project taught us that, despite the increased value of repairing
composite materials compared to fixing traditional materials like metal or aluminum,
doing so needs a great deal more precision and complexity. because composite is more
than just a material; I discovered during the composite repair process that the material is
expensive and that you need the necessary skills and knowledge to remedy all types of
damage.

LOBRAMONTEL, KYLE AUDREY

Name/Signature

Checked by: Mr. Carlos Carpio

Date:

24
Reflection:
On our third meeting, we managed to find the damaged part of our honeycomb and
then we removed it so we can repair or replace it with another honeycomb and fiber. Next
we grind the surface of the damaged part but make sure that you wear safety or protective
gear so the dust of fiber won’t go to your respiratory system.

MERCADO, MERGEL
Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 29, 2023

25
Reflection:
.
I’d learned in this activity how to check how big the damages were, and how to
mark the composite structure by layer of the fiber in the structure. I’d also learn how to
sand properly with safety because of the dust that is very dangerous for our health when
we exhale the dust because the fiber dust is cancerous, and also I’ve learned how to
remove the damaged materials inside the structure.

RAMOS, VINCE RENIER M.

Name/Signature

Checked by: Mr. Carlos Carpio

Date: March 29, 2023

26
ACTIVITY 4 : CENTER AND EDGE REPAIR

OBJECTIVE:
To understand the process and procedures of composite structure repair. The bonded composite
repair reduces stresses in the damaged region and prevents cracks from opening or growing. Composite
materials are used in a wide range of applications in aerospace, marine, automotive, surface transport
and sports equipment markets. Damaged laminate constructions, fiber reinforced composites, and other
composite materials are repaired with composite materials. The bonded composite repair reduces stress
in the damaged area and prevents fractures from forming or expanding.

EQUIPMENT:
 Digital Weighing Scale
 Shears
 Squeegee
 Step-ply Cutting Knife
 Long Nose Plier
 Pneumatic Grinder
 Circle Templates
 Marker

MATERIALS:
 Nomex Honeycomb
 Fiberglass (Dry)
 Peel Ply
 Non-Perforated Release Ply
 Perforated Release Ply
 Breather / Bleeder Cloth
 Laminating Epoxy

27
PROCEDURE:
1. Fabricate a honeycomb replacement core using the original size.
2. Cut a piece of fiberglass that is large enough for the repair plies 1, 2, and 3.
3. Prepare a cult plate with bagging film for resin application and prepare a work area for layup
procedures.
4. Weight the fabric base on the fabric to resin ratio.
5. Mix the desired amount of resin (Part A & B) plus ten (10) grams of micro balloons as a filler.
Mix for three minutes.
6. Apply micro balloons around the replacement core and panel damage area.
7. Observe proper distribution of micro balloons around the damaged area and fill in the gaps.
Correct Ribbon direction is necessary
8. Apply the repair plies one, two and three
9. Perform the proper vacuum bagging procedure.
10. Check for vacuum leak.

28
ILLUSTRATIONS/ SPECIFICATION
CUTTING OF TEMPLATE FOR HONEYCOMB REPAIR

APPLYING MIXED RESIN AND MICROBALLOONS

29
 HONEYCOMB REPAIR

FABRICATION OF REPAIR PLIES

30
PICTURES WITH FINISHED PRODUCT

31
Reflection:
We also given instructions on how to repair the damage and rebuild the foundation
of the composite material in its excellent quality form inside the damage inspection,
repair edge damage inspection and repair. This allowed us to maximize our competence
in checking and identifying the damaged section of the composite material.

BAUTISTA, VICTOR PAUL

Name/Signature

Checked by: Mr. Carlos Carpio

Date: April 12, 2023

32
Reflection:
In our last meeting, we need to put the newly piece of our honeycomb to repair and
a resin to stick it on our product. We draw a part of our damaged part of our honeycomb
to the yellow pad paper and we need to measure it front of our fiber. After that we cutted
that part and putted that on our honeycomb. We opened our vacuum and leave it for a
while to make a progress and finish it. I learned a lot in this subject/training and thanks to
Mr. Carpio because the he teaches this activities step by step is clear and makes it easier,
also for us to success in this training is we need to work hard every step and we need a
solid teamwork in order for us to complete this training.

JULIANO, SHEAN KEANU

Name/Signature

Checked by: Mr. Carlos Carpio

Date: April 12, 2023

33
Reflection:
Review and Edge Repair, repairing the honeycomb composite's edges. The tip of
the wing is typically where a composite edge can be located. To check the amount and
length of the damaged structure of the composite on an aircraft, first use the knock test to
remove the damaged edge portion of the composite. Then, proceed as in his third activity,
removing the member with damaged edges first. Composite. The procedure is finished
after the composite material and its auxiliary layers (nonporous release liner, vent liner,
and vent liner) are ready and placed in a vacuum seal with a vacuum-filled base. Using a
hot bonder to cure the composite is the last stage. Hot bonders are used to shorten cure
times for composite repairs because time is of the essence in the aerospace industry. This
activity emphasized the significance of comprehending the fundamentals underlying the
use and production of composite materials in the aerospace industry as well as their
present and potential uses in the production of aircraft. the ability to mend many types of
damage.

LOBRAMONTEL, KYLE AUDREY

Name/Signature

Checked by: Mr. Carlos Carpio

Date: April 12, 2023

34
Reflection:
For our last meeting, we repaired the damaged part of our honeycomb structure.
We replaced a new core honeycomb to the damaged part. We make a new cut of fiber
that is the same size as the damaged part that we removed last meeting. After replacing
the fibers to the damaged part, we vacuum sealed our honeycomb for the curing process.
Therefore I conclude that during our HCCT LAB, teamwork can make the process easier
and you have the knowledge on how to repair a composite structure.

MERCADO, MERGEL
Name/Signature

Checked by: Mr. Carlos Carpio

Date: April 12, 2023

35
Reflection:
.
On the final day of doing the HCCT, we practiced grinding and removing the
cracked piece of fiberglass cloth. To accommodate the new core, a honeycomb structure
was created. The damaged portion was then patched up using the brand-new cloth and
adhesive. We successfully made the vacuum bag and sealed it without any leaks. During
the repair process, it is essential to put our knowledge of equipment and materials to use.
Since manufacturing and fastening the edges is far more challenging than doing so with
the round central core, I've learned that increased accuracy and precision are crucial. The
edge has to be parallel to the other edges. With this last activity, I came to the conclusion
that while it may be challenging to complete, it will be simpler if cooperation, teamwork,
and communication are used throughout.

RAMOS, VINCE RENIER M.

Name/Signature

Checked by: Mr. Carlos Carpio

Date: April 12, 2023

36