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CompositeMaterials

BOY SCOUTS OF AMERICAMERIT BADGE SERIESCompositeMaterials“Enhancing our youths’ competitive edge through merit badges”

Requirements1. Do the following:a. Explain to your counselor the most likely hazards youmay encounter while working with composite materials and what you should do to anticipate, mitigate andprevent, and respond to these hazards. Describe theappropriate safety gear and clothing that should beused when working with composite materials.b. Explain the precautions that must be taken whenhandling, storing, and disposing of resins, reinforcements, and other materials used in composites. Includein your discussion the importance of health, safety,and environmental responsibility and awareness.c. Describe what a material safety data sheet (MSDS) isand tell why it is used.2. Do the following:a. Explain what composite materials are. Include a briefhistory of composites and how they have developed.b. Compare the similarities and differences betweencomposites and wood, aluminum, copper, and steel.Describe the physical, electrical, mechanical, corrosive,flammability, cost, and other such properties. For eachof these raw materials, give one example of how itcan be shaped and used for a specific application.3. Describe how composite materials are made. Then dothe following:a. Discuss three different composite reinforcementmaterials, their positive and negative characteristics,and their uses. Obtain the MSDS for each one anddiscuss the toxicity, disposal, and safe-handlingsections for these materials.composite materials    3

b. Discuss three different resins used in composites,their positive and negative characteristics, and theiruses. Obtain the MSDS for each one and discussthe toxicity, disposal, and safe-handling sectionsfor these materials. Include thermoset resins andthermoplastic resins in your discussion.c. For each of the three resins you chose for requirement 3b, think of a new application that might beworth developing.4. With your parent’s permission and your counselor’sapproval, do ONE of the following:a. Visit a company that manufactures or repairsproducts made with composites. Discuss whatyou learn with your counselor.b. Find three composites-related websites. Share anddiscuss what you learn with your counselor.5. Do the following: a. U se composite materials to complete two projects, atleast one of which must come from the CompositeMaterials merit badge pamphlet. The second projectmay come from the pamphlet OR may be one youselect on your own that has been approved by yourcounselor in advance.b. W ith your counselor’s assistance, find an appropriatesite where the projects can be safely completed underyour counselor’s supervision and/or the supervisionof an adult approved by your counselor who isknowledgeable about composites.c. W ith your counselor, determine how the finishedprojects will be evaluated. Using those guidelines,evaluate the completed projects with your counselor.6. Find out about three career opportunities in compositematerials. Pick one and find out the education, training,and experience required for this profession. Discuss thiswith your counselor, and explain why this professionmight interest you.4    Composite Materials

Composite Materials Resources.Composite Materials ResourcesScouting LiteratureChemistry, Engineering, Inventing, ModelDesign and Building, Robotics, and SpaceExploration merit badge pamphletsVisit the Boy Scouts of America’sofficial retail website (with yourparent’s permission) at http://www.scoutstuff.org for a complete listing of all merit badgepamphlets and other helpfulScouting materials and supplies.BooksMarshall, Andrew C. Composite Basics,7th ed. Marshall ConsultingPublishing, 2005.Rutan, Burt. Moldless CompositeSandwich Aircraft Construction.Rutan Aircraft, 2005.Strong, A. Brent. Fundamentals ofComposites Manufacturing: Materials,Methods, and Applications. Societyof Manufacturing Engineers, 2007.PeriodicalsComposites ManufacturingAmerican Composites ManufacturersAssociationTelephone: 703-525-0511Website: http://www.acmanet.org/cm-magazineComposites TechnologyGardner Publications Inc.Telephone: The Boy Scouts of America gives specialthanks to the American CompositesManufacturers Association for its assistancewith the development and production of theComposite Materials merit badge pamphlet.For more information about composites, visit the ACMA’s websiteat http://www.acmanet.org.78    Composite Materials

.Composite Materials ResourcesOrganizations and WebsitesAmerican Composites ManufacturersAssociationWebsite: http://www.acmanet.orgAmerican Society for CompositesDepartment of Civil and EnvironmentalEngineering and Engineering MechanicsUniversity of DaytonWebsite: http://www.asc-composites.orgCenter for Composite MaterialsUniversity of DelawareTelephone: 302-831-8149Website: ://www.compositesworld.comMSDS OnlineWebsite: http://www.ilpi.com/msdsNetCompositesWebsite: http://www.netcomposites.comOccupational Safety and HealthAdministrationToll-free telephone: 800-321-6742Composites safety htmlAcknowledgmentsThe Boy Scouts of America is extremelygrateful to the M.C. Gill Corporation,El Monte, California, for its generousgift to fund the development and production of this new Composite Materialsmerit badge and pamphlet. The M.C.Gill Corporation is a composites industry leader around the globe.Thanks to the many individualsand groups involved with the development and production of the merit badgeand pamphlet. In particular, thanks tothe following: Merwyn C. “M.C.” Gill,Stephen Gill, Matt Lowry, and ArmondBeal, M.C. Gill Corporation; Phil Gill,Royal Plastic; John P. Busel, Larry Cox,Robert Lacovara, Andy Rusnak, andMissy Henriksen (former executivedirector), American CompositesManufacturers Association; Denny Fink,Jim Scholler, and Ken Weber, NORACInc.; Matthew Benson, CompositesTechnology Center, Winona (Minnesota)State University; Peter Joyce, U.S.Naval Academy at Annapolis; CharlesBotsford, P.E., AeroVironment Inc.;Steve Nutt, Ph.D., Merwyn C. GillComposites Center, University ofSouthern California; Jack Beauchamp,Ph.D., California Institute of Technology;Donald Klosterman, Ph.D., Center forBasic and Applied Composites Research,University of Dayton (Ohio); HilaryGregg, M.A., La Canada, California;John D. Tickle, Strongwell; FrankMoore, The Boeing Company; TerryPrice, M.A., Cerritos CommunityCollege, Norwalk, California;and Sven Rundman.Thanks to members of Troop 4and Troop 5, Austin, Texas, for theirassistance with photography.The Boy Scouts of America is grateful to the men and women serving onthe Merit Badge Maintenance Task Forcefor the improvements made in updatingthis pamphlet.composite materials    79

78 composite materials Composite materials resources. Composite Materials Resources scouting literature Chemistry, Engineering, Inventing, Model Design and Building, Robotics, and Space Exploration merit badge pamphlets Books Marshall, Andrew C. Composite Basics, 7th ed. Marshall Consulting Publishing, 2005. Rutan, Burt. Moldless Composite

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