The module introduces manufacturing processes of composite materials and their corresponding underlying manufacturing principles to provide a deeper understanding of the relationship between design, manufacturing processing and materials properties. Various manufacturing methods are discussed, including short polymer fibre composites, advanced thermoplastic composites, advanced thermoset composites, melt metallurgical processes, powder metallurgical processes, advanced hybrid fibre metal laminates and ceramic matrix composite manufacturing route via melt infiltration, chemical vapour infiltration and polymer impregnation and pyrolysis processes. The real life applications of each manufacturing processes are also covered in this module.
On successfully completing this module, you should be able to:
1. Derive the basic transport equations and constitutive laws for composite processing;
2. Identify the key characteristics of different composite manufacturing processes and their associated advantages/disadvantages;
3. Select the appropriate manufacturing processes based on precursor materials;
4. Design and model the manufacturing processes of composite materials;
5. Explain the influence of manufacturing parameters on the finished composite parts.
6. Evaluate the various sustainability metrics of composite manufacturing processes using lifecycle engineering
AHEP Learning Outcomes: SM7M, SM9M, EA6M, EA7M, P12M, P10m, E11M
Basic transport equations and constitutive laws for composite processing: Continuity equation (in the presence of fibres), resin/suspension viscosities, reaction kinetics and permeability
Polymer matrix composite manufacturing - Short fibre composites: Compression moulding, extrusion and injection moulding with detailed analytical analysis on the basic steps involved, flow model and cure cycle
Polymer matrix composite manufacturing – Advanced thermoplastic composites: Sheet forming processes and pultrusion with detailed discussion of cell model and consolidation of thermoplastics.
Polymer matrix composites manufacturing – Advanced thermoset composites: Autoclaving, liquid moulding and filament winding. The processing steps involved, flow model, process model, heat transfer and resin flow of all these processes will be discussed.
Metal matrix composites manufacturing – Melt metallurgical process, powder metallurgical process and hybrid composite: Pressure-less and pressurised infiltration processes, centrifugal and gas pressure infiltration, discontinuously reinforced metal matrix composites – formation of billets for forging, extrusion and rolling processes and continuously reinforced metal matrix composites – diffusion bonding of foils, manufacturing principles of GLARE, fabrication of GLARE parts and structures and mechanical behaviour of GLARE for Aircraft structures
Ceramic matrix composites manufacturing – Melt infiltration, Chemical Vapour Infiltration and Polymer Impregnation and Pyrolysis Process: The processing steps involved: Coating of fibre tows to tailor the fibre/matrix interface, manufacturing composite green body, generate porous preform and Si infiltration process and applications, Isothermal CVI and Gradient CVI, manufacturing of preform and pyrolysis
The module will be delivered primarily through large-class lectures introducing the key concepts and methods, supported by a variety of delivery methods combining the traditional and the technological. The content is presented via a combination of slides, whiteboard and visualizer.
Learning will be reinforced through tutorial question sheets.
This module presents opportunities both for formative and summative assessment.
You will be formatively assessed through a number of progress tests and tutorial sessions.
Additional opportunities are provided for you to self-assess your learning via tutorial problem sheets.
Summative Assessment takes the form of a written closed-book exam at the end of the module. The exam is specifically formulated to assess design-based learning outcomes in addition to the other learning outcomes for the module.
||Closed-book written examination
You will receive feedback on examinations in the form of an examination feedback report on the performance of the entire cohort.
You will receive feedback on your performance whilst undertaking tutorial exercises, during which you will also receive instruction on the correct solution to tutorial problems.
Further individual feedback will be available to you on request via this module’s online feedback forum, through staff office hours and discussions with tutors.
Dr Koon-Yang Lee