Course Details

Objective

By end of course participants will be able to understand

• Understand the basic principles of materials science, including structure, properties, and behavior of materials.
• Identify and describe various types of composite materials, including thermosets, thermoplastics, and reinforced composites.
• Comprehend the key factors that influence material selection for different engineering applications.
• Learn about the different testing methods used to evaluate the mechanical, thermal, and chemical properties of materials.
• Understand the role of material testing equipment, including universal testing machines, hardness testers, and impact testers.
• Interpret material test results to assess material performance and suitability for specific applications.
• Apply appropriate testing standards (e.g., ASTM, ISO) in conducting material tests.
• Identify common failure modes in materials and composites and how to prevent them through proper testing and material selection.

Content

Day 1: Introduction to Materials Science

• • Overview of materials science: Definition and scope.
  • Classification of materials: Metals, polymers, ceramics, and composites.
  • Basic atomic structure and properties of materials (e.g., mechanical, thermal, electrical).
  • Key factors affecting material performance (stress, strain, fatigue, creep).
  • Types of materials: Ferrous and non-ferrous metals, polymers, ceramics, and composites.
  • Material properties and how they are measured.
  • Introduction to composites: Structure, types, and applications.
  • Industry examples of material selection in various sectors (aerospace, automotive, construction).

Day 2: Composite Materials – Types and Properties

• • Introduction to composite materials: Definition, structure, and types (fibers, matrices, and reinforcements).
  • Types of composites: Polymer matrix composites (PMCs), metal matrix composites (MMCs), ceramic matrix composites (CMCs).
  • Key properties of composite materials: Strength, stiffness, thermal resistance, fatigue resistance.
  • Common materials used in composites: Carbon fiber, glass fiber, aramid, and natural fibers.
  • Manufacturing processes for composite materials: Lay-up, filament winding, resin transfer molding (RTM), and autoclave processing.
  • Advantages and limitations of composite materials.
  • Design considerations for composite materials in various applications (aerospace, automotive, sports equipment, etc.).

Day 3: Material Testing Methods and Equipment

• • Overview of material testing: The importance of testing for material selection and quality control.
  • Common mechanical tests: Tensile, compression, shear, and bending tests.
  • Hardness testing: Methods and standards (e.g., Rockwell, Vickers, Brinell).
  • Impact testing: Charpy and Izod tests for ductility and toughness.
  • Thermal testing methods: Differential scanning calorimetry (DSC), thermal conductivity, and expansion.
  • Non-destructive testing (NDT) methods: Ultrasound, X-ray, and Eddy current testing for composites.
  • Introduction to universal testing machines (UTMs) and how they work.

Day 4: Advanced Testing for Composites and Failure Analysis

• • Testing composite materials: Special considerations for fiber-reinforced composites.
  • Methods for testing composite lamina and laminate properties.
  • Testing for damage tolerance: Fatigue and environmental exposure testing (UV, moisture, temperature).
  • Microstructure analysis: Scanning electron microscopy (SEM) and other imaging techniques for composites.
  • Failure modes in composite materials: Delamination, fiber breakage, matrix cracking, and debonding.
  • Failure analysis techniques: Fractography and microscopy.

Day 5: Data Interpretation, Reporting, and Industry Standards

• • Interpreting test results: Stress-strain curves, hardness values, impact energies.
  • Using material data sheets and test reports.
  • Applying industry standards: ASTM, ISO, and MIL standards for material testing.
  • Ensuring accuracy in reporting: Data validation and quality assurance.
  • Review of composite materials and their testing techniques.
  • Advanced topics: Sustainability in composite materials and recycling.
  • Q&A session and course wrap-up.

NOTE:

Pre-& Post Tests will be conducted.

Case Studies, Group Exercises, Group Discussions, Last Day reviews, and assessments will be carried out.

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Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily to examine the effectiveness of delivering the course.

Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group Work& Practical Exercises
• 20% Videos& General Discussions