Composite Materials Course

Lesson 1 • Introduction to Composite Properties

Surveys mechanical, thermal, and electrical properties achievable in composites. Sets performance benchmarks used throughout the course.

Lesson 2 • Definition and Historical Development

Traces composites from ancient mud-brick to modern aerospace applications. Provides context for why composites replaced conventional materials in high-performance uses.

Lesson 3 • Classification of Composite Systems

Categorizes composites by matrix type, reinforcement geometry, and scale. Enables systematic material selection based on structural classification.

Lesson 4 • Constituent Materials Overview

Examines properties of fibers and matrices individually before combination. Connects constituent behavior to composite-level performance expectations.

Lesson 1 • Glass and Aramid Fiber Systems

Compares E-glass, S-glass, and aramid fiber properties and cost trade-offs. Guides selection for marine, ballistic, and structural applications.

Lesson 2 • Thermoset Matrix Chemistries

Details epoxy, polyester, vinyl ester, and bismaleimide resin systems. Relates cure chemistry to glass transition temperature and toughness.

Lesson 3 • Thermoplastic Matrix Systems

Introduces PEEK, PPS, and nylon-based thermoplastic composites and their processing windows. Highlights recyclability and impact resistance advantages over thermosets.

Lesson 4 • Reinforcement Architectures

Examines unidirectional, woven, braided, and non-crimp fabric forms. Connects textile architecture to in-plane and out-of-plane property distributions.

Lesson 1 • Rule of Mixtures and Bounds

Derives Voigt and Reuss bounds for longitudinal and transverse moduli. Establishes accuracy limits of simple mixture rules for engineering estimates.

Lesson 2 • Classical Lamination Theory

Builds the ABD stiffness matrix for multi-ply laminates under in-plane and bending loads. Enables prediction of laminate deformation and coupling effects.

Lesson 3 • Strength Criteria for Composites

Applies maximum stress, maximum strain, and Tsai-Wu failure criteria to ply-level stress states. Identifies first-ply failure and progressive damage sequences.

Lesson 4 • Interlaminar Stress and Delamination

Analyzes out-of-plane stresses at free edges and ply drops using elasticity solutions. Connects interlaminar tension to delamination onset in laminates.

Lesson 1 • Hand Layup and Spray-Up Processes

Covers manual lamination and spray-up techniques for low-volume, large-part production. Identifies quality risks from operator variability and void content.

Lesson 2 • Filament Winding and Pultrusion

Analyzes continuous fiber processes for pressure vessels, pipes, and structural profiles. Relates winding angle and pull speed to mechanical property outcomes.

Lesson 3 • Vacuum Infusion and Resin Transfer Molding

Explains closed-mold liquid infusion processes that improve fiber volume fraction and surface finish. Compares VARTM, RTM, and light RTM tooling requirements.

Lesson 4 • Prepreg and Autoclave Processing

Details prepreg storage, layup, and autoclave cure cycles for aerospace-grade laminates. Links cure pressure and temperature profiles to void content and Tg.

Lesson 1 • Defect Classification and Disposition

Categorizes porosity, delamination, fiber waviness, and foreign object inclusions by severity. Establishes repair-or-reject decision logic based on structural criticality.

Lesson 2 • Tooling Materials and Design Principles

Compares aluminum, steel, Invar, and composite tooling for thermal expansion compatibility. Guides tool design for part accuracy, durability, and cost.

Lesson 3 • Statistical Process Control for Composites

Applies control charts and capability indices to composite manufacturing variables. Identifies assignable causes of variation in fiber volume and void content.

Lesson 4 • Cure Monitoring Techniques

Applies dielectric analysis, fiber optic sensing, and ultrasonic methods to track resin cure in real time. Enables adaptive cure cycle control to minimize defects.

Lesson 1 • Laminate Optimization Strategies

Uses gradient-based and genetic algorithm methods to optimize ply angles and thicknesses. Balances weight, stiffness, strength, and manufacturing constraints simultaneously.

Lesson 2 • Laminate Design Rules and Guidelines

Presents industry-standard rules for ply orientation, balance, symmetry, and minimum ply percentages. Prevents common design errors that cause warpage and premature failure.

Lesson 3 • Finite Element Modeling of Composites

Implements shell and solid element models with ply-by-ply material definitions in FEA software. Validates models against analytical solutions and experimental data.

Lesson 4 • Stress Analysis Under Combined Loading

Solves laminate response to combined in-plane, bending, and thermal loads using ABD relations. Extends analysis to curved panels and open-section beams.

Lesson 1 • Adhesive Bonding of Composite Joints

Analyzes single-lap, double-lap, and scarf joint geometries using shear-lag and FEA models. Selects adhesive systems based on peel strength and service temperature.

Lesson 2 • Damage Assessment in Service

Applies visual inspection, tap testing, and portable NDT to identify in-service damage. Classifies damage by type and extent to determine repair urgency.

Lesson 3 • Bonded Repair Design and Execution

Designs scarf and external patch repairs for structural and cosmetic damage. Covers surface preparation, adhesive application, and heat-blanket cure in the field.

Lesson 4 • Maintenance Programs and Damage Tolerance

Establishes inspection intervals and damage growth limits within a damage-tolerance framework. Integrates composite-specific requirements into structural maintenance plans.

Lesson 1 • Regulatory Certification Pathways

Navigates airworthiness, marine, and industrial certification frameworks for composite structures. Prepares compliance documentation and substantiation reports for regulatory review.

Lesson 2 • Statistical Basis for Design Allowables

Applies B-basis and A-basis statistical methods to coupon data for structural allowable generation. Addresses sample size requirements and population distribution fitting.

Lesson 3 • Environmental Conditioning and Durability

Conditions specimens for moisture, temperature, and UV exposure to establish environmental knockdown factors. Quantifies property retention across the service environment envelope.

Lesson 4 • Building-Block Test Approach

Structures the certification test pyramid from coupons through elements, subcomponents, and full structures. Reduces certification risk by validating analysis at each level.