Lesson 1Risks and limitations per family: long-term performance, repairability, supply chain, cost volatilityThis section evaluates risks and limitations across material families, including creep, fatigue, corrosion, environmental degradation, and ageing. It also considers repairability, inspection, supply chain resilience, and cost volatility over product life.
Time-dependent damage: creep and fatigueCorrosion, oxidation, and environmental attackInspection, nondestructive testing, and repairSupply chain risks and material availabilityCost volatility and total ownership costLesson 2Aluminium alloys: typical grades, advantages for lightweight panels, corrosion and fatigue considerationsThis section reviews common wrought and cast aluminium alloys used in lightweight panels. It covers designation systems, key properties, corrosion and fatigue behaviour, joining options, and typical trade-offs versus steels and composites.
Aluminium alloy series and designation systemsMechanical properties of common panel alloysCorrosion mechanisms and protection methodsFatigue behaviour and design against crackingForming, joining, and repair of aluminium panelsLesson 3Fibre-reinforced polymers (CFRP, GFRP, natural-fibre composites): stiffness-to-weight, lay-up architectures, durability and moisture sensitivityThis section explores fibre-reinforced polymers, including CFRP, GFRP, and natural-fibre laminates. It discusses fibre architectures, lay-up strategies, matrix selection, anisotropy, damage modes, moisture sensitivity, and long-term durability.
Unidirectional, woven, and multiaxial fabricsPrepreg, infusion, and compression mouldingStiffness-to-weight indices and optimisationImpact damage, delamination, and fatigueMoisture uptake and environmental durabilityLesson 4Natural-fibre and bio-based composites: sustainability benefits, variability, mechanical limitsThis section focuses on natural-fibre and bio-based composites, emphasising sustainability metrics, life-cycle impacts, and recyclability. It also addresses variability in fibres, moisture uptake, processing routes, and mechanical performance limits.
Common natural fibres and bio-based matricesProcessing routes for bio-composite laminatesMechanical properties and design allowablesMoisture uptake, swelling, and durabilityLife-cycle assessment and end-of-life optionsLesson 5High-strength steels and advanced alloys: properties, weight penalty, forming and joining considerationsThis section covers high-strength steels and advanced metallic alloys, including AHSS, maraging steels, and light alloys. It addresses strength–ductility trade-offs, forming limits, weldability, joining, corrosion protection, and weight implications.
Classes of high-strength and advanced steelsStrength–ductility trade-offs and forming limitsWeldability, joining, and heat-affected zonesCorrosion protection and surface treatmentsWeight penalty versus performance benefitsLesson 6Technical ceramics and ceramic matrix composites: stiffness and temperature resistance vs brittleness and manufacturabilityThis section examines technical ceramics and ceramic matrix composites, highlighting stiffness, hardness, and temperature resistance. It contrasts these with brittleness, flaw sensitivity, joining challenges, and manufacturing routes such as sintering.
Crystal structures and toughening mechanismsThermal shock resistance and high-temperature useProcessing: powder prep, forming, and sinteringJoining, sealing, and interface engineeringDesign against brittleness and flaw sensitivityLesson 7Overview of candidate material families: metals, polymers, ceramics, composites, hybrid systemsThis section surveys metals, polymers, ceramics, composites, and hybrids as candidate families. It compares density, stiffness, strength, toughness, temperature capability, and cost, and introduces charts and indices for early-stage screening.
Key property ranges for structural metalsThermoplastics and thermosets as engineering polymersCeramics and glasses for high-temperature serviceFibre-reinforced composites and sandwich structuresHybrid and multimaterial systems in designLesson 8Polymer matrices and thermoplastics (PA6, PEEK, PP): toughness, processing (injection moulding, thermoforming), temperature limitsThis section analyses polymer matrices and key thermoplastics such as PA6, PEEK, and PP. It covers molecular structure, crystallinity, toughness, melt behaviour, processing by injection moulding and thermoforming, and service temperature constraints.
Molecular structure and crystallinity in polymersProperties of PA6, PEEK, and PP in structuresInjection moulding: design and defectsThermoforming and sheet forming guidelinesGlass transition, melting point, and heat ageing
