Lesson 1Risks and limitations per family: long-term performance, repairability, supply chain, cost volatilityThis part checks risks and limits across material groups, including creep, fatigue, corrosion, environmental wear, and ageing. It also looks at repairability, checks, supply chain strength, and cost changes 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 2Aluminum alloys: typical grades, advantages for lightweight panels, corrosion and fatigue considerationsThis part reviews common shaped and cast aluminium alloys used in lightweight panels. It covers naming systems, key traits, corrosion and fatigue behaviour, joining options, and usual trade-offs against steels and composites.
Aluminum alloy series and designation systemsMechanical properties of common panel alloysCorrosion mechanisms and protection methodsFatigue behavior and design against crackingForming, joining, and repair of aluminum panelsLesson 3Fiber-reinforced polymers (CFRP, GFRP, natural-fiber composites): stiffness-to-weight, lay-up architectures, durability and moisture sensitivityThis part explores fibre-reinforced polymers, including CFRP, GFRP, and natural-fibre laminates. It discusses fibre setups, lay-up plans, matrix choice, unevenness, damage types, moisture effects, and long-term durability.
Unidirectional, woven, and multiaxial fabricsPrepreg, infusion, and compression moldingStiffness-to-weight indices and optimizationImpact damage, delamination, and fatigueMoisture uptake and environmental durabilityLesson 4Natural-fiber and bio-based composites: sustainability benefits, variability, mechanical limitsThis part focuses on natural-fibre and bio-based composites, stressing sustainability measures, life-cycle effects, and recyclability. It also addresses changes in fibres, moisture absorption, making routes, and mechanical limits.
Common natural fibers 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 part covers high-strength steels and advanced metal alloys, including AHSS, maraging steels, and light alloys. It addresses strength-ductility trade-offs, shaping limits, weldability, joining, corrosion protection, and weight effects.
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 part looks at technical ceramics and ceramic matrix composites, highlighting stiffness, hardness, and heat resistance. It contrasts these with brittleness, flaw sensitivity, joining challenges, and making routes like 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 part surveys metals, polymers, ceramics, composites, and hybrids as possible groups. It compares density, stiffness, strength, toughness, heat capability, and cost, and introduces charts and indices for early choice.
Key property ranges for structural metalsThermoplastics and thermosets as engineering polymersCeramics and glasses for high-temperature serviceFiber-reinforced composites and sandwich structuresHybrid and multimaterial systems in designLesson 8Polymer matrices and thermoplastics (PA6, PEEK, PP): toughness, processing (injection molding, thermoforming), temperature limitsThis part analyses polymer matrices and key thermoplastics like PA6, PEEK, and PP. It covers molecular structure, crystal formation, toughness, melt behaviour, processing by injection moulding and thermoforming, and service heat limits.
Molecular structure and crystallinity in polymersProperties of PA6, PEEK, and PP in structuresInjection molding: design and defectsThermoforming and sheet forming guidelinesGlass transition, melting point, and heat aging
