Composites Materials Science and Manufacturing

Lectures	Hours	Credits
Composite materials structure and characterization	28	4
Specific materials (smart, biobased, nanofilled materials)	8	1
Composite materials manufacturing	8	2
Lab sessions	4	1
Composites processes modeling	28	4
Mechanics of composites and sandwich structures Structures and process robustness	32	5
Project : design and manufacturing of a composite part	32	4
Research Project	80	5
Foreign Languages	40	4
Sports	20	1
TOTAL	280	31

Syllabus description

Composite materials structures and characterization (28h, 3 credits)

• Composites materials constituents and specificities
• Markets and key figures
• Technical and economical characteristics
• Sandwich structures specificities
• Preform and polymer characterization techniques for processing modeling
• Characterization of mechanical properties
• Non destructive evaluation techniques

Composite materials manufacturing (Lecture : 8h, 2 credits ; lab session : 4h, 1 credit)

• Exhaustive presentation of composites processes
  • Continuous processes
  • Liquid Composite Molding processes
  • Open mold processes
  • Consolidation processes
  • Long/short fiber thermoplastics molding
• Materials requirements, type of parts produced and economical aspect of each process
• Recent developments in composites manufacturing

Lectures are completed with a lab session on infusion manufacturing

Specific materials (8h, 2 credits)

Physical, thermomechanical and economical aspects, as well as application market of :

• Nano-reinforced polymers
• Bio-based materials and biocomposites materials for the living
• Smart materials

Composites processes modeling (28h, 4 credits)

• Understanding the influence of process and material parameters on cycle times and part quality
• Interaction between the physics involved (energy, flow in porous media, mechanics, polymerization kinetics…)

Mechanics of composites and sandwich structures (32h, 5 credits)

• Laminate plate theory through continuum mechanics for homogeneous anisotropic materials and through heterogeneous materials approaches
• Evaluation of unidirectional and multilayered composites mechanical properties
• Influences of thermal and moisture effects
• Long term behavior and damage mechanisms.
• Structures reliability and process robustness principles applied to composites materials
• Applications through various examples and practical analytical works.
• Applications using commercial designing software on realistic parts.

Project : Design and manufacturing of a composite part (32h, 4 credits)

Through this project, students are invited to apply the different knowledge presented in the other lectures. From a book of requirements concerning a structural application, students should design a composite parts by :

• Proposing a geometry and the material used
• Defining the laminate structure and justify its mechanical response using adapted analytical or numerical tools
• Choosing the manufacturing process and evaluate the cycle time
• Determining the investment requirements and part cost analysis
• Manufacturing of a prototype

Research Project (80h, 5 credits)

Students are proposed to choose between :

• A research project concerning at least on of the following :
  • material characterization
  • Process development and/or optimization
  • Part development
• An innovative and creative project where the student
  • Propose an innovative part and a short competitive study
  • Analyze the different functions and propose a design
  • Define the manufacturing steps and a short economical study
  • Manufacturing of a prototype

Complementary activities (5 credits)

• 2 Languages (including French for foreigners), 4 credits
• Sports (selection among 15 disciplines), 1 credit