Unit 1

Types of reinforcements, their mechanical properties and functions -ceramics, glass, carbon, boron.silicon carbide, metal, aramid.Forms of reinforcements- particulate, fibre, filaments, whiskers, flakes. Pre-fabricated forms- preforms, prepegs, fabrics, honeycomb. Type of matrix, its mechanical properties and functions- polymers (thermosets and thermoplastics), metals, ceramics, glass and carbon.Basic principles in the design of composites and selection of matrix and reinforcement.Bonding mechanisms.

Unit 2

Anisotropic behaviourand relationship between structure-mechanical properties.Mechanical testing- tensile, compressive, Intra-laminar shear, Inter-laminar shear and fracture. Polymer Matrix Composites: Types of thermoset and thermoplastic resins. Principles in the selection of matrix and the reinforcements.Process selection criteria.Mould and tool making.Basic manufacturing steps- impregnation, lay-up, consolidation and solidification.

Unit 3

Manufacturing processes for polymer composites- lay-up, compression moulding, extrusion, injection moulding, sheet forming, pultrusion, hot press & autoclave techniques and filament winding. Metal and ceramic matrix composites- wettability of reinforcement to matrix and bonding, methods of manufacturing reinforcements with intermediate wetting layer. Manufacturing processes for metal matrix composites: casting methods- gravity & low pressure die, investment, squeeze, spray forming, compression moulding and thixo-moulding. Manufacturing processes for ceramic matrix composites: reaction sintering, electro-deposition, spray forming, infiltration. Applications of composites: daily usages- industrial, automotive and aerospace, advanced composites, design- selection and process of composite for new application, case studies.

Course Objectives

• To introduce various types of reinforcements and matrices for composites
• To impart knowledge on the fundamentals of design of composites and structure property relations
• To familiarize with suitable tools and methods for manufacturing of composites
• To understand advance composite materials and processes

Course Outcomes

• CO1: Identify the importance of base matrix and reinforcements of composites for different applications.
• CO2: Select the mould, tool, matrix and reinforcements for composites
• CO3: Identify suitable processes and parameters for the manufacture of various composites
• CO4: Select appropriate composite materials, design of composites for real time applications.

CO – PO Mapping

Textbook(s)

• Clyne, T.W. and Withers, P.J., ‘An Introduction to Metal Matrix Composites’, Cambridge Univ. Press 1993.
• Matthews, F.L., and Rawlings, R.D, ‘Composite Materials: Engineering and Science’, Chapman & Hall, London 1994.

Reference(s)

• Suresh, S., Martensen, A., and Needleman, A., ‘Fundamentals of Metal Matrix Composites’, Butterworth, Heinemann, 1993.
• Mallick, P. K., ‘Fiber-reinforced Composites: Materials, Manufacturing and Design’, Marcel Dekker, 1993.
• Mazumdar, S.K., ‘Composites Manufacturing-Materials, Product, & Process Engineering’, CRC Press, 2002.

Evaluation Pattern