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INTRODUCTION TO REENGINEERED MATERIALS

Abstract

In the recent years US aerospace, trucking, heavy equipment industry and civil infrastructure is facing with challenging problems of aging metal components. These components are typically made out of structural steel and aluminum. This paper discusses development of a new short course which introduces students with basic principles of reengineering design and manufacturing procedures for aging metal components. Special emphasis is placed on the use of lightweight high strength fiberglass and carbon composites. This course is specifically designed for the senior/first year graduate students from Mechanical, Civil, Architectural and Industrial engineering departments. Typically students taking this short course have prerequisites including strength of materials, machine design and material science. The proposed course will be useful in securing high tech jobs particularly where the reengineering skills are essential.

Introduction

This paper presents a new short course (typical duration of about three weeks), which introduces both seniors and first year graduate students from Mechanical, Civil, Architectural and Industrial engineering students a concept of reengineered materials. The course is typically divided into three sessions (one session per week). Each session runs approximately three times in a week, with duration of fifty minutes each. The details of the three sessions are provided below:

Session One - Overview of Composites

In the first lecture of Session 1, students are introduced to composite materials. Students learn that a composite material is made of two or more chemically different materials with a distinct interface between them. The individual constituents maintain their own properties. However, the combination of materials develops a material that has properties and characteristics different than those of the original constituents. The properties of the composite material depend on the properties and geometry of the constituent materials and the distribution of the phases. They also learn about high specific strength and high specific moduli, improved corrosion and wear resistance, low thermal conductivity, and increased fatigue life typical of composites. They also learn some specific disadvantages including cost, a lack of high productivity manufacturing methods, and clear-cut design rules. Some work is also devoted to the different fibers used such as glass, carbon, aramid, boron and alumina. They are also introduced to the more inexpensive and popular resins such as polyester, vinyl ester, cyanate ester and epoxy1.

In the second lecture of Session 1, students are introduced to and the different manufacturing techniques. There are various methods that are used to manufacture composite laminates 2. These methods include wet lay-up, prepreg method, autoclave processing, filament winding, pultrusion, resin transfer molding (RTM) and vacuum assisted resin transfer molding (VARTM). Students

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Kelkar, A., & Bolick, R. (2009, June), Introduction To Reengineered Materials Paper presented at 2009 Annual Conference & Exposition, Austin, Texas. 10.18260/1-2--5473