AA432x: Composite Materials Overview for

Engineers

Course Dates

Tuesday, November 18 through Tuesday, January 27 (8 weekly lessons, with a 2-week holiday
break from December 23 through January 5)

Course Description

Composites are used in many industries today to enable high-performance products at economic
advantage. These industries range from space to sports and include manufactured products for
aircraft, transportation, energy, construction, sports, marine, and medical use. There are many
material, economic, and aesthetic advantages to using composites, but a solid knowledge of the
physical properties, including the mechanics, tooling, design, inspection and repair, and
manufacturing options is required for working in this medium as they are intrinsically linked.

This course provides an introduction to the fundamentals of composite materials for high
performance structures from the viewpoint of aerospace engineering design, manufacturing, and
repair. The modules of this course are designed to address critical areas of composite technologies
that focus on materials, manufacturing, mechanics, design, inspection, and repair. In this course
students will learn how composite materials achieve properties of strength, weight ratios and
durability that surpass aluminum in aircraft design. For these high performance applications
engineers typically rely on laminated structures, which are built up from many layers of ply-
materials with various fiber orientations. Using this process the mechanical properties of the
composite part can be tailored to specific applications resulting in significant weight and cost
savings. Tailoring specific properties and designing innovative laminate structures highlights the
multidisciplinary nature of this industry and how it touches the expertise of many disciplines
including engineers, mechanics, and inspection specialists.

After successfully completing this course, students will be able to identify the unique
characteristics of composites and understand how advanced composite structures are designed,
manufactured and maintained.

NOTE: This course is offered on an audit basis only. Certificates, statements of achievement, and
official grades will not be issued. This free course provides enrolled students with complete
access to all of the course material, tests, and online discussion forums. Assessments are provided
to help students measure their progress in learning course content and determine their own
readiness, if they wish, to apply for the University of Washingtons online Certificate Program in
Composites, expected to launch later in 2015.

Feedback and enrollment information may be analyzed and shared with The Boeing Company for
course improvement and research purposes. All data will be anonymized to protect student
identity.

Course Objectives

After completing this course, students will be able to:

demonstrate understanding of fundamentals in materials, manufacturing, mechanics,
design, and repair of polymeric matrix composites;
identify advantages and disadvantages of polymeric matrix composites with respect to
metals; and
apply the knowledge acquired to the design and manufacturing of high-performance
composite structures.

Prerequisites
No prerequisites are required, but an understanding of engineering (particularly of mechanics of
materials), physics, and chemistry will be beneficial.

The lessons on mechanics of composites (weeks 5 and 6) assume students have a basic knowledge
of matrix algebra. Students who wish to review principles of matrix algebra should see Course
Materials, below, for a suggested resource.

Estimated Workload
Students with the requisite background in engineering may expect to spend 3 to 4 hours per week
on viewing the lecture videos, reviewing the course handouts, taking the ungraded and graded
quizzes, and participating in discussion forums.

Course Materials
Required:
All required materials are included in the weekly Courseware pages.

Suggested Readings:
To gain further understanding of the course materials, the following textbook is suggested, but not
required:
Composite Materials Overview: Materials, Manufacturing, Analysis, Design and Repair, by
K. Y. Lin, 2015. (Forthcoming.)

Matrix Algebra Resources

To get the most out of the lessons on mechanics of composites (weeks 5 and 6), you should be
familiar with matrix algebra. A basic tutorial on this area is below. If you are not yet comfortable
with matrix algebra, you are encouraged to view this tutorial or find other resources to help you
with this topic.

AA432x: Composite Materials Overview for Engineers Syllabus p. 2 (updated 11/19/14)

 Matrix Algebra
https://www.khanacademy.org/math/precalculus/precalc-
matrices/Basic_matrix_operations/v/scalar-multiplication

MATLAB
MATLAB is a software program for numerical computing, simulations, and other engineering and science
applications. During the second half of this course, AA432x students be given problem exercises and quiz
questions that use the MATLAB programming language. These exercises and questions will be submitted
through the edX interface; students will not need to download the software to complete these
problems.

For those interested in exploring MATLAB on their own, thanks to support from MathWorks, a free
downloadable license is available to students enrolled in AA432x for the duration of the course. The
license for the trial version is located in the Courseware section of the course; click on the MATLAB
button at the bottom of the Courseware page. This license is free and will expire roughly two weeks
after the end of the course. You will need to create a MathWorks account to download MATLAB to set
up your account. Please use the MATLAB Installation Help forum for any installation problems.

Course Team
Instructor: Dr. Kuen Y. Lin, University of Washington
Dr. Kuen Y. Lin (Ph.D., Massachusetts Institute of Technology) is a
Professor in the William E. Boeing Department of Aeronautics and
Astronautics. With The Boeing Company, he co-developed an award-
winning certificate program in Aircraft Composite Structural Analysis
and Design at the University of Washington. His current research
focuses on critical composite technologies for the next generation of
aerospace vehicles.

Teaching Assistant: Luke Richard, Ph.D. Candidate, University of

Washington
Luke is currently a Ph.D. Candidate in the University of Washington
department of Aeronautics and Astronautics, performing research in
composite delamination arrest. Working with Boeing, Toray
Composites and the FAA, Lukes research aims to improve the design
and certification of composite structures which experience
delaminations in service.

For their generous contributions to the development and review of this online course, thanks go to
Boeing Company partners Barry McPherson, Education Programs Leader; Michael Richey, Ph.D.,
Associate Technical Fellow; Dave E. French, Engineer and Learning Scientist; Fabian Zender, Ph.D.,
Project Implementation Manager; and Kathleen Chang, Ph.D., Program Manager.

Thanks also go to University of Washingtons Timothy Kieran OMahony, Ph.D., Research Associate at
the Learning in Informal and Formal Environments Center; Jonathan Keib, videographer and video

AA432x: Composite Materials Overview for Engineers Syllabus p. 3 (updated 11/19/14)

editor; Emily West, Program Manager; Steve Kerr, Professor Emeritus, Learning Sciences and
Educational Technology; Mark Ellison-Taylor, Director of Distance Learning Design and Development;
and other members of the UWPCE team. We are grateful for the support of edX staff, especially Melanie
MacFarlane, Program Manager, and to Brandon Armstrong of MathWorks.

Weekly Learning Objectives

After completing the video lectures, self-assessment (ungraded) quizzes, and graded quizzes,
students will be able to meet the following learning objectives.

Module 1Introduction

1. Identify composite materials and explain why are they are used.
2. Describe the history of composite applications in aircraft, space, transportation, energy,
electronics, sports and medical industries.
3. Identify advantages of using composites in high performance structures.
4. Relate the increasing usage of composites to the benefits provided by the material.

Module 2Differences between Metals and Composites

1. Describe the key differences between anisotropic and isotropic materials.

2. Outline areas where tailored specific strengths can be utilized.
3. Compare and contrast the service life (fatigue) and environmental (damage/corrosion) effects
on metallic vs. composite structures.
4. Identify the key damage mode for composites and composite damage tolerance capabilities.
5. Outline the cause of discontinuous stresses in composites and how it differs from metals.

Module 3Properties of Fiber, Matrix, and Composites

1. Explain the function of the fiber and matrix in a composite.

2. Identify the key differences between thermoplastic and thermoset matrix composites.
3. List common composite products and their unique properties.
4. Explain the strengthening mechanism that makes composites stronger.
5. Apply knowledge of environmental effects to design of composite structures.

Module 4Manufacturing of Polymeric Matrix Composites

1. Relate the fundamental physics in composite manufacturing.

2. Identify the available manufacturing processes for polymeric composites.
3. Describe typical defects introduced in manufacturing and the methods utilized to minimize
these defects.
4. Define common terminology in composites manufacturing.
5. Recognize special tooling considerations required for composite manufacturing.

AA432x: Composite Materials Overview for Engineers Syllabus p. 4 (updated 11/19/14)

Module 5 (Weeks 5 and 6)Mechanics of Composites

1. Apply Hookes Law to unidirectional composites.

2. Outline the stress-strain relations of a unidirectional composite subjected to mechanical,
thermal and moisture loads.
3. Calculate stress/strain/curvature of a laminate under constant axial forces and bending
moments.
4. Explain the unusual behaviors which may occur in laminates such as bending/stretching
coupling and stretching-shear coupling.
5. Justify the use of a specific layup orientation based on the loading conditions and CLT.
6. Identify the role of lamina and their arrangement in a laminate.

Module 6 (Weeks 7 and 8)Design, Inspection, and Repair

1. Outline the advantages and disadvantages of composites with respect to Product Lifecycle
Management.
2. Describe general considerations and process involved in composite structural design.
3. Identify typical in-service damage types for composites.
4. List non-destructive inspection techniques for detecting damage in composites.
5. Describe basic types of composite repair and their benefits.

Schedule
AA432x has eight weekly lessons and runs from November 18, 2014 through January 27, 2015,
with a two-week holiday break. A new lesson will be released each Tuesday of the course, except
during the break. Once the weekly content is released you may view the materials and take
quizzes at any time before the end of the course.

Note: During the holiday break, you will be able to access the course and any content released to
that point, but course staff will not be available. We are opening the lessons in weeks 5 and 6,
which focus on mechanics, on December 16th. This means that students will be able to get a head
start on the more mathematically challenging part of the course, including the MATLAB problems
that begin in week 6, if they so choose.

To keep up with the course, you are strongly encouraged to complete the course work by the
suggested due dates listed below. All quizzes must be completed by two weeks after the end of
the course.

Suggested Due Dates for Course Activities

Date lesson opens View all video lectures, complete Complete graded quiz
knowledge checks, and participate in
discussion forums
Week 1: November 24, 2014 November 25, 2014
November 18,

AA432x: Composite Materials Overview for Engineers Syllabus p. 5 (updated 11/19/14)

2014
Week 2: December 1, 2014 December 2, 2014
November 25,
2014
Week 3: December 8, 2014 December 9, 2014
December 2, 2014
Week 4: December 15, 2014 December 16, 2014
December 9, 2014
Week 5: December 22, 2014 December 23, 2014
December 16,
2014
Holiday Break: No new lesson content will be released during this two-week
December 23 period, and teaching staff will not be available. Use this time to
through January 5 catch up on any uncompleted coursework, or to begin Week 6.
Week 6: January 12, 2015 January 13, 2015
December 16,
2014 (opens early)
Week 7: January 19, 2015 January 20, 2015
January 13, 2015
Week 8: January 26, 2015 January 27, 2015
January 20, 2015
Quizzes close: To get feedback on quiz answers, quizzes must be submitted
February 10, 2015 within two weeks of the course end date, e.g., by February 10,
2015.

Assessments and Forums

Quizzes

Each week will include two types of quizzes: ungraded quiz questions, to help you quickly assess your grasp
of the material, as well as graded quizzes.

1. Knowledge-check Quizzes. Most video presentations in this course are following by a brief
quiz of 1 to 4 questions to help you check your understanding of the key concepts
presented. These quizzes are ungraded, and you have unlimited attempts to check the
answers. You are encouraged to taking these knowledge-check quizzes immediately after
viewing the videos.

AA432x: Composite Materials Overview for Engineers Syllabus p. 6 (updated 11/19/14)

 2. Graded Quizzes. At the end of Weeks 1-7 is a graded quiz consisting of 10 or more questions, most
of these multiple choice. For most of these questions, you have up to two attempts to get the
correct answer.

Note: Keep in mind that this course is offered only on an audit basis. No certificate, statement of
achievement, or official grade will be issued. The scores you earn in the course will help you assess
your mastery of the course content.

MATLAB Problems

Beginning in week 6, you will have exercises and problems making use of MATLAB. In addition to
three ungraded MATLAB problems, you will get eight graded problems assigned during weeks 6
and 8.

Discussion Forums

Each weekly lesson includes two or more discussion forums with guiding questions in order to
facilitate conversations among students across the globe on topics related to design,
manufacturing, and repair of composite materials. Discussion forums are not graded.

Grading
This course is offered only on an audit basis. No certificate, statement of achievement, or official
grade will be issued. For those students wishing to assess their mastery of the course topics, we
are providing numerous ungraded knowledge-check quizzes and eight graded quizzes.

The graded quizzes have varying numbers of questions each week, and some quizzes and MATLAB
problems are worth more than other, as shown below:

Graded Item / Weight

Weeks 1-3 and 6-7 Quizzes: 10% each = 50%
Weeks 4 and 5 Quizzes: 15% each = 30%
Week 6 MATLAB Problems: 6.5.1: 1%, 6.7.1: 1%, 6.7.2: 2%, 6.8: 2%, 6.10.1: 2%, 6.10.2: 2% =
10%
Week 8 MATLAB Problems: 8.5: 5%, 8.8: 5% = 10%
Total 100%

The grading scale may help you interpret how well you have met the courses learning objectives:

Grading Scale
90-100%: Excellent
80-89%: Very Good
70-79%: Good
60% or higher: Pass
40-59%: Those who completed all the lectures, knowledge-check quizzes, and graded quizzes,

AA432x: Composite Materials Overview for Engineers Syllabus p. 7 (updated 11/19/14)

 and scored 40-59% have attained some competency in this area. They are
encouraged, however, to repeat the course the next time it is offered to master more
of the learning objectives.
39% or below: Those who completed all the lectures, knowledge-check quizzes, and graded
quizzes, and scored 39% or below are encouraged to study engineering fundamentals
before attempting the class again in order to develop necessary background.

Students who wish to build on their understanding of composites should consider applying later in 2015
to the University of Washingtons fee-based certificate program in Composite Structural Analysis and
Design.

UW Certificate Program in
Composite Structural Analysis and Design
Want to learn more about composites? The University of Washington is planning to launch a new,
online certificate program, Composite Structural Analysis and Design, later in 2015. Information
about course dates, fees, and application deadlines will be made available later.

The edX course you are now taking, AA432x: Composite Materials Overview for Engineers, is
valuable preparation for the UWs certificate program, but is not a requirement. To be admitted to
the UW program, individuals must complete an application and hold a B.S. in engineering or
equivalent. Students scores in this edX course (AA432x) will not be used to determine whether
they are admitted to the certificate program. However, your performance in AA432x should give
you some indication of your readiness for the coursework in the UW certificate program.

AA432x: Composite Materials Overview for Engineers Syllabus p. 8 (updated 11/19/14)