UNIT 138: COMPOSITE MATERIALS IN ENGINEERING

BN033521 Unit 138: Composite Materials in Engineering

Issue 1 September 2012 Pearson Education Limited 2012
1
Unit 138: Composite Materials in Engineering
Unit code: L/504/1914
QCF level: 5
Credit value: 15
Aim
The aim of this unit is to provide the learner with a knowledge and understanding of composite
materials, terminology, design, methods of production and how to select a suitable composite for
chosen applications. The range of study will include fibre-reinforced composites, metal matrix,
cermets and ceramic composite materials.
Unit abstract
Light, strong and corrosion-resistant, composites are being used in an increasing number of
products as manufacturers discover the benefits of these versatile materials.
The focus of the learning outcomes is on ensuring learners can identify, design and select
appropriate materials and manufacturing methods for components and how these materials are
being implemented into a wider range of markets.
Learning outcomes
On successful completion of this unit a learner will:
1. Understand the functions and properties of composite materials
2. Understand appropriate theories and principles in the design of composite products
3. Be able to evaluate the manufacturing methods of composite products
4. Be able to investigate applications of composites within existing and developing markets.
UNIT 138: COMPOSITE MATERIALS IN ENGINEERING

BN033521 Unit 138: Composite Materials in Engineering
Issue 1 September 2012 Pearson Education Limited 2012
2
Unit content
1 Understand the functions and properties of composite materials
Classify composites: examples under the headings: dispersion strengthened, particle
reinforced fibre reinforced and hybrids; show considerations of volume fractions, geometric
details and strengthening mechanisms
Matrix materials: functions and properties required of a matrix material
Reinforcement materials: functions and properties required of a reinforcement material;
forms of supply: filament, whisker, roving cloth, mat and pre-impregnated products
Range of composite materials: polymeric, metallic and ceramic matrix materials;
reinforcement types: glass, carbon, aramids, polythene; typical metallic and ceramics; hybrid
composites: honeycomb and foams; with reference to properties, characteristics and uses
2 Understand appropriate theories and principles in the design of composite products
Design philosophy: influence of stiffness and second moment of area; effects of subdividing a
structure; structure loading coefficient; pre-stressing; monocoque/shell structures; material
efficiency criterion
Strenthening and toughening: notch sensitivity; crack control; adhesion; work to fracture
Zirconia toughening in ceramics
Model strength and stiffness: law of mixture equation; relative strength and stiffness of matrix
and reinforcement; preferred combinations; influence of volume fraction
Effects of reinforcement: reinforcement efficiency; packing models; practical limitations;
voids; relationship between volume fraction, weight fraction and composite density;
associated design calculations
Failure mechanisms: tensile; compressive; buckling, fatigue; Griffith crack length; fracture
toughness; damage tolerance
3 Be able to evaluate manufacturing methods of composite products
Manufacturing methods: resin/fibre processing: hand-lay-up, spray-up; resin transfer
moulding; filament winding; centrifugal moulding; hot and cold press moulding; pultrusion;
appropriate terminology
Metal/ceramic matrix composite processing: isostatic pressing; sintering; reaction bonding;
powder metallurgy; squeeze casting; liquid pressure forming
Machining composites: mechanical cutting; ultrasonic; water jet; laser methods
Joining composites: fasteners; bonding; friction welding
Coatings technology: chemical and physical vapour deposition methods
UNIT 138: COMPOSITE MATERIALS IN ENGINEERING
BN033521 Unit 138: Composite Materials in Engineering
Issue 1 September 2012 Pearson Education Limited 2012
3
4 Investigate applications of composites within existing and developing markets
Viability of composites: cost analysis; processing /operating cost; computer aided design; part
complexity; durability; corrosion resistance
Justify composite applications: analyse composite products; justification of material types;
design; production method
Report on adopting a composite product: investigation into the production of a component or
assembly; propose composite material design; manufacturing details to supersede an existing
product design
Current and expected developments: current/expected developments in aerospace; military
equipment; transport; motor racing; sports equipment; space; commercial products;
construction; renewable energy generation
UNIT 138: COMPOSITE MATERIALS IN ENGINEERING

BN033521 Unit 138: Composite Materials in Engineering
Issue 1 September 2012 Pearson Education Limited 2012
4
Learning outcomes and assessment criteria
Learning outcomes
On successful completion of this
unit a learner will:
Assessment criteria for pass
The learner can:
LO1 Understand the functions and
properties of composite
materials

1.1 state the classifications of composite materials
1.2 describe functions and properties of matrix materials
1.3 describe how reinforcement materials are
manufactured and supplied
1.4 investigate the range of composite materials used in
composite manufacture and products
LO2 Understand theories and
principles in the design of
composite products
2.1 explain design philosophy involved in composite
structures
2.2 describe the strengthening and toughening
mechanisms in polymeric, metallic and ceramic
composites
2.3 describe how to model strength and stiffness of fibre
reinforced composites
2.4 analyse the effects of reinforcement on composite
properties
2.5 explain typical failure mechanisms in composite
materials
LO3 Be able to evaluate
manufacturing methods of
composite products
3.1 investigate manufacturing methods of composite
products
3.2 evaluate manufacturing methods of composite
products
3.3 describe techniques for machining composite materials
3.4 explain techniques for joining composite materials
3.5 explain the technology and applications of hard ceramic
coatings
LO4 Be able to investigate
applications of composites
within existing and developing
markets
4.1 evaluate the suitability of composites compared with
conventional materials
4.2 justify the use of composite materials for particular
applications
4.3 report on adopting a composite material as a
replacement to conventional materials
4.4 demonstrate an awareness of current and predicted
developments in the use and manufacture of
composites.
UNIT 138: COMPOSITE MATERIALS IN ENGINEERING
BN033521 Unit 138: Composite Materials in Engineering
Issue 1 September 2012 Pearson Education Limited 2012
5
Guidance
Links
This unit is sufficient to standalone or could be linked to Unit 8: Engineering Design or
Unit 69: Advanced Computer-aided Design Techniques. Entry requirements for this unit are at the
discretion of the centre. However learners should have completed the appropriate BTEC National
or equivalent units and BTEC Higher National Unit 21: Materials Engineering.
Essential requirements
Access to suitable laboratory equipment and a supply of relevant materials is necessary.
Computers and CAD software will be required, dependent on the design.
Employer engagement and vocational contexts
Wherever possible, centres should provide a practical approach to learning supported by visits to
composite engineering facilities and the attendance of guest speaker(s) from relevant design and
manufacturing environments.


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