Lightweighting Professional Course

The objective of the FRP Module is to give an overview of all key aspects of fiber reinforced plastics, which must be taken into account when lightweight design strategies are applied. This then allows the participants to select the most suitable Advanced Modules to take.

On completion of this module the course participants will be able to understand which factors are not only important for the manufacture and use of fiber reinforced plastics but also crucial for the application of lightweight design in the development of fiber reinforced plastic products.

This module aims to give you an overview of metal powders and how they can be used to produce components that have a lower mass than conventional production routes. One application for metal powders that is subject to much attention is additive manufacturing, also known with the name of metal 3D printing. This module will describe additive manufacturing techniques and how they may be deployed to reduce mass in service.

By the end of this module, you should be able to:

• Explain how components made from metal powders and/or by additive manufacturing can be used to reduce mass, compared to cast and machined components.
• Describe the main routes by which metal powders can be converted in to solid, dense components.
• Describe the main additive manufacturing production routes.
• Relate manufacturing techniques to the types of powder that are optimal for each process.
• Describe how powders may be characterised, what properties are relevant for different manufacturing techniques and the techniques that can be used to measure such characteristics.
• Critically assess the suitability of a powder for a process or vice-versa.
• Explain how a general component could be redesigned to take advantage of additive manufacturing and how this could lead to lightweighting.

The aim of the STEEL Module is to give an overview of steel grades and the applicable production technologies, depending on the objectives for the development of a lightweight product. You will also learn what you need and how to transfer the laboratorial knowledge to industrial scale.

After successful completing of the »STEEL« advance level of the lightweight professional training course, the participants will be able to:

• differentiate various steel grades according to their functionality
• understand which factors are important from the development of a lightweight product from the view of material and technology
• planning and transfer of laboratorial knowledge to industrial scale
• distinguish between different manufacturing methods and requirements for their implementation

The aim of the MAGNESIUM Module is to give an overview of potential for the application magnesium alloys and applicable production technologies, depending on objectives for the development of a lightweight product. You will also learn what you need and how to transfer the laboratorial knowledge to industrial scale.

After successful completing of the »MAGNESIUM« advance level of the lightweight professional training course, the participants will be able to:

• differentiate various magnesium alloys according to their functionality
• understand which factors are important from the development of a lightweight product from the view of material and technology
• planning and transfer of laboratorial knowledge to industrial scale
• distinguish between different manufacturing methods and requirements for their implementation

After an introductory review of key-properties of Aluminium and its alloys, and a summary of relevant application fields, this Module will address the main processing routes (primary production, recycling, rolling, extrusion, casting) and the guidelines for alloys and processes selection. Welding and joining processes, which are fundamental in several industrial application fields will be presented, as well as the challenging solutions offered by conventional and innovative surface finishing techniques. Basic concepts to be adopted in quality control and evaluation will be described. The main techniques for process and properties modelling will be reviewed, to properly approach design methods and solutions suitable for Aluminium alloys. The Module will finally include some case studies of development of Aluminium alloys components for lightweight, taking into account both rolled and/or extruded and cast components. All case studies will present, taking advantage from LCA and other software tools, the eco-sustainability potential associated to Aluminium alloys.

The mission of cast iron Module is to offer a complete overview of different cast iron materials (according to international standards), from grey iron to austempered ductile iron, to the point of comparing cast irons with steels. This module is structured for analyzing different foundry production processes and also to examine in depth all properties and technical advantages of cast irons materials, which are everyday more relevant in (lightweight) design components, maintaining always a focus on low environmental impact. All participants will have the chance to study other important topic as quality requirement and casting defects, fatigue design and surface heat treatment up to a special welding and joining topic about cast irons. At the end of the course, this module will show some real successful examples of lightweight designed components.

The aim of the Polymer Module is to give an overview of different Polymer Materials and their typical production technologies for the development of a light- and cost effective product. You will get a detailed overview of the basic Polymer properties and how to transfer theses, into industrial applications.

After successful completing of the »POLYMER« advance level of the lightweight professional training course, the participants will be able to:

• Differentiate various Polymer types according their properties
• Evaluate the best Polymer material for right application
• Distinguish between different manufacturing processes concerning the Material and functionality of the Lightweight part
• Planning and transfer of laboratorial knowledge to industrial scale