Design with Aluminum Course

Course Description:

This course was developed by Kettering University and the Center for Advanced Automotive Technology (CAAT). Design with Aluminum is an introductory course focusing on the basics of engineering design, properties, manufacturing processes, design aspects, and design guidelines along with several real life examples and applications of aluminum alloy materials commonly used in automotive and other applications. The topics are covered using 'blended learning' and 'flipped classroom' approaches. The lecture handouts, together with homework assignments, course projects, and exams are designed to train the targeted students in community colleges with basic math, CAD and mechanics experience, for associate degrees and/or certificate programs. This course is designed to meet over a period of seven weeks (or more), two meetings per week, and two hours per meeting.

Course Contents

Included materials in the Design with Aluminum Course are a syllabus, homework assignments, PowerPoint lectures, a pre exam assessment survey, projects, and a test. The 7-page syllabus includes sections on course information, course learning outcomes, course topics and roadmap, and grading and assessment. Homework materials include homework instructions, a grading rubric, instructions on obtaining homework answers, and five homework assignments.

Below is a list of files contained in the .zip attachment. Files are .docx and .pptx. The size of each file is included in parenthesis.

Design with Aluminum Course (31 files, 101.6 MB)

• Homework
  • HW Format for Design with Aluminum (HW_Format.docx 268 KB)
  • Design with Aluminum Grading Rubric (HW_Grading Rubric.docx 223 KB)
  • HW1: Basics of Engineering Design (HW1_Engineering Design.docx 228 KB)
  • HW2: Material Selection Using Ashby Charts, Stress-Strain Curve (HW2_Material Selection using Ashby_Stress-strain curve.docx 574 KB)
  • HW3: Aluminum Manufacturing, Corrosion Prevention (HW3_Manufacturing Methods of Aluminum Products_Func. Perform, Corrosion.docx 300 KB)
  • HW4: Design for Cost Optimization, Extruded Products (HW4_Design for Cost Optimization_Extruded Products.docx 231 KB)
  • HW5: Design of Rolled Products, Automotive Applications (HW5_Rolled Products - Automotive Applications.docx 231 KB)
  • Obtaining homework answers (READ ME.docx 14 KB)
• Lectures
  • Designing with Aluminum (Module 0_Topics on Engineering.pptx 163 KB)
  • Topic 1: Engineering Design (Module 1_Engineering Design.pptx 5.3 MB)
  • Topic 2: Material considerations (Module 2_Material Considerations.pptx 5.7 MB)
  • Topic 3: Basic mechanical physical properties of aluminum (Module 3_Basic mechanical physical properties of aluminum.pptx 5.6 MB)
  • Topic 4: Products and manufacturing methods of Aluminum with applications (Module 4_Products and manufacturing methods of aluminum.pptx 17.9 MB)
  • Topic 5: Design for functional performance – Corrosion (Module 5_Design for functional performance - corrosion.pptx 4.5 MB)
  • Topic 6: Aluminum Design for Cost Optimization (Module 6_Optimum Cost Design.pptx 10.9 MB)
  • Topic 7: Characteristics of extruded products (Module 7_Characteristics of extruded products.pptx 14.2 MB)
  • Topic 8: Rolled aluminum products (Module 8_Rolled aluminum products.pptx 12.2 MB)
  • Topic 9: Car Body Structures (Module 9_Car Body Structures.pptx 21.6 MB)
  • Thumbnails (Thumbs.db 261 KB)
• Pre_post assessment
  • Pre and Post Course Offering Survey Questions (Pre Exam_Assessment Survey.docx 211 KB)
• Projects
  • Project 1 – Aluminum Manufacturing Processes: Relative Comparison and Cost Benefit Analysis (Project 1_Aluminum Manufacturing Processes.docx 221 KB)
  • Project 2 – Car Body Structures with Aluminum (Project 2_Car Body Structures with Aluminum.docx 221 KB)
• Syllabus
  • Syllabus and Roadmap (Syllabus and Roadmap.docx 238 KB)
• Test and Quizzes
  • Final Exam (Final Exam - Automotive Applications.docx 227 KB)