What Design Engineers need to know about Materials

& Properties of Material

M S Dasgupta, BITS Pilani

M. S. Dasgupta, BITS Pilani, Pilani campus

1

Factors/Criteria in Material Selection

Function
Mechanical Properties
Failure Modes
Manufacturability
Cost
Environmental Considerations

M. S. Dasgupta, BITS Pilani, Pilani campus

2

Material Design
Properties of a newly discovered material can
suggest new product
eg: High-purity silicon : Transistor

Need for a new product can demand the

development of a new material
eg: Space Technology: Lightweight Composites
M. S. Dasgupta, BITS Pilani, Pilani campus
3

Important classes of materials (6)

Metals
Polymers
Elastomers

Ceramics
Glasses
Composites

A good design exploits and brings out the

true potential of materials selected.

M. S. Dasgupta, BITS Pilani, Pilani campus

4

Key Material Properties for Design

General:
Cost
Density

Mechanical

Elastic Modulus
Strength
Toughness
Fracture Toughness
Damping Capacity
Fatigue Endurance Limit

Wear
Archard Wear Constant

Thermal

Thermal Conductivity
Thermal Diffusivity
Specific Heat
Melting Point
Glass Temperature
Thermal Expansion Coefficient
Thermal Shock Resistance
Creep Resistance

Corrosion/Oxidation
Corrosion Rate
Parabolic Rate Constant
M. S. Dasgupta, BITS Pilani, Pilani campus
5

Material Stereotypes
Metals
High Moduli
Can undergo
Alloying, Heat Treatment

Formed by Deformation
Ductile
Yields before fracture

Prey to Fatigue,
Corrosion

Ceramics/Glasses
High Moduli, Hard,
Abrasion/Corrosion
resistant
Cutting Tools

Retain Strength at
High Temperature
Brittle
Prey to high contact
stresses, low
tolerance for cracks
6

M. S. Dasgupta, BITS Pilani, Pilani campus

Material Stereotypes

Polymers and Elastomers

Low Moduli, High Strength
High Elastic Deflection
Snap fits

Corrosion Resistant
Easy to Shape
Minimize Finishing
Operations
Temperature Dependent
Properties

Composites
High Moduli, Strength,
Lightweight
Can be Tough
Optimal performance
at room temperature
Expensive
Difficult to Form/Join

M. S. Dasgupta, BITS Pilani, Pilani campus

7

Material Index
Combination of material properties which
characterize performance in a given
application
Functional Geometeric Material

,
,

p f
Needs , F Parameters, G Characteristics , M

p f1 ( F ) f 2 (G) f 3 (M )
M. S. Dasgupta, BITS Pilani, Pilani campus
8

Modulus-Density charts

M. S. Dasgupta, BITS Pilani, Pilani campus

9

Other Materials Selection Charts

Strength-Density
Modulus-Relative Cost
Strength-Relative Cost
Specific Modulus-Specific
Strength
Fracture ToughnessModulus
Fracture ToughnessStrength
Loss Coefficient-Modulus

Facture ToughnessDensity
Conductivity-Diffusivity
Expansion-Conductivity
Expansion-Modulus
Strength-Expansion
Strength Temperature
Wear Rate-Hardness
Environmental Attack
Chart
M. S. Dasgupta, BITS Pilani, Pilani 10
campus

Environmental Attack Chart

M. S. Dasgupta, BITS Pilani, Pilani campus

11

Manufacturing & Material Selection

Manufacturability

Castability
Formability/Workability
Machinability
Coatability
Heat Treatment
M. S. Dasgupta, BITS Pilani, Pilani 12
campus

CLASSIFICATION OF FERROUS ALLOYS

FERROUS
STEELS

CAST IRON

LOW ALLOY

LOW
CARBON
PLAIN

HIGH
STRENGH
LOW ALLOY

HIGH ALLOY

MEDIUM
CARBON

PLAIN

DUCTILE
IRON

HIGH
CARBON

PLAIN
HEAT
TREATABLE

GRAY
IRON

WHITE
IRON
TOOL

MALLEABLE
IRON
STAINLESS

M. S. Dasgupta, BITS Pilani, Pilani 13

campus

Nomenclature: AISI/SAE
Carbon Steels

In percentage

10xx

Plain Carbon

11xx

Resulfurized

12xx

Resulfurized and
rephosphorized

Manganese steels
13xx

Mn 1.75

Nickel steels

23xx

Ni 3.5

25xx

Ni 5.0

Nickel Chromium Steels

31xx

Ni 1.25 Cr 0.65-0.80

32xx

Ni 1.75 Cr 1.07

33xx

Ni 3.50 Cr 1.50-1.57

34xx

Ni 3.50 Cr 1.50-1.57

14

BIS CLASSIFICATION SYSTEM

The Bureau of Indian Standards (BIS) was set up after

the enactment of the Bureau of Indian Standards Act,
1986.

It operates a product certification scheme, and grants

licenses to manufacturers covering a whole lot of
industries ranging from agriculture to electronics.

The certification entitles to use the ISI (Indian

Standards Institution) mark, which is considered the

symbol of quality in India.

M. S. Dasgupta, BITS Pilani, Pilani 15
campus

1. Standard Steels:
a) Fe 290 (New)
St 290 (Old)
Structural steel sheets for plain drawn or
enameled parts, tubes of oil well casing,
steam etc.,
Ultimate Tensile strength of 290 N/mm2.
b) FeE 220 (New)
Ultimate Tensile strength of 290 N/mm2.
Structural steel of yield strength of 220N/mm2.
2. Plain Carbon Steel:
50C4 (New)
C50 (Old)
Plain carbon steel. Average carbon content in
hundredths of a percent.
4 denotes the grade (as per the requirement).

M. S. Dasgupta, BITS Pilani, Pilani 16

campus

BIS CLASSIFICATION Continued

Alloy steel:
20
Cr18
Ni25
Mn25

20 Cr18 Ni25 Mn25 *

0.2% Carbon
18% Chromium
2.5% Nickel
0.25% Manganese

M. S. Dasgupta, BITS Pilani, Pilani 17

campus