Materials Selection &

Design Considerations

1
Chapter 23 -
 CHAPTER 22: MATERIALS SELECTION AND
DESIGN CONSIDERATIONS

ISSUES TO ADDRESS...
• Price and availability of materials.
• How do we select materials based on optimal
performance?
• Applications:
-- shafts under torsion
-- bars under tension
-- plates under bending
-- materials for a magnetic coil.

Chapter 23 - 2
 PRICE AND AVAILABILITY
• Current Prices on the web: e.g., http://www.metalprices.com
-- Short term trends: fluctuations due to supply/demand.
-- Long term trend: prices will increase as rich deposits
are depleted.
• Materials require energy to process them:
-- Energy to produce -- Cost of energy used in
materials (GJ/ton) processing materials ($/MBtu)
Al 237 (17) elect resistance 25
PET 103 (13) propane 17
Cu 97 (20) oil 13
steel 20 natural gas 11
glass 13
paper 9
Energy using recycled
material indicated in green.
Chapter 23 - 3
 RELATIVE COST, c, OF MATERIALS
Graphite/
Metals/ Composites/
Ceramics/ Polymers
Alloys fibers
Semicond
100000
50000 $ / kg
20000
Diamond c=
Pt
Au ($ / kg)ref material
10000
5000
Si wafer • Reference material:
Relative Cost (c)

2000
1000 Si nitride -- Rolled A36 plain
500 carbon steel.
Ag alloys
200
Tungsten
CFRE prepreg • Relative cost, c ,
100 Ti alloys AFRE prepreg
50
Si carbide
Carbon fibers
fluctuates less
Aramid fibers over time than
Cu alloys GFRE prepreg
20
10
Al alloys
Mg alloys Al oxide Nylon 6,6 actual cost.
PC
5 high alloy
Epoxy
E-glass fibers Based on data in Appendix
Glass-soda PVC PET
2 LDPE,HDPE C, Callister, 7e.
Steel Wood
PP AFRE, GFRE, & CFRE = Aramid,
1 pl. carbon PS Glass, & Carbon fiber reinforced
0.5 epoxy composites.

0.1 Chapter 23 - 4
Concrete
0.05
 STIFF & LIGHT TENSION MEMBERS
F, δ • Bar must not lengthen by more than δ
under force F; must have initial length L.
-- Stiffness relation: -- Mass of bar:
L F δ
=E (σ = Eε) M = ρLc 2
c2 L

c c • Eliminate the "free" design parameter, c:

FL2 ρ
M=
δ E
minimize for small M
specified by application

E
• Maximize the Performance Index: P=
(stiff, light tension members) ρ
Chapter 23 - 5
 STRONG & LIGHT TENSION MEMBERS
F, δ • Bar must carry a force F without failing;
must have initial length L.
-- Strength relation: -- Mass of bar:
L σf F
= M = ρLc 2
N c2

c c • Eliminate the "free" design parameter, c:

ρ
M = FLN
σf
minimize for small M
specified by application
σ
• Maximize the Performance Index: P= f
(strong, light tension members)
ρ

Chapter 23 - 6
 STRONG & LIGHT TORSION MEMBERS
Mt • Bar must carry a moment, Mt ;
must have a length L.
L τ -- Strength relation: -- Mass of bar:
τf 2Mt M = ρπR 2L
τ =
N πR 3

• Eliminate the "free" design parameter, R:

2R ρ
2/3
M = (2 πNMt ) L
τf2 / 3
specified by application minimize for small M

τf2 / 3
• Maximize the Performance Index: P=
(strong, light torsion members) ρ
Chapter 23 - 7
 DATA: STRONG & LIGHT
TENSION/TORSION MEMBERS

Increasing P
Strength, σf (MPa) for strong
10 4 Ceramics
torsion members
Cermets
10 3 PMCs
Steels
|| grain Metal
10 2 Adapted from Fig. 22.2,
alloys Callister 7e. (Fig. 22.2 adapted

10 Polymers from M.F. Ashby, Materials

Selection in Mechanical
Design, Butterworth-
Increasing P grain Heinemann Ltd., 1992.)
1
for strong
tension 0.1
members 0.1 1 10 30
Density, ρ (Mg/m3)
Chapter 23 - 8
 DATA: STRONG & LIGHT
BENDING MEMBERS

• Maximize the Performance Index: σ 1/ 2

P=
Increasing P ρ
for strong
10 4 bending members
Strength, σf (MPa)

Ceramics
Cermets
10 3 PMCs
Steels
|| grain Metal
10 2 Adapted from Fig. 6.22,
alloys Callister 6e. (Fig. 6.22 adapted
from M.F. Ashby, Materials
10 Polymers Selection in Mechanical
Design, Butterworth-
grain Heinemann Ltd., 1992.)
1
0.1
0.1 1 10 30
Density, ρ (Mg/m3)
Chapter 23 - 9
 DETAILED STUDY I: STRONG, LIGHT
TORSION MEMBERS
τf2 / 3
• Maximize the Performance Index: P=
ρ
• Other factors:
--require σf > 300 MPa.
--Rule out ceramics and glasses: KIc too small.
• Numerical Data:
material ρ (Mg/m3) τf (MPa) P [(MPa)2/3m3/Mg]
CFRE (vf = 0.65) 1.5 1140 73
GFRE (vf = 0.65) 2.0 1060 52
Al alloy (2024-T6) 2.8 300 16
Ti alloy (Ti-6Al-4V) 4.4 525 15
4340 steel (oil 7.8 780 11
quench & temper)
Data from Table 22.1, Callister 7e.

• Lightest: Carbon fiber reinforced epoxy

(CFRE) member. Chapter 23 - 10
 DETAILED STUDY I: STRONG, LOW
COST TORSION MEMBERS

• Minimize Cost: Cost Index ~ c M ~ c /P (since M ~ 1/P)

where M = mass of material
cost/mass of material
c = relative cost = cost/mass of low-carbon steel
• Numerical Data:
material P [(MPa)2/3m3/Mg] c ( c /P)x100
CFRE (vf = 0.65) 73 80 112
GFRE (vf = 0.65) 52 40 76
Al alloy (2024-T6) 16 15 93
Ti alloy (Ti-6Al-4V) 15 110 748
4340 steel (oil 11 5 46
quench & temper) Data from Table 22.2, Callister 7e.

• Lowest cost: 4340 steel (oil quench & temper)

• Need to consider machining, joining costs also.

Chapter 23 - 11
 DETAILED STUDY II: OPTIMAL
MAGNET COIL MATERIAL
• Background(2): High magnetic fields permit study of:
-- electron energy levels,
-- conditions for superconductivity Pulsed
magnetic
-- conversion of insulators into conductors. capable of
600,000 gauss
• Largest Example: field during
-- short pulse of 800,000 gauss 20ms period.
(Earth's magnetic field: ~ 0.5 Gauss)
• Technical Challenges: Fractured
-- Intense resistive heating magnet
can melt the coil. coil.
(Photos
-- Lorentz stress can exceed taken at NHMFL,
Los Alamos
the material strength. National Labs,
NM (Apr. 2002)
• Goal: Select an optimal coil material. by P.M. Anderson)
(1) Based on discussions with Greg Boebinger, Dwight Rickel, and James Sims, National High
Magnetic Field Lab (NHMFL), Los Alamos National Labs, NM (April, 2002).
(2) See G. Boebinger, Al Passner, and Joze Bevk, "Building World Record Magnets", Scientific
American, pp. 58-66, June 1995, for more information.
Chapter 23 - 12
 LORENTZ STRESS & HEATING
• Applied magnetic field, H:
Applied N = total number of turns
magnetic field H L = length of each turn
H = N I/L
current I
• Lorentz "hoop" stress: • Resistive heating:
(adiabatic) elect. resistivity
Iµo HR σf I 2ρ e
σ= (≤ ) ∆T = ∆t (< ∆Tmax )
A N A2cv
A temp increase specific heat
σ during current
pulse of ∆t
Magnetic
field R
points
out of Force
= Iµ o H
plane. I length
Chapter 23 - 13
 MAGNET COIL: PERFORMANCE INDEX
• Mass of coil: • Applied magnetic field:
M = ρd AL H = N I/L

• Eliminate "free" design parameters A, I from the

stress & heating equations (previous slide):
--Stress requirement --Heating requirement
H2 1 σf H ∆t ∆Tmax 1 cv
≤ ≤
M 2πR 2Lµo N ρd M 2πRL ρd ρe

specified by application specified by application

Performance Index P1: Performance Index P2:
maximize for large H 2/M maximize for large Ht1/2/M
Chapter 23 - 14
 MAGNET COIL: COST INDEX
• Relative cost of coil: • Applied magnetic field:
$= cM H = N I/L

• Eliminate M from the stress & heating equations:

--Stress requirement --Heating requirement

H2 1 σf H ∆t ∆Tmax 1 cv
≤ ≤
$ 2πR 2Lµo N ρd c $ 2πRL ρd c ρe

specified by application specified by application

Cost Index C1: Cost Index C2:
maximize for maximize for
large H 2/$ large Ht1/2/$
Chapter 23 - 15
 INDICES FOR A COIL MATERIAL
• Data from Appendices B and C, Callister 7e:
Material σf ρd cv ρe P1 P2 C1 C2
1020 steel (an) 395 7.85 0.8 486 1.60 50 2 63 2.5
1100 Al (an) 90 2.71 12.3 904 0.29 33 21 3 1.7
7075 Al (T6) 572 2.80 13.4 960 0.52 204 15 15 1.1
11000 Cu (an) 220 8.89 7.9 385 0.17 25 5 3 0.6
17200 Be-Cu (st) 475 8.25 51.4 420 0.57 58 3 1 <0.1
71500 Cu-Ni (hr) 380 8.94 12.9 380 3.75 43 1 3 <0.1
Pt 145 21.5 1.8e4 132 1.06 7 19 <1 <0.1
Ag (an) 170 10.5 271 235 0.15 16 <1 <1 <0.1
Ni 200 462 8.89 31.4 456 0.95 52 2 2 <0.1
units MPa g/cm3 -- J/kg-K Ω-m3 σf /ρd (cv/ρe)0.5 P1 / c P2/c
ρd
Avg. values used. an = annealed; T6 = heat treated & aged;
st = solution heat treated; hr = hot rolled
• Lightest for a given H: 7075 Al (T6) P1
• Lightest for a given H(∆t)0.5: 1100 Al (an) P2
• Lowest cost for a given H: 1020 steel (an) C1
• Lowest cost for a given H(∆t)0.5: 1020 steel (an) C2 Chapter 23 - 16
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 17
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 18
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 19
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 20
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 21
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 22
Case Study 1: Materials Selection for a Torsionally
Stressed Cylindrical Shaft

Chapter 23 - 23
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 24
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 25
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 26
Chapter 23 -
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 28
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 29
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 30
Case Study 2: Artificial Total Hip Replacement

Chapter 23 - 31
Case Study 3: Chemical Protective Clothing

Chapter 23 - 32
Case Study 3: Chemical Protective Clothing

Chapter 23 - 33
Case Study 3: Chemical Protective Clothing

Chapter 23 - 34
Case Study 3: Chemical Protective Clothing

Chapter 23 - 35
 SUMMARY
• Material costs fluctuate but rise over the long
term as:
-- rich deposits are depleted,
-- energy costs increase.
• Recycled materials reduce energy use significantly.
• Materials are selected based on:
-- performance or cost indices.
• Examples:
-- design of minimum mass, maximum strength of:
• shafts under torsion,
• bars under tension,
• plates under bending,
-- selection of materials to optimize more than one
property:
• material for a magnet coil.
• analysis does not include cost of operating the magnet.
Chapter 23 - 36
 ANNOUNCEMENTS
Reading:

Core Problems:

Self-help Problems:

Chapter 23 - 37