Material Selection

Yi-Hsiang Chang & Mileta Tomovic School of Technology

Outline
Historical development of engineering materials Properties of engineering materials Interaction between part material and function, process, and shape General practice of material selection

Objectives
Students will be able to Recall knowledge from their previous engineering curriculums Understand the interaction between different product design elements

The use of materials

Ashby (2005)

The evolution of engineering materials

Things to pay attention
Relative importance of different engineering materials along the historical timeline The development of new materials due to the innovation of chemical and material engineering The employment of various materials to respond to the demands of new product designs and manufacturing processes
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Engineering materials
Metals
Steels, cast irons, al-alloys, cu-alloys, zn-alloys, tialloys PE, PP, PET, PC, PS, PEEK, PA (nylons), polysters, phenolics, epoxies Aluminas, silicon carbides, silicon nitrides, zirconias Soda glass, borosilicate glass, silica glass, glassceramics
Glasses Elastomer Metal

Polymers

Ceramics

Ceramic Hybrid

Polymer

Glasses Elastomers
Isoprene, neoprene, butyl rubber, natural rubber, silicones, EVA Composites, sandwishes, segmented structures, lattices, weaves 6

Hybrids

Critical material properties

Ashby (2005), Table 3.1 General Mechanical Thermal Electrical Optical Eco-properties Environmental resistance
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Material properties
General
Density, price

Mechanical
Elastic moduli (Youngs, shear, bulk), yield strength, ultimate strength, compressive strength, failure strength, hardness, elongation, fatigue endurance limit, fracture toughness, loss coefficient (damping capacity)

Material properties
Thermal
Melting point, glass temperature, maximum/minimum service temperature, thermal conductivity, specific heat, thermal expansion coefficient, thermal shock resistance

Electrical
Electrical resistivity, dielectric constant, breakdown potential, power factor

Material properties
Optical
Optical (transparent, translucent, opaque), Refractive index

Eco-properties
Energy/kg to extract material, CO2/kg to extract material

Environmental resistance
Oxidation rates, corrosion rates, wear rate constant
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Interaction in-between
The central problem of materials selection in mechanical design the interaction between four elements: function, material, process, and shape (Ashby, 2005)
Function: Dictates the choice of both material and shape Material: Influence the manufacturing process (its formability, machinability, weldability, heat-treatability, etc.) Process: Interacts with shape (size, precision, and cost) Shape (macro-shape): Depends on the materials and combination of processes

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Parameters to define function

Function/performance Product cost Delivery date Quantity Environmental issues Safety Quality Energy consumption Reliability Maintenance Mechanical loading Size & weight Spatial constraints Aesthetics Transportation & packaging Personnel Service life Noise radiation Operating instructions Human factors Health issues Government regulations Shelf-life storage Operating costs Environmental conditions (Thompson 1998)

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Constraint-driven design
Design parameters can be either design objectives (especially for engineering optimization) or design constraints (limitations) A product design might have multiple objectives and multiple constraints. Conflicting constraints can be employed as penalty functions. (We might want to insert an example or examples here.) To identify feasible solutions, either the analytical methods or the graphical methods can be applied. More detail can be found in the problem identification and problem solving PowerPoint file.
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Material selection
Major factor: Function Minor factor: Shape
Function

Material
Material families, classes, sub-classes, and members Material attributes Material limits and indices

Shape

Process

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Material selection strategy

Four steps (Ashby 2005) Translate design requirements
Express as function, constraints, objectives and free variables
All mate rials

Translate de sign re quire me nts

Screen using constraints

Eliminate materials that cannot do the job

Scre e n using constraints

Rank using objective

Find the screened materials that do the job best

Rank using obje ctiv e

Se e k supporting information

Seek supporting information

Research the family history of top-ranked candidates
Final mate rial choice

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Example (Ashby 2005, 6.11)

Design requirements of pressure vessels
Function: Pressure vessel (contain pressure p safely) Constraints: Radius R specified Objective:
Max safety using yield-before-break criterion, or Max safety using leak-before-break criterion

Free variables: Choice of material

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Pressure vessel example

Want < f (yield strength of the wall) Use K1C as plain-strain fracture toughness
The largest tolerable crake size (for the integrity of the K M 1 = 1C vessel) for a material:
f

The maximum pressure is carried most safely by the K12C M2 = material: f The thinnest wall of a material is that with the largest yield strength: M3 = f
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Selection of materials
M2

M1
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M3

Ranking of materials
Material M1 M3 (MPa) Stainless steel Low alloy steels 0.35 0.2 300 800 Nuclear pressure vessels are made of grade 316 stainless steel These are standard in this application Hard drawn copper is used for small boilers and pressure vessels Comment

Copper

0.5

200

Aluminum alloys Titanium alloys

0.15 0.13

200 800

Pressure tanks of rockets are aluminum Good for light pressure vessels, but expansive

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Selection of processes
Each process is characterized by a set of attributes: The materials it can handle, the shapes it can make and their precision, complexity, and size. Process selection is to find the best match between process attributes and design requirements.
Function

M aterial

Shape

Process
Attributes: Material, shape and size Minimum section thickness, tolerance and roughness Minim um section, batch size, captal cost

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Classifying processes
Shaping
Primary: Casting, molding, deformation, powder, and special methods Secondary: machining, heat treatment

Joining
Adhesives, welding, fasteners

Finishing
Polish, coating, paint/print, texture
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Classes of process
(Ashby 2005, Fig 7.11)

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Process selection strategy

Four steps (Ashby 2005) Translate design requirements
Identify desired material class, shape class and process attributes
All proce sse s

Translate de sign re quire me nts

Screen using constraints

Eliminate processes that cannot meet the translated design requirements
Scre e n using constraints

Rank using objective

Order (a) by desired batch size, or (b) by relative cost

Rank using obje ctiv e

Seek supporting information

Research the family history of top-ranked processes

Se e k supporting information

Final proce ss choice

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Process-material matrix (Ashby 2005, Fig. 7-16)

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Selection of shape
Major factor: Function, process Minor factor: Material
Function Shape
Shape factors for bending and tw isting

Material

Co-selection of material and shape Indices that include shape

Process

Macro/micro shape factors

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Shape consideration
Shape factors
Spatial limitation Load consideration: Axial tension, bending, torsion, axial compression

Macro and micro shape factors

Structural strength Internal/microscopic shape

Limitations
Empirical limitation Local bulking limitation
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Process-shape matrix

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Reference
Ashby, M. F. (2005). Materials selection in mechanical design. (3rd ed.). Burlington, MA: Elsevier Thompson, B. S. (1998). Creative engineering design. (3rd ed.). Okemos, MI: Okemos Press Juvinall, R. C., and Marshek, K. M. (2006). Fundamentals of machine component design. (4th ed.). Hoboken, NJ: John Wiley & Sons

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Additional Reading
NAP (1995). Computer-aided materials selection during structural design. Ashby, M. F. (1999). Materials selection in mechanical design. (2nd ed.). CES Materials & Process Selectors (computer-aided material and process selection) by Granta Material Intelligence

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Acknowledgments
The author wishes to acknowledge the support from the Society for Manufacturing Engineers Education Foundation, SME-EF Grant #5004 for Curriculum Modules in Product Lifecycle Management.

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