1.

Introduction
➢ Summary of Lecture-02
Lecture-03 2. Performance requirements in material selection
➢ Definitions & some facts

3. Material selection process

4. Pressure Vessel Related Standards
➢ ASME Code Sec. II, Part-D
5. Examples
➢ Equipment, Materials, and Part Dimensions
References:
• Mahmood M. Farag, “Materials and Process Selection for Engineering Design,” CRC Press, 2013

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Learning Outcomes
Emphasis
Course Outcomes Total
Very high High Medium Low
At the end of this lecture, you should be able to
Design pressure vessels using ASME
CLO1 standards and emphasis on safety and 65.0 65.0
resource sustainability. – Explain the classification of materials
Use readily available software (e.g.
CLO2 Excel) to carryout design calculations and 10.0 10.0 – Describe the factors considered in material selection for chemical equipment
material selections

Practice leadership, cooperation, and 10.0 – Explain the methods/ steps for material selection
CLO3 10.0
accountability in a teamwork setting.

Produce a standard technical report for a 15.0 – Select candidate materials using Ashby charts
CLO4 15.0
chemical equipment design.
0.0
Total 65.0 0 15 20 100.0

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 Material selection is a critical aspect of chemical equipment design, influencing various factors such
as safety, efficiency, environmental considerations, and longevity of chemical processing plants.

• Safety and Reliability: choosing appropriate materials prevents equipment failures and accidents,
ensuring operational integrity and worker safety.

• Performance Efficiency: The right materials enhance heat transfer and pressure resistance,
improving overall process efficiency.

• Environmental Considerations: Eco-friendly materials help reduce the environmental impact,

supporting sustainable operations.

• Cost-Effectiveness: Material selection influences initial costs and long-term maintenance, balancing
upfront investment with durability. .

• Compliance with Standards: Ensuring materials meet industry codes is essential for safety and
reliability in critical equipment design.

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➢ Code: refers to a set of mandatory rules or laws that must be followed in certain jurisdictions or Material selection touches various aspects:
industries. In the context of chemical equipment design, a ‘code’ provides overarching guidelines
that govern safety, performance, and regulatory requirements. • Design Requirements – The equipment’s functional needs, Design
constraints (e.g. cost), and performance expectations (like requirements
➢ Standard (typically voluntary): refers to a technical document that outlines established practices,
pressure, temperature, and safety considerations) that the
methods, or criteria that should be followed to achieve a desired level of performance or safety.
material must fulfill.
Standards help in ensuring consistency and reliability in the final design of a chemical equipment.
• Material Properties – The inherent characteristics of the Material Selection
➢ Specification: refers to a detailed and precise description of the required characteristics,
features, and performance criteria for a particular system or component. Specifications provide material, such as strength, corrosion resistance, thermal
clear instructions on how the chemical equipment should be designed, often tailored to specific conductivity, and durability, which are crucial for ensuring the Material Manufacturing
project requirements. equipment performs well under specific operating conditions. properties process

➢ Codes and standards relevant to chemical equipment design: • Processing Methods for the Material – How the material will
• ASME BPV Sec. VIII (Div.1, Div.2, Div.3), ASME BPV Sec. II, Part-D, ASME B16, and be processed or fabricated (e.g., welding, machining, heat N.B.:
ASME B31 treating), since these processes can affect the material’s final • Cost needs to be considered in
properties and how it behaves during use. each case
• API 610, API 620, API 650
• TEMA, ASTM, etc.

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 • An incorrectly chosen material may lead to part failure and / or excessive
• Availability:
life-cycle cost.
– Are there multiple sources for the supply of materials?
• At the conceptual design stage, essentially all materials and processes are
– What is the likelihood of availability in the future?
considered in broad detail.
– Is the material available in the forms needed?
• The materials selection charts and methodology developed by Ashby are
highly appropriate at this stage. • Size limitations and tolerances on available material shapes and form
• Depending on the importance of the part, materials properties may need to
• Excessive variability in properties
be known to a high level of precision.
• Low environmental impact, including ability to recycle the material
• Material and process selection is a progressive process of narrowing from
a large universe of possibilities to a specific material and process. • Cost

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Materials are selected based on the following general criteria:

– Performance characteristics (properties)

– Processing (manufacturing) characteristics

– Environmental effect,

– Sustainability consideration,

– Business consideration

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 • Performance requirements of a material are usually expressed in terms of
physical, thermal, mechanical, electrical, or chemical properties. Materials Kingdom All materials

Family Metals, polymers, etc.

Class For metals: steels, aluminum alloy

Subclass Steels: plain carbon, low alloy

• Structure determines properties.

• At the atomic level, materials scientists are concerned with basic forces between
Member Polymer grade
atoms, which determine the density, inherent strength, and Young’s modulus.
Source:
George Dieter, Linda Schmidt,” Engineering Design,” McGraw-Hill, 2012

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• We can divide materials into:

✓ Metals

✓ Ceramics, and

✓ Polymers

• An engineering material is a material that is used to fulfill some technical

functional requirement, as opposed to being used just for decoration.

• Structural materials are typically used to resist forces or deformations in

engineering structures

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 • Ultimate tensile strength, 𝑢 , is the maximum tensile stress that a material can withstand in
the tension test, measured by load divided by the original area of the specimen. For brittle
materials it is the same as their fracture strength, but for ductile materials it is larger by a
factor of 1.3 to 3 because of strain-hardening.
• Modulus of elasticity (Young’s modulus), 𝐸, is the slope of the stress-versus-strain curve
where it initially shows linear behaviour. A material with a high 𝐸 is stiffer than a material with
a lower E and resists deformation by bending or twisting to a greater extent.
• Ductility is the opposite of strength. It is the ability of a material to plastically deform before it
fractures.
• Fracture toughness, 𝐾𝐼𝑐, is a measure of the resistance of a material to the propagation of a
crack within it.
• Fatigue properties measure the ability of a material to resist many cycles of alternating
stress. Fatigue failure, in all of its variations (high-cycle, low-cycle, and corrosion fatigue) is
Example: the number one cause of mechanical failure.
• Selecting a material with a low rate of corrosion in the environment of concern is the obvious first step
to preventing corrosion.

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• Damping capacity is the ability of a material to dissipate vibrational energy by

internal friction, converting the mechanical energy into heat.

• Creep is the time-dependent strain that occurs under constant stress or load in
materials at temperatures greater than half of their melting point.

• Impact resistance is the ability of a material to withstand sudden shock or

impact forces without fracturing.

• Hardness is a measure of the resistance of the material to surface indentation.

• Wear rate is the rate of material removal from two sliding surfaces in contact.

Fig. : Stress-Strain Curve

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 • The material properties required in a part usually are formalized through
specifications.

• Designer depends on generally accepted specifications established through

organizations such as the Society of Automotive Engineers (SAE), ANSI, ASTM,
ASME, API, or ISO.

• Often companies find that using common standards which are “consensus
standards” agreeable to a wide sector of a material producing industry, do not
provide the material quality they need for particularly sensitive manufacturing
operations.

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B. A. Miller, “Materials Selection for Failure Prevention,” Failure Analysis and Prevention, ASM
Handbook, vol. 11, ASM International, Materials Park, OH, 2002, p. 35.

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 • Ashby has created materials selection charts that are very useful in
comparing many materials during conceptual design.

• These charts are based on a large computerized material property

database.

• Ashby chart, for example, displays the elastic modulus (E) of polymers,
metals, ceramics, and composites plotted against density ( ).

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18 Charts available for material selection. 9 of the Charts are

• Young's modulus against density

• Strength against density

• Fracture toughness against density

• Young's modulus against strength

• Specific modulus against specific strength

• Fracture toughness against Young's modulus

• Fracture toughness against strength

• Loss coefficient against Young's modulus

• Thermal conductivity and thermal diffusivity

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i. Define the functions that the design must perform and translate these into
required materials properties (e.g. stiffness, strength, etc.) .

ii. Define the manufacturing parameters (e.g. no. of parts, size, complexity,
tolerance, surface finish, quality level, etc.).

iii. Compare the needed properties and parameters against a large materials
property database.

iv. Investigate the candidate materials in more details, particularly for trade-offs in
product performance, cost, fabricability, and availability in the grades and sizes.

v. Develop design data and/or a design specification.

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 i. Characterize the currently used material in terms of performance, manufacturing
requirements, and cost.

ii. Determine which properties must be improved for enhanced product function.
Often failure analysis reports play a critical role in this step

iii. Search for alternative materials and/or manufacturing routes.

iv. Compile a short list of materials and processing routes and use these to estimate
the costs of manufactured parts.

v. Evaluate the results of STEP-4 and make a recommendation for a replacement

material.

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• The basic cost of a material depends upon:

– Scarcity:
• There are two approaches to settling on the material-process combination for a part:
• As determined by either the concentration of the metal in the ore or the
– Material-first approach
cost of the feedstock for making a polymer
– Process-first approach
– The cost and amount of energy required to process the material
• In the material-first approach, the designer begins by selecting a material class and
– The basic supply and demand for the material
narrowing it down as described previously.
• Cost is such an overpowering consideration in many materials selection
• With the process-first approach, the designer begins by selecting the manufacturing
situations that we need to give this factor additional attention.
process, guided by the same factors.

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 • The cost structure for pricing many engineering materials is quite complex.

• True prices can be obtained only through quotation from vendors.

• Reference sources typically give only the nominal or baseline price.

• The actual price depends upon a variety of price extras in addition to the base price.

• Price extras are assessed for any changes from standard chemical composition, for
vacuum melting or degassing, heat treatments, and so on.

K. T. Ulrich and S. D. Eppinger, Product Design and Development, 4th ed., McGraw-Hill, New York, 2007.

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Service Considerations*

* Dennis R. Moss, Michael M. Basic, “Pressure Vessel Design Manual,” Butterworth-Heinemann, 4th Edition, Year: 2013, pp. 34.

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 Miscellaneous Design Considerations* Example-E1:

Which material property would you select as a guide in material

selection if the chief performance characteristic of the component is:
a. strength in bending;
b. resistance to twisting;
c. the ability of a sheet material to be stretched into a complex
curvature;
d. ability to resist fracture from cracks at low temperatures;
e. ability to resist shattering if dropped on the floor;
f. ability to resist alternating cycles of rapid heating and cooling?
* Dennis R. Moss, Michael M. Basic, “Pressure Vessel Design Manual,” Butterworth-Heinemann, 4th Edition, Year: 2013, pp. 35.

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Material
Selection Guide*
Thank You!

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