Materials

Selection of materials for design, Developments in material

technology, Criteria for material selection, Material selection
interrelationship with process selection process.

84
 Materials
• Over 70,000 differentkinds and grades
engineering materials are available.
of This number
grows daily.
• The car industry uses a large number of materials to
build cars, including iron, aluminum, plastic, steel,
glass, rubber, petroleum products, copper, among
others.
• These parts are used to create everything from
dashboard, needles and wiring, to the big stuff, such
as the engine block or the transmission gears.
https://www.bluedata.com

85
 Types of Engineering Materials
• Ferrous Metals (Cast iron, steel)
• Non-ferrous Metals (aluminum, magnesium, copper,
nickel, titanium)
• Plastics (thermoplastics, thermosets)
• Ceramics and Diamond
• Composite Materials
• Nano-materials

86
 Metals
• Cast Iron
• Steel
– Mild steel, medium carbon steel, high carbon steel
Cast Iron
• Specialty steel
–Stainless (tin plated or galvanized)
• Alloys (two or more pure metals)
– Steel = Iron and Carbon
– Brass = Copper and Zinc Brass
– Bronze = Copper and Tin
Stainless steel
https://www.bidorbuy.co.z http://www.eurocosm.co https://www.walmart.co
a m m
87
 Polymers
• Natural
– Animal cellulose
Thermoplastics
• Synthetic-
– Thermoplastics
– Thermosets Thermosets

http://www.raschig.de/Thermoplastics
http://www.intercosmo.net/products_overview.ht
m
88
 Ceramics
• Clay based
– Structural clay-tile, brick
– Porcelain
• Refractories Structural clay-tile

– Heat resistant (fire bricks)

• Glasses
• Inorganic cements https://lifenlesson.co
m
Glasses http://lgcroofing.com

89
Composites

• Natural Composites
– Deciduous Trees
Metal Matrix Composites
• Artificial Composites
– Metal Matrix Composites
– Polymer Matrix Composites
– Ceramic Matrix Composites
Polymer Matrix Composites

90
 The Challenges in Selection
An ever-increasing VARIETY of materials are now available, each having its
own
• Characteristics
• Applications
• Advantages
• Limitations
“Select the optimal material according to the design and in-service
requirements”

91
Properties of Materials

Physical

▪ Material property is the identity of

material, which describes its state
(physical, chemical) and behavior Chemical Properties of Mechanical
Materials
under different conditions.

Thermal

92 2
Physical Properties

https://byjus.com/chemistry/melting-and-boiling-point/

93
 Physical Properties
Physical properties describe the state of material,which
is observable or measurable. Some of the commonly
known physical properties are as:
▪ Color: Represents reflective properties of substance.
▪ Density: Amount of mass contained by unit volume of material.
▪Melting point: Melting point is the temperature at which material changes its
state from solid to liquid.
▪Boiling point: Boiling point is the temperature at which material changes its
state from liquid to gaseous.
94
Chemical Properties

https://www.slideshare.net/conchin_ddz/properties-of-materials-13-14-jm

95
 Chemical Properties
Chemical properties are the measure of reactivity
of a material in the presence of another substance
or environment which imposes change in the
material composition.

▪ Corrosion rate: Corrosion rate is measured in

terms of corrosion penetration for given period of
time at specific surrounding condition.

▪ Oxidation rate: Oxidation rate is measured in

terms of amount of material consumed forming
oxide or amount of oxide scale formed for given
period of time at specific surrounding temperature. http://www.coating.co.uk/anti-corrosion-coating/

96
 Mechanical Properties
▪ Mechanical properties describe
the behavior of material in terms of
deformation and resistance to
deformation under specific
mechanical loading condition.

▪ These properties are significant as

they describe the load bearing
capacity of product.

https://www.engihub.com/mechanical-properties-of-
metal/
97
 Mechanical Properties
▪ Strength
▪ Hardness
▪ Toughness
▪ Stiffness
▪ Elasticity
▪ Plasticity
▪ Ductility
▪ Brittle
▪ Malleability

98
 Mechanical Properties
▪ Strength is the property that enables an engineering material to resist deformation
under load. It is also defined as the ability of material to withstand an applied load
without failure.

▪ Hardness is mechanical property of engineering material and refers to the resistance of

a material against abrasion / scratching / indentation.

▪ Toughness is mechanical property that provides a measure of a material to withstand

shock and the extent of plastic deformation in the event of rupture.

99
Thermal Properties

https://global.kyocera.com/fcworld/charact/heat/thermalcond.htm
l

100
 Thermal Properties
• The thermal properties of an engineering material primarily refer to
the characteristic behavior of the material under thermal load.

▪ Thermal conductivity is a measure of the ability of material to conduct

heat.

▪ The specific heat refers to the measure of energy that is required to

change the temperature for a unit mass.

▪ The thermal diffusivity refers to the ratio of thermal conductivity and

heat capacity of a material and provides a measure the rate of heat
conduction. 101
Physical and
Mechanical
Properties of
Engineering
Materials

102
 Introduction
▪ Materials selection is an important part of a larger process of
creating new solutions to problems. This larger process is
called “Engineering Design”.
▪ Design of engineering components is limited by the
available materials, and new designs are made possible by
new materials.

103
 Introduction
▪ To see how important is the Material selection in the
Design, consider the definition of the “Engineering” used by
ABET in the U.S.A.

“Engineering is the profession in which knowledge of the

mathematical and natural sciences gained by study,
experience and practice is applied with judgement to develop
ways to utilize, economically, the materials and forces of
nature for the benefit of mankind”.

104
Need of Material Selection

Function Process
Material
Attributes

Shape

105
 The Challenges in Selection

• An ever-increasing VARIETY of materials are now available, each

having its own
• Characteristics
• Applications
• Advantages
• Limitations
• “Select the optimal material according to the design and in-
service requirements”
106
 Selection Depends on …
• Mechanical properties (Hardness, Strength)
• Physical properties (Density, Melting point)
• Chemical properties (Corrosion, Toxicity)
• Manufacturing properties (Machinability)
• Cost and availability
• Service life
• Recycling and waste disposal

107
 Selection Depends on …
• Properties of the raw material (hardness, melting point)
• Size of the final product
• Shape of the final product
• Production volume
• Quality requirements of the final product
• In-service requirements of the final product

108
 Factors influencing material selection
Properties Manufacturing Cost Analysis Environmental
Considerations Issues
• Physical • Castability/ • Availability • Ergonomic
• Mechanical formability • Material life and safety
• Thermal • Machinability • Maintenance • Recycling and
• Chemical / Coatability waste
disposal
• Heat
treatment /
Weldabilit
y
• Failure and
repairability
109
 Factors influencing material selection
Dimensional tolerance:
▪ There are some materials which can be finished to close
tolerance while others cannot.
▪ Obviously, the required dimensional tolerance for
finished components will, influence the choice of materials.
Mechanical properties:
▪ To select a suitable material for specific conditions, all
mechanical properties, e.g., toughness, hardness, strength,
etc. guide us.
110
 Factors influencing material selection
Fabrication (Manufacturing) requirements:
▪ Method of processing of the material also affects the
properties of a component, e.g., forged components can be
stronger than the casted components.
▪ Different types of working processes may also give different
types of fibre structure.
▪ However, investment casting can provide precise dimensions
at low cost in comparison to machine operations.

111
 Factors influencing material selection
Cost of processing:
▪ In most of the industries, the processing cost (labour cost)
and other costs such as overhead costs account for about
50% of the production cost.
▪ Overhead cost in automatic industries is much more
than the other costs.
▪ If one can somehow reduce all such costs, the total
production cost will automatically reduce.

112
 Factors influencing material selection

Availability of the material:

▪ We may find that sometimes the availability of the material
becomes a governing factor.
▪ When the desired material supply is
limited, then a costly
material which is available in ample quantity may be chosen.

113
 Factors influencing material selection
Service requirements:
▪ Dimensional stability.
▪ Strength.
▪ Toughness.
▪ Heat resistance.
▪ Corrosion resistance.
▪ Fatigue and creep resistance.
▪ Electrical and thermal conductivity etc.

114
 Selection of Materials

▪In particular, the selection of a specific engineering material for

a part or component is guided by the function it should perform
and the constraints imposed by the properties of the material.

▪The problem of selection of an engineering material for a

component usually begins with setting up the target Function,
Objective, Constraints and Free Variables.

115
 Selection of Materials

• The Constraints in the process of material selection are

primarily geometrical or functional in nature. For example, the
length or cross-sectional area of a component may be fixed.

• The Free Variables refer to the certain parameters that can be

adjusted in order to optimize the objective.

116
 Selection of Materials
▪ Appropriate selection of material is significant for the safe and
reliable functioning of a part or component.

▪The selection of material is primarily dictated by the specific set

of attributes that are required for an intended service.

117
 Material Index
• The Material Index (M) refers to an attribute (or a combination
of attributes) that characterizes the performance of a material
for a given application.

• The material index allows ranking of a

set of engineering
materials in order of performance for a given application.

118
 Selection Procedure
The following procedure is taken from
Material Selection in Mechanical Design by Michael
Ashby.
The basic procedure includes four basic steps:

1) Translation: Express design requirements as constraints and objectives.

2) Screening: Eliminate materials that cannot do the job.
3) Ranking: Find materials that best do the job.
4) Supporting Information: Handbooks, expert systems, web, etc.

119
 Selection Procedure
Step 1)
Translatio
n
Function: What does the component do?
Objective: What essentials conditions must be met?
Constraints: What is to be maximized or minimized?
Free Variables: Identify which design variables are
free?
120
Selection Procedure
Step 2)
Screening
Methods to evaluate large range of materials
Material Bar Charts
Property Charts (eg. density vs. Young’s
Modulus) Screen on Constraints
Rank on Objectives

121
Selection Procedure

• Step 3)
• Ranking:
• What if multiple materials remain after screening? Rank on
objectives.
• Objectives define performance metrics.
• Step 4)
• Supporting Information:
• Select, then verify with any supporting materials.
122
 Example: Tie Rod
Function: Support a tensile load
Objective: Minimize mass
Constraints: Required length, Load carrying capability without failure
Free Variables: Cross-sectional area, Material
m = A ×L ×
Density F/A <
Yield Stress
Eliminate free variable (A)
m >= (F)(L) (Density)/Yield Stress
Therefore, minimize weight by maximizing Yield Stress / Density
123
 Example: Tie Rod
The material index M1, in this case becomes (Yield Strength/Density and a
material with higher value of M1 is expected to perform better in comparison
to a material with lower value of M1.

It should be noted that the Material Index in this case provides a ratio
between the ultimate tensile strength and the density of the material.

Thus, the Material Index (M1) would provide a premise to examine if a

material with higher weight (density) has to be selected to ensure that the same
has sufficient strength to avoid failure.

124
 Introduction

Materials
Metals Ceramics Polymers Composites
Traditional Advanced Natural Artificial
Ferrous
Synthetic
Non- Natural Wood
Metal Ceramic
Ferrous Whitewares Bones
Nuclear Matrix Matrix
Brick Tiles Magnetic Nylon
Iron Silk
Abrasives Optical Polymer
Carbon Aluminum Polyester
Ceramics Woo Matrix
Steel Teflon
Copper l
Zinc DNA

125
 Metals
Metals and alloys:
▪ Metals are elements which have free valence
electrons which are responsible for their good
thermal and electrical conductivity.

▪ Metals readily loose their electrons to

form positive ions.

▪ The metallic bond is held by electrostatic

force between delocalized electrons and
positive ions. https://dir.indiamart.com

126
 Metals
General properties:
▪ High electrical conductivity.
▪ High thermal conductivity.
▪ Ductile and relatively high stiffness.
▪ Toughness and strength.
▪ They are ready to
machining, casting,
forming, stamping and welding.
Nevertheless, they are
susceptible to corrosion.
http://www.lghk.co
m
127
 Metals
Applications:

▪ Structures: buildings, bridges, etc.

▪ Automobiles: body, springs, engine
block, etc.
▪ Airplanes: engine components,
fuselage,
landing gear assembly, etc.
▪ Trains: rails, engine
components,
screwdrivers, body,
saw blades, etc. wheels
▪▪ Machine tools: drill
Electrical wiring. bits,
▪ hammers,
Magnets. http://nantero.com

128
 Ceramics
▪ Inorganic, non-metallic
crystalline compounds, usually
oxides (SiO2, Al2O3, MgO, TiO2,
BaO), Carbides (SiC), Nitrides
(Si3N4), Borides (TiB2), Silicides
(WSi2, MoSi2).
▪ Some literature includes glasses in the
same category, however; glasses are
amorphous (non- crystalline)
compounds i.e. they possess “short
range” order of atoms. http://www.liheseals.com
http://berea-college-crafts-605257.shoplightspeed.com

129
 Ceramics
General properties:
▪ Hard.
▪ High strength.
▪ Stronger in compression than tension.
▪ Brittle in nature.
▪ Low electrical conductivity.
▪ High temperature resistance.
▪ Corrosion resistance.

https://www.ceramtec.co
m
130
Applications:
Ceramics
▪ Electrical insulators.
▪ Thermal insulation and coatings.
▪ Windows, television screens, optical fibers.
▪ Corrosion resistant applications.
▪ Electrical devices: capacitors, transducers, etc.
▪ Highways and roads (concrete).
▪ Building blocks (bricks).
▪ Building binders (cement, gypsum).
▪ Biocompatible coatings (fusion to bone).
▪ Magnetic materials (audio/video tapes, hard disks etc). https://global.kyocera.com

131
Polymers
▪ A polymer is long chain molecule made up many
repeating units, called monomers.
▪ Polymers can be natural (organic) or synthetic.
▪ The properties of polymers are linked directly to their
structure, which is dictated mostly by intermolecular
bonds.
Examples:
Polymers are everywhere: in plastics (bottles, toys,
packaging), cosmetics, shampoos and other hair care
products, contact lenses, nature (crab shells, amber),
https://www.starrapid.com
food (proteins, starches, gelatin, gum, gluten), fabric, https://www.slideshare.ne
t
balls, sneakers, and even in our DNA.
132
 Polymers
Thermoplastics: such as Polyethylene
(PE) and Polymethylmethacrylate
(Acrylic and PMMA) are composed of
“linear” polymer chains. They flow
under shear when heated. They can be
compression- or injection- molded.

Thermosets: such as Polystyrene (PS)

and Polyvinylchloride (PVC) are
composed of “branched” polymer
chains. They do not flow when heated.
The monomers are ‘cured’ in a mold.

https://sciencestruck.com

133
 Polymers
General properties: (Compared with metals)

▪ Polymers have lower density, lower stiffness and tend to creep.

▪ High thermal expansion and corrosion resistance.
▪ Low electrical and thermal conductivities.
high
▪ The prime weakness is that polymers
do not withstand temperatures.

134
 Polymers
Applications:
▪ Clothing and upholstery material (vinyls, polyesters, nylon)
▪ Mouldable products (computer casings, telephone)
▪ Biomaterials (organic/inorganic interfaces)
▪ Water-resistant coatings (latex)
▪ Low-friction materials (teflon)
▪ Adhesives and glues
▪ Containers
▪ Liquid crystals
▪ Synthetic oils and greases
http://www.petroquim.c
▪ Soaps and surfactants l
135
 Composites
▪ A combination of two or more materials to achieve better properties
than that of the original materials. These materials are usually composed of
a Matrix and one or more of Filler material.
▪ The primary objective of engineering composites is to increase strength to
weight ratio.
General properties:
▪ Low weight.
▪ High stiffness.
▪ Brittle.
▪ Low thermal conductivity.
▪ High fatigue resistance.
▪ Their properties can be tailored according to the component materials.
http://globalandchinaresearch.blogspot.com

136
 Composites
Applications:
▪ Sports equipment (golf club shafts,
tennis rackets, bicycle frames).
▪ "Smart" materials
(sensing and responding).
▪ Aerospace materials.
▪ Thermal insulation.
▪ Concrete.
▪ Brake materials.

https://usharama.edu.in

137
 Composites
Example:
▪ Reinforced cement concrete, a structural
composite obtained by combining cement,
sand (fine aggregate), gravel (coarse
aggregate), and thick steel fibers.

▪ Wood is a natural composite of

cellulose
fibers in a matrix of polymer called lignin.

http://surfcivil.blogspot.com
https://buildabroad.org

138
 General Requirements for Early Materials and
Process Selection
In order to be of real design value, the information on which the initial
selection of material/process combinations and their ranking is to be
based should be available at the early concept design stage of a new
product. Such information might include, for example:

• Product life volume

• Permissible tooling expenditure levels
• Possible part shape categories and complexity levels
• Service or environment requirements
• Appearance factors
• Accuracy factors
139
Selection of Manufacturing Processes
1. Many combinations of processes and materials are not possible.
Figure shows a compatibility matrix for a selected range of
processes and material types.
2. Many combinations of processes are not possible and, therefore,
do not appear in any processing sequences.
3. Some processes affect only one attribute of the part, particularly
surface treatment and heat-treatment processes.
4. Sequences of processes have a natural order of shape generation,
followed by feature addition or refinement by material removal
and then material property or surface enhancement.
Processes can be categorized as:
• Primary processes
• Primary/secondary processes
• Tertiary processes 140
141
142
Selection of Materials

• Grouping of Materials into Process Compatible Classes

• Material Selection by Membership Function Modification
• Material Selection by Dimensionless Ranking

143
 Grouping of Materials into Process Compatible
Classes
• Rather than using a single comprehensive materials database, it is
preferable to divide the material databases into classes related to
the principal shape-generating processes used in discrete parts
manufacture.

• A typical scenario might involve the specification of possible shape

attributes, size, and one or more production and performance
parameters.

• The next step would be to change the input specifications or add

to the specification list, or to investigate a process further for
acceptable associated materials.
144
 Material Selection by Membership Function
Modification
One challenge of designing a system so that appropriate materials are
chosen at the early stages of design lies in modeling ambiguous or
vague material constraints.

For instance, a designer may want to use a material with a yield stress
of “about” 2000 psi and a service temperature “in the neighborhood
of” 90°C.
A conventional database search for materials with properties greater
than those specified would unnecessarily exclude materials with
properties close to the desired values, but not in the range specified.
145
Ambiguity in the material constraints specified by the designer is
modeled by providing the designer with different levels of accuracy to
further describe the material constraints specified.

These levels could correspond, for example, to the qualifiers

“approximately,” “close to,” and “more or less.” These levels of
precision are illustrated in Figure. The ability to assign different levels
of accuracy or precision to each constraint is an advantage of fuzzy
logic.

146
147
148
Material Selection by Dimensionless Ranking
• Concerned with establishing a simple procedure for comparing
materials based on either single fundamental properties, or the
general form of derived parameters.

• Such material comparisons may typically be required on the basis

of total performance, best performance per unit weight, or best
performance per unit cost.

• A procedure is established later in this for making these

comparisons on a dimensionless scale from 0 to 100.
149
Process Capabilities
• A great deal of general information is available on manufacturing
processes in a wide range of textbooks, handbooks, and so on.

• Each process can be analyzed to determine the range of its capabilities in

terms of attributes of the parts that can be produced.

• Included in these capabilities are

• shape features that can be produced,
• natural tolerance ranges,
• surface roughness capabilities, and so on.
• These capabilities determine whether a process can be used to produce
the corresponding part attributes.
150
151
152
153
Thank You

154