Selecting Materials

Product function interdependence Mechanical properties Physical properties Families of materials Materials first screening

When do we select specific materials?

Customer Needs Formulation

Concept Design Abstract embodiment ? Physical principles Material Geometry

Customer requirements Importance weights Eng. characteristics House of Quality Eng. Design Specs

Configuration Design

arrangement of parts/features (i.e. shaping materials)

Therefore, lets examine

Formulation
Concept Design materials Configuration Design Parametric Design Detail Design manufacturing processes

Interdependence - compatibility

Material Properties

Manufacturing Processes

compatible materials & processes

Interdependence - capability
capable processes for the geometry

Manufacturing Processes

Product Geometry

Product function is interdependent

Material Properties

Product Function

Manufacturing Processes

Product Geometry

Example
Design a support for the electric motor

Tekniker-ILL neutron monochromator

Example

Tekniker-ILL neutron monochromator

Example

Tekniker-ILL neutron monochromator

Example

Tekniker-ILL neutron monochromator

Material properties

Mechanical properties quantities that characterize the behavior of a material in response to external, or applied forces

Physical properties quantities that characterize the behavior of a material in response to physical phenomena other than mechanical forces (e.g. such as heat, electricity, radiation)

Mechanical properties
stress

F/A
A

ductile ?
S ut
Sy

L L

brittle
elastic plastic

strain

L L L

stiffness ?

Strength = stress at failure = (failure)

Mechanical properties

Fundamental properties
Characteristic Strength Elastic strength Stiffness Ductility Hardness Corrosion resistance Behavior strong, weak elastic then plastic flexible, rigid draws, forms easily resists surface indentation resists chemicals, oxidation Property ultimate strength yield strength modulus of elasticity % elongation, % area reduction Brinell No. galvanic series Units MPa (ksi) MPa (ksi) MPa (Mpsi) dimensionless MPa (ksi) activity number

Fundamental properties
Characteristic Fatigue resistance Conductivity (heat, electric) Creep resistance Impact resistance Density (mass) Density (weight) Temperature tolerance Behavior endures many load cycles Property endurance limit thermal conductivity electrical conductivity creep strength Charpy energy mass density weight density melting point Units MPa (Mpsi) (Btu/hr) / (F-ft), Mhos MPa (ksi) N-m, (ft-lbs) kg/m3, (slugs/ft3) N/m3, (lbs/ft3) degrees C, F

conducts, insulates

time dependent stretching shock, impact loads heavy, light softens, or melts easily

Material families / sub-families

Materials

Metals Ferrous

Plastics Thermoplastics Thermosets Elastomers

Ceramics

Composites

Family (Ashby)

Non-ferrous

Sub-family

Material sub-families / classes

Materials

Metals Ferrous Cast iron Carbon steel Alloy steel Stainless steel

Family Sub-family

Classes

Metals
Metals

Ferrous cast iron carbon steel alloy steel stainless steel

Non-ferrous aluminum brass bronze copper lead magnesium nickel tin titanium tungsten zinc

Polymers
Polymers

Natural and synthetic rubbers

Thermoplastics
ABS acetal acrylic nylon polycarbonate polyethylene polypropylene polystyrene vinyl

Thermosets alkyd epoxy melamine phenolic polyester urethane

Elastomers butyl fluorocarbon neoprene nitrile polysulfide rubber silicone

Polymers
No chemical reaction

Cross-linking

Ceramics
Ceramics alumina beryllia diamond magnesia silicon carbide silicon nitride zirconia

Composites

Composites
carbon fiber ceramic matrix glass fiber Kevlar metal matrix

Composites
Manufacturing process
Carbon fiber Style 282 bidirectional. Araldite epoxy resin with HY956 additive.

Composites
College Park Foot

Otto Bock Advantage

Ossur Flexwalk

Pie protsico dinmico 2004

Pie protsico dinmico 2005

Composites

Marlon Shirley Ossur Cheeta Flex-Foot Date of birth: April 21, 1978 Hometown: Thatcher, Utah Current Home:San Diego, CA Date of birth: Sep 15, 1986

Cameron Clapp Otto Bock C-Leg

Property profiles by family

Materials selection
prospective materials and processes

functional? manufacturable?

screening

rejected materials and processes

feasible materials and processes

relative performance?

rating

best material(s) and processes

Screening: How do we choose a material?

Product function depends upon material, manufacturing process, geometry We have to consider all three

Do we select a few feasible materials first then select the specific mfg process?

or Do we select a few feasible mfg processes then select the specific material?

Screening: Materials first approach

Application Information
1. Applied loads

magnitude cyclic nature (steady, fatigue) rate (slow, impact) duration (creep) 2. Ambient conditions temperature moisture sunlight chemical liquids/vapors 3. Safety 4. Cost

Screening: Manufact process first approach

Part Information
1. Production volume 2. Part size (overall) 3. Shape capability (features)

boss/depression 1D boss/depression >1D holes undercuts (internal/external) uniform walls cross sections (uniform /regular) rotational symmetry captured cavities

Materials selection
prospective materials and processes

functional? manufacturable?

screening

rejected materials and processes

feasible materials and processes

relative performance? rating

best material(s) and processes

Rating: Material indices

Given the same cost/volume which is stronger? index = Strength/cost

Given the same cost/volume which is stiffer?

index = Youngs modulus/cost

Ashby Chart

How can we use it?

Summary

Product function interdependence Mechanical properties Physical properties Families, sub, classes of materials Ashby charts Materials first approach Process first approach