MSE 280: Introduction to Engineering Materials

Materials Selection and Design

Reading: Callister Ch. 21

© 2007, 2008 Moonsub Shim MSE280

Materials Selection and Design
For selection, one must establish a link between materials and
function, with shape and processing also playing possibly
important roles (ignored for now) function

AREAS OF DESIGN CONCERN Materials

Function- support a load, contain a Attributes: physical,
pressure, transmit heat, etc. mechanical, thermal,
What does the component do? electrical, economic, shape
environmental.
Objective- make things cheaply, light weight,
increase safety, etc., or combinations of these.
What needs to be maximized or minimized?
process
Constraints- make things within given budget,
max required weight,
weight safety requirements,
requirements
etc., or combinations of these.
What are non-negotiable conditions to be
met?
What are negotiable but desired
conditions? Following “Materials Selection in Mechanical
Design”, M. Ashby Modified from D. Johnson

© 2007, 2008 Moonsub Shim MSE280

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 Design & Selection: Materials Indices
Material index (performance index) is a combination of materials
properties that characterizes the Performance of a material in a given
application.

Performance of a structural element may be specified by the functional

requirements, the geometry, and the material’s properties.

Performance[ (Functional needs, F); (Geometric, G); (Material Property, M)]

For OPTIMUM design, we need to MAXIMIZE or MINIMIZE the

Performance.

Consider only the simplest cases where these factors form a separable
equation.
Performance = f1(F) f2(G) f3(M)
From D. Johnson

© 2007, 2008 Moonsub Shim MSE280

Examples of Materials Indices

Function, Objective, and Constraint Index

Tie, minimum weight, stiffness E/ρ

Beam, minimum weight, stiffness E1/2/ρ

Beam, minimum weight, strength σ2/3/ρ

Beam, minimum cost, stiffness E1/2/Cmρ Cm =cost/mass

Beam, minimum cost, strength σ2/3/Cmρ

Column, minimum cost, buckling load E1/2/Cmρ

Spring, minimum weight for given energy storage σYS2/Eρ

Thermal insulation, minimum cost, heat flux 1/(α Cmρ) α =thermal cond

Electromagnet, maximum field, temperature rise κ Cpρ κ =elec. cond

Why different dependences? – linear vs. square root etc.
Modified from D. Johnson
© 2007, 2008 Moonsub Shim MSE280

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 Example 1: Material Index for a Light, Strong, Tie-Rod
A Tie-rod is common mechanical component.
A = x-area Functional needs: F, L, σf
F • Tie-rod must carry tensile force, F.
L • NO failure. Stress must be less than σf. (f=YS, UTS)
• L is usually fixed by design, can vary Area A.
• While
Whil strong,
t needs
d to
t be
b lightweight,
li ht i ht or low
l mass.
-Strength relation:
Tie-Rod has to be able to withstand applied tensile load
F
Applied tensile stress = ≤σ f
A
Including safety factor: F σf
≤
A S Safety factor

- Mass of rod: m = ρLA

- Eliminate the "free" design parameter, A:
F σf
≤
A = m/ρL m / ρL S
© 2007, 2008 Moonsub Shim MSE280

Example 1: Material Index for a Light, Strong, Tie-Rod

- Rearrange:
ρ
m ≥ (FS)(L) minimize for small m
σf
Functional Needs (how much Geometrical Material properties
applied load and safety factor) parameter (1/Performance index)

Fixed by service requirements!

** Compare
p to Performance = f1(F)
( ) f2(G)
( ) f3(M)
( )

Or Maximize the σf
P=
Performance Index: ρ Light, strong, tie-rod

© 2007, 2008 Moonsub Shim MSE280

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 Example 1B: square rod (it’s all the same!)

F, δ • Carry F without failing; fixed initial length L.

-Strength relation: - Mass of bar:
σf F
= m = ρLc 2
L S c2

• Eliminate the "free" design parameter, c:

c c ρ
m = ( FLS )
σf
minimize for small M
specified by application

• Maximize the Materials Performance Index:

(strong, light tension members) σf
P=
ρ
From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

Ashby Plots: Strength (σf ) versus Density (ρ)

Strength can be YS for metals and polymer, compressive strength for
ceramics, tear strength for elastomers, and TS for composites, for
example. σ
P= f or σ f = ρP
ρ
- take log for easier comparison
log σ f = log ρ + log P
- To select materials, consider a
minimum performance index
(e.g. P = 10 Pa/g/m3)
With P = 10 and ρ = 0.1,, σf = 1
P = 10 Pa/g/m3 With P = 10 and ρ = 1, σf = 10

Taken from: Materials Selection for

With P = 10 and ρ = 10, σf = 100
Mechanical Design Ed. 2, M. Ashby
All materials lying on this line can
perform equally well.

© 2007, 2008 Moonsub Shim MSE280

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 Ashby Plots: Strength (σf ) versus Density (ρ)

log σ f = log ρ + log P P = 100 Pa/g/m3

P = 10 Pa/g/m3

Notice that for the same

strength, P =100 material will
require 10 times less mass than
P = 10 material.
e.g. for σf = 100 MPa

ρ
Taken from: Materials Selection for m = ( FLS )
Mechanical Design Ed. 2, M. Ashby σf

1Mg / m3 10Mg / m 3
then: mP =100 = ( FLS ) and mP =10 = ( FLS )
100MPa 100MPa
mP =10 = 10mP =100
© 2007, 2008 Moonsub Shim MSE280

Example 2: Material Index for a Light, Stiff Beam in Tension

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 ΔL
2
=E (σ = Eε) m = ρLc 2
c L

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

FL2 ρ
m=
ΔL E
minimize
i i i ffor smallll m
specified by application
E
• Maximize the Performance Index: P=
(stiff, light tension members) ρ
From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

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Example 3: Material Index for a Light, Stiff Beam in Deflection
F
b Bending is common mode of loading, e.g., 
b golf clubs, wing spars, floor joists.
L
δ=deflection A = b2
• Bar with initial length L must not deflect by more than δ under force F.
- Stiffness relation: - Mass of bar:
F ⎛ L3 ⎞ F ⎛ L3 ⎞ ⎛ m ⎞
2
E ≥ ⎜⎜ 4 ⎟⎟ = ⎜⎜ 2 ⎟⎟ m = ALρ or A = ⎜⎜
2
⎟⎟
δ ⎝ 4b ⎠ δ ⎝ 4 A ⎠ ⎝ Lρ ⎠
F ⎛ L5 ρ 2 ⎞
• Eliminate the "free" design parameter, A: E≥ ⎜ ⎟
δ ⎜⎝ 4m 2 ⎟⎠
specified by 1/ 2
application ⎛ FL5 ⎞ ρ Maximize E 1/ 2
m ≥ ⎜⎜ ⎟⎟ P=
⎝ 4δ ⎠ E1/ 2
Light, Stiff Beam
ρ
minimize for small m
If only beam height can change (not A), then P = (E1/3/ρ) (Car door)
If only beam width can change (not A), then P= (E/ρ)
© 2007, 2008 Moonsub Shim MSE280

Performance of Square Beam (deflection) vs. Fixed Height or Width

Light, Stiff Plate E/ρ

(width change only)

Light, Stiff Beam E1/2/ρ

(cross sectional area change)

Light, Stiff Panel E1/3/ρ

(height change only)

From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

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 Example 4: Energy efficient car design
• One way to improve fuel efficiency is to reduce mass of
the car.
• Typical
T i l weight
i ht di
distribution
t ib ti iin a car
– Steel 71% (body panels)
– Cast iron 15% (engine, gear box, axle…)
– Rubber (tires, hoses…)
– Rest: glass, zinc, copper, aluminum, polymers….
• Largest reduction may come from body panels

• C
Compare diff
differentt candidate
did t materials
t i l ffor b
body
d
panel that can reduce weight without
compromising yield strength.

© 2007, 2008 Moonsub Shim MSE280

Example 4: Energy efficient car design

b d L and b must remain constant (only d
can change).
L
- Flexural strength relation: - Mass of panel:

σf =
3FL m = ρLbd
2bd 2
- Eliminate “free” design parameter:
3FL ⎛ ρLb ⎞
2
ρLb σf =
d= ⎜ ⎟
m 2b ⎝ m ⎠

3FL3b ⎛⎜ ρ ⎞⎟ Minimize
m= ⎛ σ 1f / 2 ⎞
2 ⎜⎝ σ 1f / 2 ⎟⎠ or maximize
P=⎜ ⎟
performance index: ⎜ ρ ⎟
⎝ ⎠
© 2007, 2008 Moonsub Shim MSE280

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 Example 4: Energy efficient car design
ρ(Mg/m3) σy(MPa) σy1/2/ρ
⎛σ 1/ 2
⎞ Mild steel 7.8 220 1.9
P=⎜ f
⎟
⎜ ρ ⎟
⎝ ⎠ High
g str. steel 7.8 500 2.9
Steel Al alloy 2.7 193 5.1
GFRP 1.8 75 4.8
Al alloys

- Glass Fiber Reinforced Polymer: Can

creep at T above 60oC.

- Al alloy: best performance but limited

strength and higher cost of production.

- High strength steel: least amount of

P=2
changes w.r.t. manufacturing changes
from mild steel but also least in
performance improvement.

© 2007, 2008 Moonsub Shim MSE280

Example 5: Torsionally stressed shaft

Establish a criterion for selection of light and strong solid cylindrical shaft
that is subjected
j to torsional stress.

1. Required strength
2 Mass
2. M
3. Other considerations (e.g. materials cost)

Goal: choose material to maximize strength with minimum

mass and cost
© 2007, 2008 Moonsub Shim MSE280

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 Example 5: Torsionally stressed shaft

- Strength requirement: - Mass of the shaft:

Shear stress at radius r
m m
2M
τ = 3t Mt = applied ρ= = 2
V πr L
πr torque

2M t
τ f ≥τ =
πr 3
- Eliminate “free” design parameter:
2M t
m τf = 3
r= ⎛ m ⎞
πLρ π ⎜⎜ ⎟
⎟
⎝ πLρ ⎠
© 2007, 2008 Moonsub Shim MSE280

Example 5: Torsionally stressed shaft

⎛ ρ ⎞
Rearrange: m = (2 M t )
2/3
(π 1/ 3
)
L ⎜ 2/3 ⎟
⎜τ ⎟
⎝ f ⎠
Functional needs (how much Geometrical Material properties
applied load – should also parameter (1/Performance index)
include safety factor)
** Compare to:
Fixed by service
Performance = f1(F) f2(G) f3(M)
requirements!

⎛ ρ ⎞ ⎛ τ 2f / 3 ⎞
Choose material to minimize ⎜ 2 / 3 ⎟ or maximize ⎜ ⎟
⎜τ ⎟ ⎜ ρ ⎟
⎝ f ⎠ ⎝ ⎠
© 2007, 2008 Moonsub Shim MSE280

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Materials selection chart
(“Ashby plot”)

⎛ τ 2f / 3 ⎞
P=⎜ ⎟
⎜ ρ ⎟
⎝ ⎠

3 3
log τ f = log P + log ρ
2 2

© 2007, 2008 Moonsub Shim MSE280

Strength vs Density

• Let’s say we want to

constrain our search to
materials with P > 10.
300MPa
• Additional
Additi l constraints
t i t may
be added, e.g.
-Require minimum
strength: σf > 300 MPa.
-Rule out brittle P = 10
materials – no ceramics.

Search area is now

limited to the shaded
area (minus ceramics) in
the Ashby plot.

© 2007, 2008 Moonsub Shim MSE280

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 Details: Strong, Light Torsion
Members
τ2f / 3
• Maximize the Performance Index: P= >10
ρ
• Other factors:
--require σf > 300MPa.
--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 78
7.8 780 11
quench & temper)
Data from Table 6.6, Callister 6e.

• Lightest: Carbon fiber reinf. epoxy

(CFRE) member.

From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

Price and Availability of Materials

• Current Prices on the web(a): TRENDS
-Short term: fluctuations due to supply/demand.
-Long term: prices increase as deposits are depleted.

• Materials require energy to process them:

- Energy to produce - Cost of energy used in
materials (GJ/ton) processing materials ($/GJ)(g)
Al 237 (17)(b) elect resistance 25
PET 103 (13)(c) propane 11
Cu 97 (20)(b) natural gas 9
steel 20(d) oil 8
a http://www.statcan.ca/english/pgdb/economy/primary/prim44.htm
glass
13(e) a
b
http://www.metalprices.com
http://www.automotive.copper.org/recyclability.htm
paper c http://members.aol.com/profchm/escalant.html
9(f) d http://www.steel.org.facts/power/energy.htm
e http://eren.doe.gov/EE/industry_glass.html
Recycling indicated in green. f http://www.aifq.qc.ca/english/industry/energy.html#1
g http://www.wren.doe.gov/consumerinfo/rebriefs/cb5.html

From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

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 Relative Cost (in $) of Materials
Graphite/
Metals/ Composites/
Ceramics/ Polymers
Alloys fibers
Semicond
100000
50000 $ /kg
20000 Pt
Diamond $=
10000
Au ($ /kg) ref material
5000
($ )

Si wafer
2000 • Reference material:
1000
500
Si nitride -Rolled A36 carbon steel.
Relaative Cost

Ag alloys
200 CFRE prepreg
Tungsten
100 Ti alloys Si carbide AFRE prepreg • Relative cost fluctuates less
Carbon fibers
50
Aramid fibers than actual cost over time.
Cu alloys G FRE prepreg
20
Al alloys
10 Mg alloys Al oxide Nylon 6,6
PC
5 high alloy
Epoxy
E-glass fibers
Glass-soda PVC PET
2 Steel LDPE,HDPE Wood
PP
1 pl. carbon PS
0.5
Based on data in Appendix
0.1 C, Callister, 6e.
Concrete
0.05

From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

Details: Strong, Low-Cost Torsion

Members
• Minimize Cost: Cost Index ~ m$ ~ $/P (since m ~ 1/P)
• Numerical Data:
material P (MPa)2/3m3/Mg) $ ($/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 6.7, Callister 6e.

• Lowest
L t cost:
t 4340 steel
t l ((oilil quench
h & ttemper))

• Need to consider machining, joining costs also.

From D. Johnson
© 2007, 2008 Moonsub Shim MSE280

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 Example 6: Safe Pressure Vessel
Recall Design Example from Failure Section of the course…

Spherical gas/fluid tank

under pressure p

Circumferential wall stress:

pr
σ=
2t
Two possible designs for safety:
A) Plastic distortion before leaking (i.e. the mechanical deformation
before leak occurs).
- Calculate relative maximum critical crack length where plastic
deformation occurs before catastrophic crack propagation for 1040
Steel, Ti alloy and Stainless steel.
B) Leak-before-break (e.g. to prevent pressure build-up leading to
explosion). Achieved when ac = t (i.e. complete opening before crack
propagation).
- Calculate the relative maximum pressure for same 3 materials as A).
© 2007, 2008 Moonsub Shim MSE280

Example 6: Safe Pressure Vessel

A) Plastic distortion before leaking
- Yield strength - Fracture toughness

σ y ≤σ c K = Yσ c πac
Ic
Critical stress for crack propagation

- Sub in σy for σc: K ≥ Yσ y πac

Ic
Larger the tolerable crack
2 size the better.
-solve for ac: 1 ⎛⎜ K Ic ⎞⎟ Therefore, maximize this
ac ≤
πY 2 ⎜⎝ σ y ⎟⎠ quantity.

K Ic
P1 =
σy
© 2007, 2008 Moonsub Shim MSE280

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 Example 6: Safe Pressure Vessel
B) Leak-before-break
Pressure on the wall:
- Fracture toughness
σ = pr t=
pr
K Ic = Yσ πac 2t
or
2σ
Since leak-before-break occurs when ac = t: 2
⎛K ⎞
K Ic = Yσ πt sub in for t
K Ic = Yσ
πpr σ = 2 ⎜ Ic ⎟
⎜ ⎟

2σ πpr ⎜⎝ Y ⎟⎠
2
-Vessel should not ⎛K ⎞
σ y ≥ σ = 2 ⎜ Ic ⎟
⎜ ⎟
yield from the stress
on the wall: πpr ⎜⎝ Y ⎟⎠
K Ic2
P2 =
2 higher the tolerable
-solve for p: 2 K Ic
p≤ pressure the better.
σy
Y πr σ y
2 Therefore, maximize
this quantity.
© 2007, 2008 Moonsub Shim MSE280

Example 6: Safe Pressure Vessel

Yield-before-break
P1 = KIc/σy
Steels
Leak-before-break Cu-alloys
P2 = (KIc)2/σy Al-alloys
P1=0.5 m1/2
Thin wall, strong P2=10 m
P3 = σys
e.g. Require a minimum
strength of 100 MPa

P3=100 MPa
• Large pressure vessels
are always made of steel.

© 2007, 2008 Moonsub Shim MSE280

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 Summary
• Performance index and Ashby Plot.
– Combination of properties to choose optimum
materials to satisfy two or more needs.
• Specific examples:
– Strong and light tie-rod
– Stiff and light beam (tension)
– Stiff and light (deflection)
– Strong and light panel (auto body panels)
– Strong (torsion), light and cheap shafts
– Pressure vessel

© 2007, 2008 Moonsub Shim MSE280

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