1. Answer no.

1
a) In 1903, Wright Brothers initiate first flight, used spruce & steel wire structure,
aluminium engine block, and fabric skin. They use that because easy on
manufacturing, cost effective, lightweight. In 1915, all metal airplane was invented
in that era. After that, stressed skin construction was applied at LFG Roland C.II in
1916.
In 1930’s aluminium use on aircraft increased. In 1931, there was experiment use
stainless steel construction, Budd BB-1 Pioneer. Plastic use expands in 1936. The
most advanced materials in that era, composites material, was invented at cockpit
component in 1942. In 1940’s – 1950’s superalloys were applied for high
temperature work, for example for turbochargers and jets.
In 1969 carbon fiber composites was applied at Rolls-Royce RB211 jet turbofan
engine. Boron fiber composites also applied in 1970 at F-14 Tomcat. And in 1981,
ceramics material was applied at space shuttle thermal protection tiles. Aluminium-
Lithium was applied at space shuttle external fuel tank in 1998. Advanced material,
like GLARE, and other composites material was applied in 2005 until now. And now,
aerospace industry develop some future materials, like smart materials and
nanotechnology.
b) The reasons why these materials were adopted are:
1) These materials are lightweight than other materials
2) Besides lightweight, these materials also have high strength and high stiffness
3) From economic aspect, these materials have high cost effective than other
materials
c) All aircraft structure are not built out of stainless steel because stainless steel has
high density, so that if all aircraft structure are built out of stainless steel, the
weight of the aircraft will be large. From the Appendix B.1 Callister (2007), the
average density of stainless steel is 7.85, about 3 times larger than aluminium and
composites. Besides, if use this materials on all aircraft structure, it will require
more fuel to move the aircraft, so it costs a lot of money and causes more
pollution.
d) Some materials replace other materials because over time, there have been many
discoveries and material innovations that are most suitable for application to flying
vehicles. From the Wright brothers, the materials used were simple materials, such
as spruce & steel wire structure and fabric skin, then switched to stainless steel,
then aluminium was used, advanced materials such as composites, and future
materials.
e) The future for aircraft materials is:
1) Smart materials: these materials are able to sense changes in their
environment and then respond to these changes in predetermined manners-
traits that are also found in living organism [1]. One of application in aircraft is
these materials is used in helicopter to reduce aerodynamic cockpit noise that
is created by the rotating rotor blades.
2) Nanoengineered Materials: these materials are made from manipulation atom
and molecules structure. Because these materials are focus manipulating atom

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 and molecules to form a new structure and the size is very small, so it is named
nanoengineered materials. Some examples of nanoengineered materials on
aerospace: nanostructured metals, polymer nanocomposites, tribological and
anti-corrosion coatings [2].
2. Answer no. 2
a) The four buildings block of the material science and engineering are:
1) Processing
Processing is certain steps taken on a material to get an object/product with
the desired performance. The example of processing is cutting, casting,
welding, heat treatment, etc.
2) Structure
Structure in material is related to the arrangement of its internal components.
The structure of the material consists of a subatomic arrangement that show
relationship of the electron to the nucleus, atomic arrangement, microscopic
structure, and macroscopic structure that can be seen by the eye [1]. The
example of structures of the metal are simple cubic, body-centered cubic,
closest-packed, face-centered cubic, etc.
3) Properties
Property is a material trait in terms of the kind and magnitude of response to a
specific imposed stimulus [1]. The example of properties is transparent or
opaque, conductive or non-conductive, etc.
4) Performance
The capabilities of a material to satisfy criteria of certain standard. For
example, a beam that can receive 10MPa load.
The interconnection of the blocks is structure is depends on processing,
properties of material is based on the structure, and the performance is based
on the properties.
b) From the 4 blocks of the material science and engineering, we can know the
difference between the material science and material engineering.
• Material science is science that investigating relationship between structure
and properties. So that, material science is focus on structure and properties of
the material.
• Material engineering is designing or engineering the structure with the specific
process to produce certain performance that we want based on its properties.
In that case, material engineering is focus on processing and performance.
3. Answer no. 3
a) DRO in the design process has a role as the concept and rules of the design of a
product. In creating an object that has a certain performance, we must pay
attention to several aspects that must not be violated, whether from the aspects of
geometry, performance, cost, manufacturing, environment, etc. Therefore, a DRO
is made to optimize the design process of a product.
b) There are several material selection process, but I will use the method from the
Michael Pfeifer’s book. The flowchart of material selection process is shown in
Figure 1.

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 Figure 1 Material selection process flowchart [3]
From the Figure 1, we see the first step in material selection process is define product
design requirement and objectives. The second step is defining subassembly design
requirements. The third step is defining product element design requirements. I
define the first three steps of this material selection process with “define the
problem and solution with DRO”.
The fourth step is identifying material selection criteria for a product element. The
fifth step is identifying material option, are these materials acceptable option. If
acceptable, then evaluate these materials. If not acceptable try several ways, like
modify product element requirement, identify the previous step, invent a new
material, or cancel product if there are not other ways anymore. If all these steps
were completed and the material is acceptable and satisfy the requirement, then
select the optimum materials.
c) The process can change the structure because while doing manufacturing process,
especially heat treatment, the molecules of the material will receive heat energy,
so that the molecules will be moving. If the position of the molecules too different
from the initial position, it will change the structure.
One example of a manufacturing process that clearly changes its structure is heat
treatment. Now look at a solid metal, where the structure is packed very densely. If
a metal is heated, the particles in the material elements will scatter faster because

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 they get more kinetic energy due to high temperatures [4]. This makes the
molecules in the metal become more tenuous, so that from solid metal will turn
into liquid, and so on until it turns into a gas, where the molecules can move freely.
Also, the higher temperature, it will increase electrical resistance of a metal due to
increase speed of electron [4].
One of the application of this process is annealing. Annealing is heat treatment that
will change the physical and chemical properties that increase material ductility
and reduce its hardness.
4. Answer no. 4

Figure 2 A circular shaft

a) From the data we get
𝑇 𝜏 𝑇𝑅
= ⇔𝜏= Eq. 1
𝐽 𝑅 𝐽
and
𝜋𝑅 4
𝐽= Eq. 2
2
From Equation 1 and Equation 2 we get
2𝑇
𝜏= Eq. 3
𝜋𝑅 3
The safety factor of the material is
𝜏𝑓
𝑁= Eq. 4
𝜏𝑎𝑙𝑙𝑜𝑤𝑒𝑑
with 𝜏𝑎𝑙𝑙𝑜𝑤𝑒𝑑 = 𝜏
The formula of the shaft mass 𝑚 with density 𝜌 is
𝑚 = 𝜋𝑅 2 𝐿𝜌 Eq. 5
From Equation 5 we can arrange the formula
𝑚
𝑅=√ Eq. 6
𝜋𝐿𝜌
We can substitute Equation 6 to Equation 3 to find mass formula of the shaft
1 3
2𝑇 𝜏𝑓 2𝑇𝜋 2 (𝐿𝜌)2
𝜏= 3 ⇔ = 3 Eq. 7
𝑚 𝑁
𝜋 (√𝜋𝐿𝜌) 𝑚2

From the Equation 7 we can get the formula of mass

2
2 1 3 𝜌
𝑚= (2𝑁𝑇)3 (𝜋 2 𝐿) ( 2) Eq. 8
𝜏𝑓 3
b) Performance index of material is defined by

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 2
𝜏𝑓 3 Eq. 9
𝑃=
𝜌
Based on the above relationship, the performance index of material is affected by
density and material torsion yield strength. The higher the performance index
value, the better the material is.
c) Material selection based on maximising the performance index
Table A1 Yield Strength in Tension (𝜎𝑦 ), Density (𝜌), and Material Cost per Unit Mass (𝑐𝑚 )
for Five Candidate Materials
Material 𝜎𝑦 (𝑀𝑃𝑎) 𝜌 (𝑘𝑔⁄𝑚3 ) 𝑐𝑚 (£⁄𝑘𝑔)
Ductile Cast Iron
230 7150 0.4
(GJS 350)
Al Alloy (5083) 280 2670 1.6
Medium Carbon
350 7800 0.38
Steel (AISI 1040)
Ti-6Ai-4V 900 4430 18
CFRP (Quasi-
550 1575 35
Isotropic)
From Table A1, we only know the material yield strength in tension. So, assume
that the yield strength in torsion is half the yield strength in tension.
Table A2 Yield Strength in Tension (𝜎𝑦 ), Yield Strength in Torsion (𝜏𝑓 ), Density (𝜌), and
Performance Index (𝑃) for Five Candidate Materials
𝜎𝑦 𝜏𝑓 ≈ 50% 𝜎𝑓𝑎𝑖𝑙 𝜌 𝑃
Material 2
(𝑀𝑃𝑎) (𝑀𝑃𝑎) (𝑘𝑔⁄𝑚3 ) ((𝑀𝑃𝑎) ⁄(𝑔⁄𝑐𝑚3 ))
3

CFRP (Quasi-
550 275 1575 26.85
Isotropic)
Ti-6Ai-4V 900 450 4430 13.26
Al Alloy (5083) 280 140 2670 10.10
Medium
Carbon Steel 350 175 7800 4.01
(AISI 1040)
Ductile Cast
230 115 7150 3.31
Iron (GJS 350)
From the Table A2, we know that CFRP has the highest performance index value. It
means this material has high yield strength in torsion, but also lightweight.
∴ Therefore, the best material based on maximising the performance index is
CFRP
d) Calculate the cost material
𝑐 = 𝑐𝑚 𝑥 𝑚 Eq. 10
Substitute Equation 8 to Equation 10, we get
2
2 1 3 𝜌
𝑐= 𝑐𝑚 (2𝑁𝑇)3 (𝜋 2 𝐿) ( 2) Eq. 11
𝜏𝑓 3

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 We can arrange the Equation 11 with performance index variable. This form
2
2 1 3
((2𝑁𝑇) (𝜋 𝐿) ) is a constant and not related to performance index.
3 2

𝑐𝑚
𝑃′ = Eq. 12
𝑃
From the Equation 12, we know that the lower value of 𝑃′ , the more economic the
material is.
e) Material selection based on minimising the material cost
Table A3 Tabulation of 1⁄𝑃, Material Cost per Unit Mass (𝑐𝑚 ), and the Product of 1⁄𝑃 and
𝑐 for Five Candidate Materials
1⁄𝑃 𝑃′
Material 2 𝑐𝑚 (£⁄𝑘𝑔) 2
((𝑘𝑔⁄𝑐𝑚3 )⁄(𝑀𝑃𝑎) ) 3 ((£⁄𝑐𝑚3 )⁄(𝑀𝑃𝑎)3 )
Medium
Carbon Steel 249.31 0.38 94.74
(AISI 1040)
Ductile Cast
302.35 0.4 120.94
Iron (GJS 350)
Al Alloy (5083) 99.03 1.6 158.45
CFRP (Quasi-
37.24 35 1303.55
Isotropic)
Ti-6Ai-4V 75.44 18 1357.90
From the Table A3, we know that for one performance index value, medium carbon
steel (AISI 1040) has the lowest cost (most economic).
∴ Therefore, the best material for the shaft is medium carbon steel (AISI 1040)
Note: although the best material is medium carbon steel (AISI 1040), but there
are many aspects that must be consider too. Also, what kind of shaft is not given
in detail. But, if high strength of shaft is required, then my material suggestion
is Aluminium Alloy (5083), because its has performance index above 10 (which
is better than medium carbon steel) but also relatively cheap than Ti-6Ai-4V
and CFRP and the price is not too high from medium carbon steel.
References
1. Callister, William D (2007). Materials Science and Engineering: An Introduction (7th ed.).
Hoboken, New Jersey: John Wiley & Sons. ISBN 978-0-4717-3696-7.
2. Azonano (2012). Nanotechnology in Aerospace Materials.
https://www.azonano.com/article.aspx?ArticleID=3103
3. Pfeifer, Michael (2009). Materials Enabled Designs: The Materials Engineering
Perspective to Product Design and Manufacturing. Butterworth-Heinemann. ISBN 978-
0-7506-8287-9.
4. Sciencing (2018). How Does Temperature Affect Metal?.
https://sciencing.com/temperature-affect-metal-4845.html.

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