Exercises for Unit 1: Browsing 4.4. Find, by Browsing, the Level 1 record for Titanium alloys via OS Og Metals and alloys / Non-ferrous / Titanium alloys Table: | MaterialUniverse 1.2 Find, by Browsing, the Level 1 record for Phenolics via Polymers and elastomers / Polymers / Thermosets / Phenolics [ill Matoriaitniverse 4] [BM Ceramics and gtassos 1.3 Find, by Browsing, the Level 7 record for the ceramic Alumina via >i Ceramics and glasses / Technical ceramics / Alumina (2 Metals and atoys it oy ds: composites ete 41.4 Find, by Browsing, the Level 2 record for Age-hardening wrought aluminum alloys via ‘Metals and alloys / Non-ferrous / Aluminum and alloys / Age-hardening ... 1.5 Find, by Browsing, the Level 2 record for Plywood via Hybrids / Natural materials / Plywood2feuy are eu 'sSU07 304 pasn axe 1eU) SJeus|eW JO} spiodes “Bulyaseas STE amma (serperios) _seuous J ‘mopuin —sto0, 90188 MOIR ots Bulyoueas (Gai) sousedousew pasequaiels (aH ‘Vid) ejaeeounouoidunBuiLjewos™Aiod, (Wd) epnoeNIog (v9) siauuhiod as0in30 ‘rouifjodorg & s1 yeu) jeus|eW Aue 10} spi0de1 "Bulyoieeg, ssunsey Aq ‘puis 8b (Sq) eveshsfiog (yd Koy) e1eKinevieuIKineUsiog = (0d) arevoqieahied 80)6 ajeoiso10q 09 wo ponuop onse\dousoup ‘ergepesbopog 851 'yig) @PeKIod ssunsey Aq ‘Puls Lb 23151 4m oppoe/Ajoq 104 prooes aug ‘Bulyouees 1} MUN 40} sesio1ex3 Aq ‘Puls 9bERAT Exercises for Unit 1: Exploring the science 1.9 How is Fracture toughness measured? Double click in any record on the field name “Fracture toughness”. ‘racure toughness Result Dofinition and measurement. The fracture (aeons) | Thermal properties ‘toughness, (units: MPa m"” or MNim'”) zs eee tas earpereeoe measures ine resistance ofa material to the propagation of a rack. tis measured by foeding a sample containing a delberately- introduced contained cack of length c or a Surface crack of length 2 recording the tens stesso" orthe bending oad F*at which the crack suddenly propagates. ‘Young's modulus Electrical properties lctcal conductivity Dietetni stenath Skess sorForoeF Displacement Fare f Mesring tre ugine Kc 1.40 What is the Dielectric strength of a material? Double click in any record on the field name "Dielectric strength”. Result Definition and measurement. The breakdown potential gradient or dielectric strength (units: MVIm) + “oft oo ooo is the electrical potential gradient at which an ingulator breaks down and a damaging surge of current like a lightning strike flows through it. Breakdown imolver a cescode of eletrans ea gang sreExercises for Unit 2: Making bar-charts Is 2.1 Make a bar chart with Fracture toughness on the Y-axis using Level 1, Mat Then Selecton | Edu Level 1: Materials and proceed as shown opposite Label two (or more) materials by clicking on the bars, Ppeaay strength = Fracture toughness Listof | Use the BOX selection tool [E]_ tof th our mates wit he highest values of acture toughness Result: (see opposite) = Change the Property UNITS from Metric to Imperial or vice versa [teats } options Unts- Us customary or Matic = Change the Currency from USS to Euro (Toots Onions Unts—Peered Coren Euro (Uh) Fracture toughness (MPa.m‘0.5)Exercises for Unit 2: Making bubble-charts 2.2 Make a bubble chart with Density on the X-axis and Yield strength on the Y-axis using Level 2, Materials settings _ 4. Selection data Edu Level 2 : Materials = Click on 2. Selection Stages Then Selecton [ Edu Level 2: Materials = Young's modulus [Yield strength] Fete and proceed as shown opposite = Label two (or more) material by clicking on the bubbles. Switch on the envelopes by clicking | a = Do any metals have yield strength less than 10 MPa (2 ksi)? Answer: yes, Lead alloys Use the BOX selection too! [J to find materials with a yield strength greater than 600 MPa (90 ksi) and a density less than 2000 kgim® (120 Ibsicubic ft) Yield strength (elastic limit) (MPa) Answer: there is only one: CFRP (see box on chart opposite), i 70 Density (kgin'3)Exercises for Unit 2: Making functions of properties 2.3 Make a bar chart with Yield strength / Density on the Y-axis using Level 1 Materials. make the function on the Y-axis. Xaxis | [Y-axis Which two materials have the highest values of Yield strength/Density? Answer: | + CFRP and = Titanium alloys 1odulus / Density to the X-axis to make a bubble chart, rials using Level 1, Mai = Right-click on the Stage name “Stage 1: Yield strength (elastic limit) / Density’ Select Edit stage ~ X-axis - Advanced, then make the function Young's modulus / Density. = Find and label CFRP and GFRP- Result: see chart opposite Yield strength (etastic lit) / DensityExercises for Unit 2: Creating your own records 2.5. You have invented a new material - Fantasticum. Its density and yield strength are Density = 2300 ~ 2600 kgim? Yield strength = 1500-1700 MPa ‘You wish to demonstrate its superiority by comparing it with the other materials of engineering, = Create anew record at Level 2 of the database: — Add record - Enter Name, Density and Yield strength Make a bubble chart of Yield strength and Density. Find and label Fantasticum and the materials nearest to it. Is it really fantastic? Result: Yes, i's impressive stuff, ight, and stronger than CFRP or Titanium ‘Aceal winner ~ provider se, itis as cheap or cheaper, as resistant failure and as corrosion resistant as the materials near it. Establishing 2 né the market place is not simple. 5 Yield strength (elastic imit) (MPa) Yanismons [—][—Jom veissveron [3505] (700) ea ans Co wen oo The new ——————— A material Density ikon’)Exercises for Unit 2: Report writing 2.6 Amanufacturer is considering the use of a Magnesium alfoy for the casing of & portable computer. He is concamed to know the thermal conduetiviy of Magner om Phat and how it compares with that of other materials. Provide a brief report filing his needs. = Make a bar-chart of Thermal conductivity using CES Level 1. Find and label possible casing materials: Magnesium alloys, Aluminum alloys, THanium alloys and CFRP. «Copy and paste the chart into WORD, starting the report In CES: Edit~ Copy In WORD: Paste spé ~ Device independent bitmap «Copy the record for Magnesium alloys and paste the relevant data into your report = Add a brief introductory text and reformat the document s0 it looks the way you want File Edit View Tools Windows ..... Paste into a ‘WORD document cut eat (conv We Paste Delete Report: Thermal properties of magnesium “The chart shows that Magnesium alloys have thermal conduct Treas ot aluminum, but much larger (2 factor of 10) than those of titanium or CFRP. Details of the thermal properties of magnesium are listed in the table. More precise data for cece magnesium alloys can be found in the CES Level 3 database. Magnesium alloys: Thermal properties 447 - 649°C 120-200 °C 50-156 Wim’C 955 = 1060 Jikg."C ustrain’C Specific hea ‘Theemal expansion coefficient 24.6 - 28 —-- | ngnete toys ‘Thermal conductivity Wim."Exercises for Unit 3: Selection using Limit and Graph stages 3.1. An eco-car maker seeks a mi design specs the material must have Young’s modulus > 70 GPa Yield strength > 500 MPa Fracture toughness > 25 MPa.m'® F a light-weight space-frame, To meet the Apply a Limit stage to Level 2: Materials as shown opposite to make a selection. Result a eee ‘Age-hardening wrought At-alloys kelbased superalloys ‘Stainless steel 3.2. The eco-car maker forgot something. The material must be light. Keep (or re-do) the Limit stage of 3.1 and add a Graph stage to find the survivors with the jensity. Exj the “Zoom” and “Hide” buttons to make the chart Zoom / Unzoom | “W/GR Hite rated rors Result (see chart opposit test mat hardening, wrought A-alloys, Titanium and that meet the requirements are Age- tanium alloys, Density (kg/m*3) 8 5 g 1. Selection data _—— [Eau Level2:materate =o 2. Selection Stages ig Graph e=) GB Tree Y Mechanical properoe Mn. Max Yeung mate [TO] Jore mol] Mp = oft] vee fran ous BE") EJ uraExercises for Unit 3: Selection using a Tre 33 Whatis Die casting? And which materials can be Die-cast? ‘Apply a Tree stage to Level 1 Materials as shown opposite. Find out about Die casting by Browsing the Processes Universe, Level 1: Alll processes. Result: the tree stage delivers the material classes can be die-cast, listed below: Magnesium alloys Zinc al loys Result: the record for Die casting gives the following information and image. Die casting. Most small aluminum, zinc or ‘magnesium components with a complex shape ~ camera bodies, housings, the chassis of by DIE CASTING. ough a system of sprues and runners, The pressure is maintained until the component is solid, when the die is opened and the component ejected. ‘The dies are precision-machined from heat- el and are water cooled to ety e stage ©) (cove) (eeree) | — 2, Selection Stages $B craph B Limit EB tree + Trees | [Process Universe ¥ {im Process Universe fi Joining [Fill Shaping — Die casting [Rl Surtace treatment |Exercises for Unit 3: Selection using a Tree plus a Limit stage 3.4 A material is required for a molded electrical enclosure. There are requirements " Processa 1e material must be able to be molded * Properties: the material must Be a good electrical insulator Have a high dielectric strength, exceeding 10 MVim Tolerate heat: maximum service temperature exceeding 150 °C Have a Young’s modulus exceeding 1 GPa Stage 1: apply a Tree Stage to Level 2, Materials (& Tree }- ProcessUniverse - Shaping - Molding ‘Stage 2: apply a Limit Stage to put constraints on properties as shown opposite. Phenolics, | Polyester Polyetheretherketone (PEEK) ‘Soda-lime glass Result: the materials in the table meet all the requirements, 2. Selection Stages icmp» Guim Edu Level 2 : Materials [+ 2. Selection Stages Buimit iG Graph ‘ondutrornsttor? [_] ood cnaecar eee (CF Peorinsuiator [Y) c00¢ insutator vide tego [ SE] [] omExercises for Unit 4: Using material indices Int and strong, with some ductility 4A Atensile component requires a material that index for selecting materials (an elongation to fracture exceeding 10%). The that are light and strong when loader M= ay/p where cy is the yield strength and 2 the density. = Make a Graph stage with these two properties as axes "Impose a LINE selection 4 to find materials with the highest values of M. Posi above the line = Add a Limit stage to impose the additional constrait Results: -— ‘Age-hardening wrought 1 Nickelbas Titanium alloys. Wrought magnesium alloys j=) 2, Selection Stages {-sseeton data <——! Strength oy 1 craph} | 2 unit | BB tree v v |[oemin 5 teams =] J seers Elongation C70] === Density pExercises for Unit 4: Using material indices =~ | [Sete 4.2 Repeat the selection of 4.1, but use the Advanced facility to make a bar-chart with the index M= %y/P onthe Y-axis. Use the BOX selection too! Eq to find the four ‘materials with the highest values of M. 2. Selection Stages LG Graph} | Limit | BS tree = Add a Limit stage to impose the additional constraint: Elongation > 10% Index 9,9 Results: the same as Exercise 4.1Exercises for Unit 4: Using material indices 4.3. A material is required for a spring that may be exposed to shock loading, and must operate in fresh and salt water. Constraints: = Fracture toughness > 15 MPa.m'® = Very good durability in fresh and salt water Objective: "Maximise stored elastic energy. The materials that store the most elastic eneray are thegeyith the 2 vy greatest value of the index &| ff erastc energy 1 108 m= foyey 23% Make a graph with Strain € Young's modulus E on the X-axis, "Yield strength ° on the Y-axis = Put ona LINE selection & of slope 0.5 ( responding to power 2) = Select materials above the line = Add the other constraints using a limit stage Results: |“ CERP, epoxy matrix (isotropic) " Nickel-based superalloys = Titanium alloys. Strength, 3 : Hon 2% | fommeny = Fe toughness [i=] os ete. an Ve Freshwater Cawood] “ satwater C00] Wodus EExercises for Unit 4: Using material indices 4.4 Repeat the selection of 4.3, but use the Advanced facility to make a bar-chart with the index 3 /E onthe Y-axis. * Plot the bar chart * Use a BOX selection [J toselect the mater with high values of the index. fe Density ey Fe toughness =] ] ate oo Freshwater Casas Saltwater (g500 Index 7 Results: same as Exercise 4.3Exercises for Unit 5: Trade off methods 5.4 The walls of fridges are sandwich panels with steel faces bonded t The core both insulates and provides stiffness. Create the trade-off materials for the core by plotting Thermal conductivity against Elastic compliance (the reciprocal of modulus, used so that a minimum is sought for the quantities on both axes). Graph stage, Level 2 Materials: X-axis: 1/Young’s modulus (use the Advanced facility) ity 2. Selection Stages + Y-axis: Thermal condu *Lapettenoneomiated “colon” — hematite we ep of bo (Ge cam} Bree Send ne «Cony pee WORD or Asbo luster and kthin ado a Results: the chart wi have low stifiness; those that are stiff are poor insulators. The ‘set on or near the trade-off surface. Rigid polymer foams offer a good compr + Young's modulus sete Level 3. Now dump Level 3 data Results: the chart now looks like this. The position for the trade-off surface is obvious. The chart can be labeled in t way. The ZOOM xxplore the ts in more detail Thetmal conductivity (vm K) ein | ‘WVoung’s modulus 17 Young’s medulus MEA Marah 2010 "poss Exercises for Unit 5: Trade off methods 5.2 Explore the trade-off bet tension. The lightest mater: lowest value of the index n 1g mass and price for a component loaded in iat meets all other constraints, of course) is that with the ploy (Density p divided by Yield strength o,). The one with lowest price is that with the lowest value of Cmp/ oy (the same as above, multiplied by the Price per unit mass Cn) Make a Graph stage using the Advanced fat X-axis: Density / Yield strength + Y-axis: Price * Density / Yield strength * Label the non-dominated “solutions” — the materials at the lower edge of the occupied zone + Copy, paste into WORD or Adobe Illustrator and sketch in a trade-off surface, Result: see chart opposite. Low alloy steels offer the best compromise. CFRP is a better choice if ight weight is more important than cost, Edu Level 2: Materials _[) Price * Density / Yield strongth List of properties * Density + Yield strength + Young's modulus Density /Yield strength (olacic Price * Density Yield strength (elastic iit)Exercises for Unit 5: Trade off methods 5.3 Repeat th ion of the trade-off between ing mass and price for a Component loaded in tension of exercise 5:2, bu ths time plting the penalty function G Z=C+am =P yqP = mea) ay ay Here «, with units of Sk, important; high o. means the exchange constant. Low ci. means weight is not important. Start with a = 1 $/kg. Then try o. = 50 $/kg. * Graph stage using the Advanced fa Y-axis: (Density / Yield strengt Use the Zoom facility to enlarge the interesting (low Z) part ofthe plot. Create the penalty function This is the value of a Results: Below for a = 1 $/kg. Low-alloy and carbon steels have the lowest Z. Opposite, for c= 50 S/kg. CFRP and Titanium alloys have the lowest Z. 4. Selection data co | Edu Level 2: Materials “(Prive + 1) 2. Selection Stages GEDA AMo} List of properties, + Density + Yield strength + Young's madulus rete & Ponalty function Z with alpha = 1) (Pico +1) Naas (Density /Yeld strength) z {Density Yield stengih *( Pice +60) Zz g 3 8 8B [Penalty function Z with alpha = 50)[ Exercises for Unit 7: Browsing processes 7A Find, by Browsing the Level 2 record for he shaping process Resin transfer ‘molding (RTM) in Shaping: Composite forming. What producs, typically, ist able to make? Subsot | Edu Level 7.2 Find, by Browsing, the Level 2 record for shaping process Abrasive jet machining pm and cutting in Shaping: Machining: non.conventional machining. Can it be fit Processtniverse used to cut glass? il Joining fll shaping Ff Surtace treatment 7.3 Find, by Browsing, the Level 2 record for the joining process Friction-stir welding in Joining: Mechanical welding. How does the process work? 7.4 Find, by Browsing, the Level 2 record for the surface coating process Metal flame ing in Surface treatment: Surface coating. What are its principal uses?Exercises for Unit 7: Searching for processes 7.5 Find, by Searching, the record for the rapid prototyping process with the trade name SLS. What classes of material can it handle? Find what Look in table: | ProcessUniverse| 7.6 Find, by Searching, the record for Flexible adhesives. Which polymers are used {or flexible adhesives? 7.7 Find, by Searching, the record for Vitreous enameling. What Functions can it perform?Exercises for Unit 9: Carbon footprint and embodied energy 9.1 What is meant by the CO; footprint of a material? Double click in any record on the field name “CO; footprint” to find out. Result: ‘The CO> footprint per ui weight, using PET as an example, is EMass of CO> directly ari sin g from PET production per year * ‘Mass of PET shipped per year (CO2)p¢r = ‘The units are kalkg, 9.2 Iron is made by the reduction of iron oxide, Fez03. Aluminum by the electro- chemical reduction of Bauxite, basically Al,O3. The enthalpy of oxidation of iron to its oxide is 6.5 MJ/kg, that of aluminum to its oxide is 16.5 Mu/kg. Compare these with the ‘embodied energies of cast iron, of carbon steel, and of aluminum, retrieved from the CES database (use means of the ranges given there) ‘What conclusions do you draw? Result: Material Enthalpy of oxidation | Embodied energy Mdikg Malkg Cast iron 55 73 Carbon steel 35 319 ‘Aluminum alloys: 165) 218 | ‘The embodied energies are between 3 and 12 times larger than the energy thermodynamically necessary to reduce the oxide to the metal. There are several reasons. Industrial processes, at best, achieve an energy-efficiency of around 33% (the blast furnace, used to make iron, is remarkably efficient). Then there is transport, energy to run, heat, light and maintain the plant in which the metal is made, and other small contributions to the total energy input per unit of output. Table: | MateriaiUniverse ( Subset [Edu Level? [) ail ial Materiaiuniverse ramics and glasses Hybrids: composites otc ie = i {Bil rolymers and elastomers 4 Aluminum alloys Eco properties Embodied energy, primary production 218 MJkg CO2 footprint, primary production 12.1. kglkgExercises for Unit 9: Eco-audits 9.3 This toaster weighs 1.3kg, is manufactured in South- power rating is 970 W. toast a pair of slices. it is used, on average, to toast 8 slices per day, drawing full power les (0.15 hours) per day over a life of 3 years. Itis recycled, as far Add record +~[Eco avait Options of materials 1s possible, at end = End of ite choice Perform an eco-audit for the toaster, using CES Level 2. = Transport needs = Use cycle * Bill of materials Press “Report” Component] Waterial —] Shaping] Wass] | process | (kg) L Body |__ Polypropylene Molded | 024 Heating element Nichrome | ___Drawn 0.03 z nner frame Low carbon stool Rolied | 0.98 5 0.75 meter) Polyurethane Molded | 0.045 : Cable core, 0.75meter_| Copper | Drawn —P Plug body Phenolic | ‘Molded | (0.037 Plug pins Brass Rolled | 008 "Transport: air freight, long haul, 11,000 km = Use cycle: Energy input/output: electric to thermal, 0.97 kW, 365 days per year, 0.15 hours per day (002 Footprint (ca) Result: the audits shown opposite. The Use phase consumes far more energy and releases more CO; than any other. Transport is second. Now switch from air freight to sea freight, The transport column shrinks dramat sch 2010 2BExercises for Unit 9: Eco-comparisons 9.4 Rank the commodity materials . Low carbon steel [Came 5 Table: [MaterialUniverse [¥]| by embodied energylkg and embodied energy, using date rom the CES Level 2 subset a tovel? [7] Use the means of the ranges given in the database. aa T fee (Energy per unit volume = Energy per unit weight x Density) {i Materiauniverse GH ceramies and glasses fa 3 vec: composten ac a ae Material Embodied energy per | Density | Embodied energy, AIR Poymers ad testomers unit mass, MJ/kg kgim? per unit vol, GJ/m? Loweabon steal —-ai8 7850 250 ‘ Agchardened Alloy 200 2880 60 Poiyethy Polyethylene 80.8 949 7 ‘olyethylene % — Density 989960 kghn’ Embodied energy 769-85 Muka The Al alloy as the highest energy content, by far, by both measures. Perk, steel has the lowest energy contents per unk volume volume. fs plyethyioneExercises for Unit 9: Eco-comparisons 1.5. Plot a bar chart for the embodied energies of metals and compare it with one for polymers, on a a “per unit yield strength” basis. function Embodied energy x Density Energy per unit strength = <0" ae ns Yield strength forthe Y-axis. For the X-axis, choose ‘Advanced ~ Trees ~ select Metals and Alloys, and Polymers and Elastomers Results: The most attractive met perspective are carbon steels and Polylactide (PLA) and starch based Embodied energy" Density /Yield stength Use the “Advanced! facility to make the _ 4. Selection data [Edu Level 2: Materials (7) 2, Selection Stages ales EBrree ‘Advanced List of properties + Density += Viel strength + Young's modulus sete 25