MATERIALS SELECTION PROCESS

By:
Frizka Vietanti, S.T., M.T., M.Sc.
Selecting Materials

 Product function interdependence

 Mechanical properties
 Physical properties
 Families of materials
 Materials first screening
 When do we select specific materials?

Customer Needs
Formulation

Customer requirements
Importance weights
Eng. characteristics
Concept Design House of Quality
Eng. Design Spec’s

Abstract embodiment
?
Physical principles
Material
Geometry arrangement of parts/features
Configuration
Design
(i.e. shaping materials)
 Therefore, let’s examine…

Formulation

Concept Design
materials manufacturing
processes
Configuration Design

Parametric Design

Detail Design
Interdependence - compatibility

Material
Properties

Manufacturing compatible
Processes materials & processes
Interdependence - capability

capable processes
for the geometry

Manufacturing Product
Processes Geometry
Product function is interdependent

Material
Properties

Product
Function

Manufacturing Product
Processes 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
F
stress
 F/A
A
ductile ?
L L  L
S ut

Sy

brittle
elastic plastic
y f L  L
strain   
L

stiffness ? E
 Strength = stress at failure = (failure)
Mechanical properties
 Fundamental properties

Characteristic Behavior Property Units

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

Characteristic Behavior Property Units

Fatigue resistance endures many load cycles endurance limit MPa (Mpsi)
thermal
Conductivity conductivity (Btu/hr) / (F-ft),
conducts, insulates
(heat, electric) electrical Mhos
conductivity
Creep resistance time dependent creep strength MPa (ksi)
stretching
Impact resistance shock, impact loads Charpy energy N-m, (ft-lbs)
Density (mass) mass density kg/m3, (slugs/ft3)
heavy, light
Density (weight) weight density N/m3, (lbs/ft3)
Temperature tolerance softens, or melts easily melting point degrees C, F
 Material families / sub-families

Materials

Metals Plastics Ceramics Composites Family

(Ashby)

Ferrous Thermoplastics

Non-ferrous Thermosets Sub-family

Elastomers
Material sub-families / classes

Materials

Metals
Family

Ferrous
Sub-family

Cast iron
Carbon steel
Alloy steel Classes
Stainless steel
Metals

Metals

Ferrous Non-ferrous
cast iron aluminum
carbon steel brass
alloy steel bronze
stainless steel copper
lead
magnesium
nickel
tin
titanium
tungsten
zinc
 Natural and
Polymers synthetic rubbers

Polymers

Thermoplastics Thermosets Elastomers

ABS alkyd butyl

acetal epoxy fluorocarbon
acrylic melamine neoprene
nylon phenolic nitrile
polycarbonate polyester polysulfide
polyethylene urethane rubber
polypropylene silicone
polystyrene
vinyl
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 protésico dinámico

2004

Pie protésico dinámico

2005
 Composites

Marlon Cameron
Shirley Clapp

Ossur Otto Bock

Cheeta C-Leg
Flex-Foot
Date of birth: April 21, 1978 Date of birth: Sep 15, 1986
Hometown: Thatcher, Utah
Current Home:San Diego, CA
Property profiles by family
Materials selection

prospective
materials and processes

functional? rejected
screening materials and processes
manufacturable?
feasible
materials and
processes
relative
rating
performance?

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? rejected
screening materials and processes
manufacturable?
feasible
materials and
processes
relative
rating
performance?

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 = Young’s 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