Machine Design I:

Static and Fatigue Failure

Module 8: Common Metals
Kathryn Wingate, Ph.D.
GWW School of Mechanical Engineering
 Course Overview

• Unit 1: Material Properties in Design

• Strength
• Modulus of Elasticity
• Ashby Plots
• Metals
• Temperature Effects

• Unit 2: Static Failure

• Unit 3: Fatigue Failure

Learning Outcomes

• Learning Outcome 1:
• Understand why this course focuses on metals

• Learning Outcome 2:
• Become familiar with the properties of common
engineering metals
Metals in Machine Design
• Machine elements: gears, bearings, shafts,
fasteners, springs
• Used across a variety of industries:
agriculture, aerospace, automotive,
biomedical, HVAC, oil and gas, construction,
maritime

• Machine Elements: Metals

• Material considerations:
• Load (Strength)
• Life (Load, Endurance Strength)
• Wear
• Environment
• Failure mode/safety
Metals

Steel

Aluminum

Titanium
Steel

Steel Iron alloyed with small

percentage of carbon
High strength (S) and other materials

High modulus of elasticity (E)

High hardness

Withstand high temperature

Heavy

Alloys give control over:

Machinability, ductility,
corrosion resistant
Aluminum

Steel Aluminum

High strength (S)

strength to weight ratio
High modulus of elasticity (E)

High hardness Corrosion resistant

Withstand high temperature High thermal conductivity

Heavy High electrical conductivity

Alloys give control over: Easy to machine, cast

Machinability, ductility, Difficult to weld, not as strong
corrosion resistant as steel and Ti
Titanium

Steel Aluminum Titanium

High strength (S)

strength to weight ratio High temperature strength
High modulus of elasticity

High hardness Corrosion resistant strength to weight ratio

High temperature High thermal conductivity
Corrosion resistant
Alloys: machine, ductility, High electrical conductivity
Biocompatible
corrosion resistant Easy to machine, cast
Difficult to weld, not as Expensive, difficult to
Heavy machine
strong as steel and Ti
Key Takeaways

• Steel: high strength, alloying

• Aluminum: strength to weight ratio,

machinability

• Titanium: strength at temperature,

biocompatibility
Automotive Applications

Steel Aluminum Titanium

- Input and output - Housings - high end exhaust systems

shafts - (transmission)
- Gears - Body panels
- Chasse - Some structure
- Structure and panels
- Axles Porsche 911 (991) turbo, 2013
- Fasteners Wiki Commons, Author: nakhon100

- Engine
- Exhaust Jaguar XE
Wiki Commons, Author: Jaguar MENA
Opel Insignia
Wiki Commons, Author: Axel Schwenke
Automotive Steels

Mild Steels:
- Easy to form
- Body panels

AHSS: S > 500 MPa

DP
- Dual Phase steel
- High energy absorption

PHS
- Press hardened steel
- High strength Jaguar XE
Wiki Commons, Author: Jaguar MENA
- Safety