PROCEDURES FOR MATERIAL SELECTION

The selection of an appropriate material and its subsequent conversion into a useful product with desired shape and properties can be a rather complex process. Nearly every engineered item goes through a sequence of activities that includes design, material selection, process selection, production, evaluation and possible redesign or modification. Numerous engineering decisions must be made along the way. Several methods have been developed for approaching a design and selection problem. The case history method is one of the simplest. Begin by evaluating what has been done in the past (engineering material and method of manufacture) or what a competitor is currently doing. This can yield important information that will serve as a starting base. Then, either duplicate or modify the details of that solution. The basic assumption of this approach is that similar requirements can be met with similar solutions. The case history approach is quite useful, and many manufactures continually examine and evaluate their competitors products for just this purpose. The real issue here, however, is how similar is similar. A minor variation in service requirements, such as a different operating temperature or a new corrosive environment, may be sufficient to justify a totally different material and manufacturing method. In addition, this approach tends to preclude the use of new materials, new technology, and any manufacturing advances that may have occurred since the formulation of the original solution. It is equally unwise, however, to totally ignore the benefits and insights that can be gained through past experience. Other design and selection activities occur during the modification of an existing product, generally in an effort to reduce cost, improve quality, or overcome a problem or defect that has

been encountered. A customer may have requested a product like the current one but capable of operating at higher temperatures, or in an acidic environment, or at higher pressure. Efforts here generally begin with an evaluation of the current product and its present method of manufacture. The most frequent pitfall, however, is to overlook one of the original design requirements and recommend a change that in some way compromises the total performance of the product.The safest and most comprehensive approach to part manufacture is to follow the full sequence of design, material selection, and process selection, considering all aspects and all alternatives. This is the approach one would take in the development of an entirely new product. In addition, for our product we choose the one material which is Magnesium. This is because magnesium is the non-toxic, non-magnetic, has high-impact strength and is resistant to denting. Magnesium is too reactive to occur in nature as an element, but its compounds are common. At 2.5 per cent, magnesium is the eighth most abundant element in the earth's crust. It is the third most abundant element in sea water which averages about 0.13 per cent magnesium by weight. Magnetite (MgCO3) is an ore for magnesium production and also the source of a range of industrial minerals. When pure, magnetite contains 47.8 per cent magnesium oxide and 52.2 per cent carbon dioxide. Natural magnetite almost always contains some calcium carbonate (as the mineral calcite) and iron carbonate (as the mineral siderite). Magnesium also occurs in dolomite, which has the formula Ca Mg (CO3)2 and in which MgCO3 constitutes 45.65 per cent (equivalent to 21.7 per cent Mg O ) and CaCO3 54.35 per cent. Magnetite color varies from white, when pure, to yellowish or grey white and brown. Hardness is 3.5 to 4.5 and the specific gravity varies from 3 to 3.2. A vitreous luster and very slow reaction with cold acids distinguishes magnetite from other carbonates. Magnetite, dolomite, sea water and lake brines are used as sources

of magnesium metal with the most common source being lake brines and sea water. Magnetite occurs in two physical forms: (1) Cryptocrystalline or amorphous magnetite and (2) Microcrystalline magnetite. It occurs in five different ways: a replacement mineral in carbonate rocks; an alteration product in ultramafic rocks (igneous rocks composed mainly of one or more dark colored ferromagnesian minerals); a vein-filling material; a sedimentary rock and as nodules formed in a lacustrine (lake) environment. Replacement-type magnetite deposits involve magnesium-rich fluids entering limestone via openings to produce both magnetite and dolomite. The alteration-type deposits are formed by the action of carbon dioxide-rich waters on magnesium-rich serpentine (a rock which has been formed from the alteration of magnesium and iron silicate minerals). The resultant magnetite may be very pure. Sedimentary deposits usually occur as thin layers of variable magnetite quality. Lacustrine magnetite deposits consist of nodules of cryptocrystalline magnetite formed in a lake environment. Both vein filling and sedimentary magnetite occurrences are rarely mined on a large scale.

Furthermore, our group chooses the next material which is Aluminum. Aluminum Limited is a premium supplier of aluminum extrusion and sheet products in Australia. is an industry leader offering innovative aluminum solutions, extensive distribution channels and value-adding services including powder coating, anodizing and light fabrication.Aluminium is recognized as one of the material shaping the automobiles of the future. Aluminum Limited is regarded as an innovator in the application of aluminum extrusion technology for the automotive industry. Aluminum is the engineering material of choice for many applications. Properties that make aluminum popular and/or suitable included Resilient, Ductile at low temperatures, Light, Strong, High strength-to-weight ratio

Corrosion resistant, Non-toxic, Heat conducting

Reflective, Electrically conducting, Non-magnetic, Non-sparking, and Non-combustible. By appropriate alloying and treatment, aluminum is available in a variety of strengths. Some aluminum has strength as high as 300 MPa and is stronger than some steels. Strength may be selected to match product needs. Aluminium products behave elastically under static and dynamic loading conditions, that is, they have the ability to resume both shape and size which is good when flexible strength is required.

Next, aluminum has the good of Strength at Low Temperatures. Brittle fracture problems do not occur with aluminum. As the temperature is reduced, aluminum alloys increase in strength without loss in quality, making them particularly suitable for low temperature applications. An aluminum moon buggy was used to negotiate the rough terrain in the deep cold of outer space. When aluminum is exposed to air, a thin oxidized film forms on the surface, protecting the metal from corrosion. When scratched, the layer rapidly reforms retaining the protection. This feature is utilized in construction, buildings and household utensils.Aluminium itself is non toxic and odorless. Its surface is smooth, easily washable and hygienic because no germs can grow on it. Thus, it is widely used in beverage cans, food packaging, cooking utensils and in the fishing and dairy industries. Aluminium it also conducts heat better than any other common metal. It is about three times as thermal conductive as steel. It is important in heat exchange applications - either heating or cooling - and commonly used in the food, chemical, petroleum, aircraft and automotive industries.

Aluminium is an excellent reflector of radiant energy. It reflects more than 80% of visible light, radiation (heat) and electric waves. The purer the metal, the more so. This feature is used for reflecting mirrors, reflectors (stoves, infra-red dryers, lighting), and wave guides. It is also used

as an insulating material in buildings and as roofing sheet.Aluminiums ability to conduct electricity is approximately 62% of that of copper, but it weighs less than 1/3. This means that it conducts about twice as much electricity as copper of the same weight.Aluminium is a very economical material as an electrical conductor and is used in power transmission cables, bases of electric bulbs and in other electric fields. This property of aluminum makes it particularly useful for a variety of electrical and electronic applications, for high voltage hardware, bus bars, magnetic compasses, parabolic antennas, computer disks, etc.Aluminiums non sparking characteristic (against itself and other non ferrous metal) makes it an essential material for products used with highly flammable or explosive substances and atmospheres.

Aluminium does not burn and so is widely used in buildings, vehicles and in other applications where fire is a potential hazard. Hazardous emissions are not generated when aluminum is exposed to heat. The natural metallic surface of aluminum is aesthetically pleasing; the surface supplied is adequate and does not require further finishing. If additional protection is required, the natural oxide film may be thickened by anodizing without affecting the metals appearance. A wide range of finishes may be applied to aluminum to enhance its surface characteristics, or alter its appearance. The metallic surface may be colored by chemical or anodizing processes. Surface textures may be created, varying from rough to matte to mirror smooth. Coatings such as paint, lacquer, enamel, electroplating or laminate may also be applied.Aluminium extrusions are seamless one-piece products both visually and functionally. There are no mechanically joined seams to mar appearance or to become loose or leak, even in tubes and other hollow shapes.Aluminium can be easily fabricated into various forms such as foil, sheets, shapes, rods, tubes and wires. It also displays excellent mach inability and plasticity in bending, cutting and

drawing. Aluminum is considered to be the best material for complex extrusion to tight tolerances.

Aluminium extrusions can be joined to other aluminum products or to different materials by all major methods, including welding, brazing, soldering, bolting, riveting, clinching, crimping, clipping, adhesive bonding and slide-on, snap together or interlocking joints.

Aluminums capacity for integral design and production can reduce cost and improve performance and reliability. Extrusion can economically provide product shapes that would be difficult, if not impossible, to produce in any other way.Aluminium extrusions can be designed for ease of assembly with other parts. The production of large items in the form of dis-assembled kits that require a minimum of manpower and skill to assemble are cost

saving.Aluminium extrusions, of uniform high quality, may be produced in large numbers with minimal rejection rates and little need for corrective fabrication. The Aluminum industry includes a large secondary metal sector which accepts scrapped aluminum products for remolding and recovery of metal. Recycling aluminum requires only 5%of the energy needed to produce new aluminium.Aluminium extrusions may be recycled and therefore have substantial scrap value.