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Materials
Materials
• A few examples:
– Thermal blanket must have poor thermal conductivity in order to
minimize heat transfer for a given temperature difference
– Large amounts of copper in superconducting magnets: copper needed
for low resistance path for large currents in case superconductivity lost
– Samarium-Cobalt Permanent Magnets on DS-1
– SR-71 structure: 85% titanium and 15% composite
– Hummer armor – should it be stiff or deflect against a bomb blast
ROD VERSUS PLATES
• Systematic selection for applications requiring multiple criteria is
more complex
• Example 1: Rod
– Design a rod that is stiff and light-weight
– Requires a material with high Young's modulus and low density
– If rod pulled in tension, specific modulus, or modulus divided by
density E/ρ, will determine best material
• Example 2: Plate
– Design a plate that is stiff and light-weight
– Plate's bending stiffness scales with thickness cubed
– Best material for a stiff and light plate is determined by cube root
of stiffness divided density ³√E/
ASHBY PLOTS
• Ashby plot is a scatter plot which displays two or more properties of a materials
• Example of stiff, light part would have Young's modulus on one axis and density
on other axis, with one data point on graph for each candidate material
– On such a plot, it is easy to find not only material with highest stiffness or
lowest density, but that with best ratio E/ρ.
– Ashby plot on next slide shows density versus Young's modulus
• Metals are represented by blue squares, ceramics by green, and polymers by red
• Using a log scale on both axes facilitates selection of material with best plate
stiffness ³√E/.
– Second plot shows same materials attributes for a database of approx 100
materials
• Materials families (polymers, foams, metals, etc.) are identified by the larger
colored bubbles
EXAMPLE OF ASHBY PLOT
METALS
CERAMICS
POLYMERS
EXAMPLE OF ASHBY PLOT
MATERIALS SELECTION RESOURCES
• http://www-materials.eng.cam.ac.uk/mpsite/interactive_charts/
– Excellent plots of properties for various materials and useful for observing
primary trends
– ‘Hover’ over material label to see details within materials sub-class
– Think about how each chart can be used in an engineering context
• http://www.matweb.com/index.aspx
• http://www.matweb.com/tools/contents.aspx
– Probably the most comprehensive materials database ever created
– Worth spending a few hours sifting and surfing this site in preparation for
selecting materials for your project
YOUNG’S MODULUS VS. COST
STRENGTH VS. DENSITY
STRENGTH VS. COST
STRENGTH VS. MAXIMUM SERVICE TEMPERATURE
COST ISSUES
• Cost of materials plays a very significant role in their selection
• For example, life cycle assessment can show that reducing weight of a car by 1 kg
averages around $5, so material substitution which reduces weight of a car can
cost up to $5 per kilogram of weight reduction more than original material
• For commercial aircraft: $450/kg
• Spacecraft: $20,000/kg
• Options:
– Injection molding
– Cast aluminum/die or mold
– Wrought aluminum/stamping
– Wrought steel/stamping
EXAMPLE 2: THRUST STAND
• Continue literature survey and review of existing and hobby thrust stands
• Rework of dimensions and performance of most likely candidate rockets to be
tested
0 f t
1 2 ft
• Corrosion resistant
• Recommendation to proceed with constructing rocket thrust stand from 316L material
PARAMETRIC CASES INVESTIGATED
• Investigated Configurations:
– Triangular cross section with circular tubing:
• Benefits – Easy to manufacture; Inexpensive to make
• Disadvantages – Very heavy; Larger size; Material not readily available
2500
SS 316L - 3x3
2000
SS 316L - 2.5x2.5
Focus on 0.25 inch
1500 wall thickness design
weight (lb)
SS 316L - 2x2
1000
Al 6061 T6 - 3x3
Al 6061 T6 - 2.5x2.5
500
Al 6061 T6 - 2x2
0
0 0.2 0.4 0.6 0.8 1 1.2
thickness (in)
STRUCTURAL FRAME
• Made from 316L 3x3 inch square tube stock with
0.25 inch wall thickness
• Frame includes several cross members for rigidity
• Gusset plates for rigidity/stiffness
• Numerous mounting holes to allow for location of
forward and aft mounting braces to accommodate
rockets of any size
• Versatile and adjustable anchoring system
STRUCTURAL ANALYSIS: ANSYS WORKBENCH
• Worst case scenario:
– 150,000 lbf axial thrust, 10,000 lbf lateral thrust, 6,000 lbf-in moment
– Yield strength design criteria: all equivalent stresses less than yield strength of material
• Results
– Equivalent (von-Mises) stresses in stand structural members are below yield
– Deformations < than 0.11 inch (2.8 mm)
• October 22, 2008: Gold futures tumbled 4.3% Wednesday to the lowest level in one year, while copper
futures were set for their worst year since 1988 in a broad sell-off that was sending stocks and
commodities sharply lower. Gold for December delivery fell $32.80, or 4.3%, to end $735.20 an ounce
on the Comex division of the New York Mercantile Exchange, the lowest closing level since October,
2007. Gold has fallen nine out of the past 10 trading sessions. Meanwhile, December copper slumped
14.15 cents, or 7.1%, to $1.8655 a pound. The metal has dropped 39% so far this year, heading for the
biggest yearly percentage drop since 1988, when trading data first became available on the Nymex.
MATERIALS SELECTION ASSIGNMENT
• Part 1: Materials selection for project prototypes
– Develop a list of criteria for 4 or 5 individual components of your design
• Example criteria: corrosion resistance, weldability, strength, hardness, etc.
– Select material properties that quantify important criteria and serve as material property metrics
• Example metrics: density, cost, tensile strength, CTE, etc.
– Examine a range of candidate materials using your metrics
• Note: if you already have a material selected, such as aluminum, survey other types of
aluminum for your metric ranges and cost.
– Perform an engineering trade-off between two or three of your variables
• Example 1: trade wall thickness vs. strength vs. cost on a component
• Example 2: trade weight vs. cost vs. fabrication time
– Identify 4-5 potential vendors of your materials including actual quotes and availability
• Note: usually McMaster-Carr is most expensive
• Come up with 3-4 questions for each team that you think should be answered at this
point in the semester
– Don’t repeat questions ‘blindly’ but re-phrase them so they are more specific and
directly ask what you feel should be answered/addressed
– Write-up questions and submit by 10 am on October 27, 2008
– In lecture on October 27, 2008 I will submit collated questions to each team *before* the
final presentations – no team caught off guard
– During the week of October 27 – October 31, we meet to together and decide which
questions need to be answered/addressed
– Interweave answers to questions in final presentation
– Audience re-assesses how well these questions have now been answered