Materials Selection –

Additive Manufacturing
Case Study Bases and Mechanical
Properties
Case studies on Material Selection
 Case Study: Selection of material for Heat Sink
• A microchip may only consume milliwatts,
but the power is dissipated in a tiny volume.
The power is low but the high power density
• The Pentium chip of today’s PCs already
reaches 85oC, requiring forced cooling.
• Multiple-chip modules (MCMs) pack as many
as 130 chips on to a single substrate. Fig. A heat sink for power micro-electronics
• Heating is kept under control by attaching
the chip to a heat sink (Figure), taking pains
to ensure good thermal contact between the
chip and the sink.
• To prevent electrical coupling and stray
capacitance between chip and heat sink, the
heat sink must be a good electrical insulator,
meaning a resistivity ρe > 1019µΩcm.
• But to drain heat away from the chip as fast
as possible, it must also have the highest
possible thermal conductivity, .
Fig: The λ - ρe chart
Fig: The λ - ρe chart
Fig: The λ - ρe chart
 Case Study: Materials for overhead transmission lines

• Electrical power, today, is generated centrally

and distributed by overhead or underground
cables.
• Buried lines are costly so cheaper overhead
transmission is widely used.
• A large span is desirable because the towers
are expensive, but so too is a low electrical
resistance to minimize power losses. Fig: A transmission line
• The span of cable between two towers must
support the tension needed to limit its sag and
to tolerate wind loads.
• Consider the simple case in which the tower
spacing L is fixed at a distance that requires a
cable with a strength f of at least 80MPa (a
constraint).
• The objective then becomes that of
minimizing resistive losses, and that means
seeking materials with the lowest possible
resistivity.
Case Study: Lightest Tie rod
 Case Study: Lightest Tie rod

M= volume * density
M= ALρ
A=M/L ρ------- (1)
Stiffness= Force/Deflection
Smin greater than equal to F/δ -------(2)
σ=F/A
F=σA ------- (3)
ϵ = δ /L
δ= ϵ L --------(4)
S= F/ δ --------(5)
S= σA/ ϵ L
 Case Study: Lightest Tie rod

E= σ/ϵ; ϵ = σ/E
S= σAE/ σ L
S= AE/L --------(6)
and
A=M/L ρ
S=ME/L2 ρ --------(7)
M= (S )(L2 ) (ρ/E) --------(8)
To minimize weight (ρ/E) should be minimum
Or (E/ρ) should be maximum (Modulus of elasticity
to density ratio should be higher)
Ashby Diagrams

Materials Selection 13
Case Study: Lightest Tie rod
Case Study: Lightest Tie rod
Case Study: Lightest Tie rod
Case Study :
Materials for Oars

Materials Selection 17
Case Study : Objective • Minimize the mass
Materials for Oars Constraints • Stiffness specified
• Length L
• Circular shape (beam)
Free Variables • Area (A) of the cross-section
• Choice of the material

L (Outboard) = 2
m
Materials Selection 18
3
Ashby Diagrams

Materials Selection 20
Case Study :
m� 𝐸 1/2
ρρ
�
Materials for Light �
Oars �

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3
Case Study :
Materials for Light and Slender Oars
m� 𝐸 1/2
ρ
CFRP - best material with more control of the properties �
Bamboo – Traditional material for oars for canoes
Woods – Traditional, but with natural variabilities
Ceramics – Low toughness and high cost 10 Gpa < E < 200
GPa

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Case Study :4:
Materials for Light and Slender Oars
Oars

1,58 kg
Probably Tube shape
Assume 2,5 kg for a Solid Oar (exagerated)
CFRP (E = 110 GPa; ρ = 1550 kg/m3)
Bamboo (E = 17,5 GPa; ρ = 700 kg/m3)

SCFRP = 853,94 N/m

SBamboo = 666,1 N/m

CFRP good for Competition Oar

Materials Selection 25
 Objective • Minimize the cost
Case Study : Constraints • Stiffness specified
Materials for CHEAP and Slender • Length L
Oars • Circular shape (beam)
Free • Area (A) of the cross-
Variables section
• Choice of the material

L (Outboard) = 2
m
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Case Study :
Materials for CHEAP and Slender
Oars

1/ 2
4∙𝜋 ∙𝑆 � 4∙𝜋 ∙ 5 1/ 2
𝜌 ∙
𝑚 ∙𝐿5 3 ∙ � 𝐶 ∙
≥ 𝐸 1/2 𝑆 ∙ 𝐿3 𝐶𝐸 𝑚1 / 2
� ≥
𝐶 = 𝑚
𝑚 =��
∙𝐶 𝑚 𝐶
�

𝑪 Cost m 𝐸 1/2
𝑪 𝒎 Cost per unit of 𝜌
� �
mass ∙𝐶 �
�
Better to consider cost
always as a function of mass

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Case Study :
Materials for CHEAP and Slender 𝐸 1/2
Oars
m 𝜌 �
Bamboo – Traditional material for oars for canoes �
∙𝐶 �
Woods – Traditional, but with natural variabilities �
Stone and Concrete – Low toughness and difficult to manufacture
10 Gpa < E < 200
GPa

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Case Study :
Materials for CHEAP and Slender
Oars

1/ 2
4∙𝜋 ∙𝑆 � 4∙𝜋 ∙ 5 1/ 2
𝑚 ∙ � 𝐶 ∙𝜌 ∙𝐶 𝑚
∙𝐿5 3 1/2 𝑆 ∙ 𝐿3 𝐸 1/2
≥ 𝐸
≥
𝐶 = 𝑚 �
𝑚
∙𝐶 𝑚
= 𝐶� 𝑚

𝑪 Cost 𝐸 1/2
𝑪 Cost per unit of m
𝒎 𝜌 �
�
mass ∙𝐶 �
�
Better to consider cost
always as a function of mass
Woods good for Commercial Oar

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 Case Study :
Materials for Car
Body
𝑆 𝑜 𝑚 𝑒 𝑐 𝑜 𝑛 𝑡 𝑒 𝑥 𝑡 → Car Evolution

1932 Ford Model

B

1934 Bonnie and Clyde

car
Thursday, October 4, 2018 30
 Case Study :
Materials for Car
Body
𝑆 𝑜 𝑚 𝑒 𝑐 𝑜 𝑛 𝑡 𝑒 𝑥 𝑡 → Car Evolution

1932 Ford Model 1970 Buick 2010 Ferrari 458 Italia

B GSX

Km/
h 325 km/h

184 km/h

80
km/h

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 Case Study :
Materials for Car
Body
𝐷 𝑒 𝑓 𝑜 𝑟 𝑚 𝑎 𝑡 𝑖 𝑜 𝑛 ? ?→𝐸 𝑁 𝐸 𝑅 𝐺 𝑌
𝐶 𝑂 𝑁 𝑆 𝑈 𝑀 𝑃 𝑇 𝐼 𝑂 𝑁

At first, automotive industry move to

too deformable cars and then move to
have a mix FOR PEOPLE SAFETY

Sometimes exaggerate
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 Objective • Maximize plastic deformation at high
Case Study : Materials load
for Car Body (Car Constraints • Geometry
Hood or Car Door) • 𝐻 𝑖 𝑔 ℎ 𝜎 𝑦
• Division for price
• Consider manufacture
Free Variables • Choice of the material

𝐿 𝐼 𝐺 𝐻 𝑇 ? ?→𝑚

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 Objective • Maximize plastic deformation at high
Case Study : Materials load
for Car Body (Car Hood Constraints • Geometry
or Car Door) • 𝐻 𝑖 𝑔 ℎ 𝜎 𝑦
• Division for price
𝐿 𝐼 𝐺 𝐻 𝑇 ? ? • Consider manufacture
→𝑚
Free Variables • Choice of the material

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 E
Case Study : Materials for Car m ρ
Body (Car Hood or Car Door) � �
� �
�
�

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Case Study : Materials
for Car Body (Car
Hood or Car Door)

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 E
m ρ
Case Study 12: �
Materials for Car Body �
� � + 𝑚 𝑖 𝑛 𝑖 𝑚 𝑢 𝑚
(Car Hood or Car
� 𝜎 𝑦 (200 MPa)
Door)
�

37
Case Study : Materials
for Car Body (Car
Hood or Car Door)

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Case Study : Materials
for Car Body (Car
Hood or Car Door)

39
Case Study : Materials
for Car Body (Car
Hood or Car Door)

Lamborghini Huracan 2015

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Case Study : Materials
for Car Body (Car
Hood or Car Door)
Manufacturing Consideration

[www.digitaltrends.com/cars/lamborghini-forged-carbon-fiber-manufacturing-process]
Thursday, October 4, 2018 Materials Selection 41
 Vacuum and pressure bag
Case Study : Materials
for Car Body (Car
Hood or Car Door)
molding

Not adapt for high productions

No way for a
commercial car
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Case Study 12:
Materials for Car Body And which Metal?
(Car Hood or Car
Door)

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 Stamping
Case Study : Materials
for Car Body (Car
Hood or Car Door)

Adapt for high productions

Thursday, October 4, 2018 Materials Selection 44

 PROCESSABILITY
Case Study : Materials
for Car Body (Car
Hood or Car Door) Metals easy to stamp

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Case Study : Materials
for Car Body (Car
Hood or Car Door)

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 PROCESSABILITY
Case Study : Materials
for Car Body (Car Metals easy to stamp
Hood or Car Door)

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Case Study 12:
Materials for Car Body
(Car Hood or Car
Door)

Thursday, October 4, 2018 Materials Selection 48

Case Study : Materials
for Car Body (Car
Hood or Car Door)

BMW M3 – Low alloy steel

Audi A8 – Al-alloys

Deeper selection?

LEVEL 3

[https://www.cartalk.com/blogs/jim-motavalli/steel-vs-aluminum-lightweight-wars-heat]
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Materials Selection Steps

Optional:

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