Materials Selection in Design

The Role of Materials Selection in Design Exploring relationships - Materials Property Charts The Materials Selection Process Design Models Selecting materials Materials Indices Case Studies of Materials Selection using CES

The Role of Materials Selection in Design

The Role of Materials Selection in Design

Materials selection is a central aspect of design In many cases materials represent the enabling step Number of available materials exceeds 100,000 Concurrent engineering has re-emphasized the role of materials.

Why Materials Selection?Materials selection is design-led Factors/Criteria?

New products. Remain competitive Properties of new materials can suggest new products (optical fiber high purity glass).

Function Mechanical Properties Failure Mode

Manufacturability Cost

Optical Fiber

Environmental Considerations

The need for a new product can stimulate the development of a new material

Increase in operational temperature of turbine components. After Schulz et al, Aero. Sci. Techn.7:2003, p73-80. Y-PSZ (Ytria - Partially Stabilized Zirconia)

Some Material Properties

Physical Density Melting point Vapor pressure Viscosity Porosity Permeability Reflectivity Transparency Optical properties Dimensional stability Chemical Corrosion Oxidation Thermal stability Biological stability Stress Corrosion . Electrical Conductivity Dielectric coonstant Coersive force Hysteresis Thermal Conductivity Specific Heat Thermal expansion Emissivity Mechanical Hardness Elastic constants Yield strength Ultimate strength Fatigue Fracture Toughness Creep Damping Wear resistance Spalling Ballistic performance .

The goal of design: To create products that perform their function effectively, safely, at acceptable cost.. What do we need to know about materials to do this? More than just test data.

http://www.matweb.com/

Materials Data - Organization

The set of properties for a particular material is called the material attributes, which includes both structured and non-structured information on the material materials selection involves seeking the best match between the design requirements and the materials attributes.

Interactions
Process

Shape

Material

Functionality

Materials Selection Methodology

Translate the design requirements into materials specifications. It should take into consideration the design objectives, constraints and free variables. Screening out of materials that fail the design constraints. Ranking the materials by their ability to meet the objectives. (Material Indices). Search for supporting information for the material candidates.

1. Defining the Design requirements

Function
"What does component do?"

Objective

Constraint

"What is to be maximized "What specific requirements or minimized?" must be met?"

Any engineering component has one or more functions (to support a load, to contain a pressure, to transmit heat, etc.).

The designer has an objective (to make it as cheap as possible, or as light as possible, or as safe as possible or some combination of these).

The objective must be achieved subject to constraints (e.g. the dimensions are fixed; the component must carry the given load without failure, it should function in a certain temperature range, etc.

Free variables: What is the designer free to change?

2. List the constraints (e.g. no buckling, high stiffness) of the problem and develop an equation for them, if possible. 3. Develop an equation of the design objective in terms of functional requirements, geometry and materials properties (objective function). 4. Define the unconstrained (free) variables. 5. Substitute the free variable from the constraint equation into the objective function. 6. Group the variables into three groups, functional requirements (F), geometry (G) and materials functions (M), to develop the performance metric (P):

7. Read off the materials index, M, in order to maximize the performance metric (P).

Materials Selection Charts

The performance metric of a design is limited by the materials. Performance metric is a function of multiple properties f(multiple properties) Charts Property 1 versus Property 2 (P1 vs P2) It can be plotted for classes and subclasses of materials (Classes: metals, ceramics, polymers, composites) (Sub-Classes: engineering ceramics, porous ceramics etc.) Combinations of properties are important in evaluating usefulness of materials. Strength to Weight Ratio: f/ Stiffness to Weight Ratio: E/ The properties have ranges E(Cu) = few % (purity, texture, etc.) Strength of Al2O3 can vary by a factor of 100 due to (porosity, grain size, heat treatment, etc.)

Modulus vs density
Density depends on
Atomic weight Atom size Packing Porosity

Speed of Sound in a solid,

v=

(E )

Elastic modulus depends on:

Bond stiffness # bonds per unit area. Which one to choose? Depends on the Performance Metrics

Material Indices
Material Indices (MI) are groups of material properties (including cost) which are useful metrics for comparison of materials Better materials have higher MIs The form of the MI depends on the functional requirements (F) and geometry (G).

Materials Indices
Materials indices are specific functions derived from design equations that involve only materials properties that can be used in conjunction with materials selection charts e.g. strong, light tie rod in tensionminimize /y e.g. stiff, light beam in bending minimize /E1/2 e.g. stiff, light panel in bending -minimize /E1/3

Derivation of MIs
The derivation of the MI will be illustrated by examples:

Example 1: Strong and light tie-rod Function Objective Constraints Tie-rod Minimize mass

m = AL
F y A

The length (L) is specified Must not fail under load Must have adequate fracture toughness

Free Variables

Materials choice Section Area (A) eliminate using above equations Minimize mass , hence, choose materials with smallest

m = AL = FL y

Example 2: Stiff and light beam Function Objective Constraints Beam of solid square section Minimize mass

m = b L
2

The beam must be stiff, i.e. small deflection (C is CEI C1 Eb 4 Stiffness _ S = 3 = a constant) L L3

Max

FL3 = 48 EI

F = ( Stiffness ) Max

Free Variables Materials choice Dimension b eliminate using above equations

SL SL m= C E L = C 1 1
3 5

1 2

1 2 E

Minimize mass , choose materials with smallest

E
1 2

Example 3: Stiff, light panel Panel with given Function width (w) and length (L) Objective Minimize mass Constraints

The panel must be stiff, i.e. small deflection (C is a constant)

m = twL t = thickness F = ( Stiffness ) Max

CEwt Stiffness _ S = L3
3

Materials choice Free Variables Dimension t eliminate using above equations

SL SL w m= CEw wL = C
3 6

1 3

1 3 E

Minimize mass , choose materials with smallest

E
1 3

Derivation of MIs: Methodology

Demystifying Material Indices

Using Materials Indices with Materials Selection Charts

Commonly used Materials Indices (MIs)

The nature of material data

Numeric:
Can extrude? Good or bad in sea water? Design guide lines Supplier information

properties measured by numbers: density, modulus, cost other properties

Non-numeric: properties measured by

yes - no (Boolean) or poor-average-good type (Rankings)

Case studies

FE modules

Failure analyses Standards and codes (ISO 14000)

Supporting information, specific: what is the experience with the

material?

Established applications

Supporting information, general: what else do you need to know?

Sector-specific approval (FDA, MilSpec)

Structured and Unstructured data

Handbooks, data sheets Reports, papers, the Web

Other Materials Selection Charts

Modulus-Relative Cost Strength-Relative Cost Modulus-Strength Specific Modulus-Specific Strength Fracture ToughnessModulus Fracture ToughnessStrength Loss Coefficient-Modulus Facture Toughness-Density Conductivity-Diffusivity Expansion-Conductivity Expansion-Modulus Strength-Expansion Strength Temperature Wear Rate-Hardness Environmental Attack Chart

Summary: Material Indices

A method is necessary for translating design requirements into a prescription for a material Modulus-Density charts Reveal a method of using lines of constant

E1 n

n = 1, 2,3

to allow selection of materials for minimum weight and deflection-limited design. Material Index Combination of material properties which characterize performance in a given application. Performance of a material: Functional Geometeric Material p = f Characteristics, M , Parameters, G , Needs, F

p = f1 ( F ) f 2 (G ) f 3 ( M )

Case 1: Materials for Table legs Design a slender, light table legs that will support the applied design load and will not fracture if struck. Column, supporting compressive loads.
Function

Objective Constraints

Minimize mass and maximize slenderness Specified length, Must not buckle Must not fracture if struck Diameter of the legs Choice of materials

mass: Maximum elastic buckling load:

Solving for r

Free Variables

The weight is minimized by selecting materials with the greatest value of the materials index:

Inverting equation (2) gives and equation for the thinnest legs which will not buckle: to yield the second materials index (maximize):
Set M1to be minimum of 5 and M2to be greater than 100 (an arbitrary choice it can be modified later if a wider choice of materials to be screened is desired). Candidate materials include some ceramics, CFRP engineering ceramics are not tough legs are subjected to abuse and this makes them a bad selection for this application Selection = CFRP must consult designer wrt cost -expensive

Case 2: Materials for Flywheels Flywheels are rotating devices that store rotational energy in applications such as automotive transmissions. An efficient flywheel stores maximum energy per unit volume/mass at a specified angular velocity. The kinetic energy the device can the device can store is limited store is limited by the material by the material strength.
Function Objective

Flywheel for energy storage.

Maximize kinetic energy per unit mass. Mass of the disc 1 2 Kinetic energy (J is the mass moment of KE = Jw 2 inertia) 1 1 For a solid round disc J J = mR 2 KE = mR 2 w2 around its rotation axis 2 4

The quantity to be maximized is the energy per unit mass

Constraints

KE 1 2 2 = R w m 4

The outer radius is fixed. It must not burst. It must have adequate toughness (crack tolerance) Choice of materials

Free Variables

The maximum radial stress (principal stress) is given by the equation: The stress must not exceed the yield stress: Hence, the material index to maximize is:

r , Max

2 2 3 + R 2 2 = R 8 2

KE 1 y = m 2

y M=

The choices are some composites (CFRP), some engineering ceramics and high strength Ti and Al alloys engineering ceramics eliminated due to lack of toughness further selection must be made on the basis of cost and energy storage capacity for specific materials e.g. CFRP can store 400kJ/kg

Case 3: Materials for Passive Solar Heating A simple way of storing solar energy for residential heating is by heating the walls during the day and transferring heat to the interior via forced convection at night. Need to diffuse heat from the outer to inner surface in 12h. For architectural reasons, the wall thickness (W) cannot exceed 0.5m Heat storage medium Maximize thermal energy storage per unit material cost. Objective Heat diffusion time through wall time (t) ~12h Constraints Wall thickness w<0.5m Working temperature TMax ~ 100oC Free Variables Wall thickness w. Choice of materials What material will maximize the thermal energy captured by the wall while retaining the required heat diffusion time of up to 12h?
Function

For a wall of thickness w, the heat (Q) per unit area of wall heated through T is given by: For the heat diffusion distance in time t: where is the thermal diffusivity, is the thermal conductivity and is the density

Q = wc p T
w = 2 Dt
D= c p

Q = 2t c p D T = 2t T D
1 2

The heat capacity of the wall is maximized by choosing a material with a high value of: The restriction on the wall thickness (w) and diffusion time (t) yield the constraint: 2

w 6 m 2 D 3 10 s 2t

Cost must be a significant consideration in this selection because the application is for housing, where cost is always a significant factor. Taking cost into consideration, the most likely choice is concrete, with stone and brick as alternatives.

Literature Resources
M.F. Ashby, Materials Selection in Mechanical Design, 2ndEd. multiple sources listed in appendices of the book materials selection charts in lecture Appendix Other references : ASM Metals Handbook Perrys Chemical Engineering Handbook CRC Handbook of Mathematics and Physics ASM Handbook of Ceramics and Composites