Lecture 1

MAT602 /
MTRM011
Course
Introduction
James Busfield

MAT 602 - Materials Selection in Design

This course considers design and how design is
related to:
Metals,
ceramics, glasses

Materials Selection,

Manufacturing (including volume),

Engineering,

Design Constraints,

Costs, and

the Customer.

MATERIALS
polymers
composites...

Casting ,
moulding

PROCESSES
powder methods,
machining...

Flat and dished

sheet

SHAPES

Understanding simultaneous engineering

prismatic,
3-D

or Ensuring students realise that in design, the selection of

material and the choice of manufacturing routes are interrelated.

MAT 602 - The Team

Course Organiser:

James Busfield
j.busfield@qmul.ac.uk
Guest Lecturers planned for 2016 include:

Dr Andy Lewis, BTG

Gavin Jackson, Henkel
Francesco Battocchio, Schlumberger
Dr Carolyn Small, Alcoa
Dr Chris Stevens, NGF Europe
Prof Allan Ritchie, DePuy

MAT 602 - Materials Selection in Design

Lecture Notes

A complete PDF version of the lecture notes will

be uploaded to QMPlus prior to every lecture
given by me and after every lecture delivered by
visiting lecturers.

MAT 602 - Materials Selection in Design

QReview

Every lecture will be recorded and will be

available to view using QReview.

MAT 602 - Materials Selection in Design

Online Forums

Online forums were first created by me for

use with MAT602.

MAT 602 - Materials Selection in Design

Course Organisation

Teaching

Lectures: 26 hours

Computer Classes: 4 hours

Group Presentations: 6 hours

Review sessions: 6 hours

Assessment

1 examination paper

77%

(multiple choice, completion answers, and long answers)

1 case study with a group presentation and report

14%

Computer laboratory exercises

9%
MAT 602 - Materials Selection in Design

Timetable

MAT 602 - Materials Selection in Design

Materials World

Metals

Polymers

Composites

Ceramics

Natural Materials

Foams

Elastomers, and

Glasses

1
Steels
Cast irons
Al-alloys

Metals
Cu-alloys
Ni-alloys
Ti-alloys

PE, PP, PC
PA (Nylon)

Alumina
Si-Carbide

Ceramics,
glasses
Soda-glass
Pyrex

Butyl rubber
Neoprene

Composites

Polymer foams
Metal foams

Foams

GFRP
CFRP

Polymers,
elastomers

Ceramic foams
Glass foams

KFRP
Plywood

Woods

Natural
materials
Natural fibres:
Hemp, Flax,
Cotton

MAT 602 - Materials Selection in Design

Types of Materials

Metals:

Strong, ductile

High thermal & electrical conductivity

Opaque, reflective.

Polymers/plastics: Covalent bonding sharing of

electrons

Soft, ductile, low strength, low density

Thermal & electrical insulators

Optically translucent or transparent.

Ceramics: ionic bonding (refractory) compounds of

metallic & non-metallic elements (oxides, carbides,
nitrides, sulfides)

Brittle, glassy, elastic

Non-conducting (insulators)

MAT 602 - Materials Selection in Design

Materials Selection

Review of relative properties of the basic material categories

MAT 602 - Materials Selection in Design

Basic material properties

Mechanical properties

1
Thermal expansion

General
Density , Mg/m3

Expense:

Cost/kg Cm, $/kg

Ductile materials

Stiffness:

Youngs modulus E, GPa

Elastic limit, y

Strength:

Elastic limit y , MPa

Fracture strength: Tensile strength ts , MPa

Youngs modulus, E

Stress

Strain

Brittle materials

Expansion: Expansion coeff. , 1/K

Tensile (fracture)

Conduction: Thermal conductivity , W/m.K

strength, ts

Youngs
modulus, E
Strain

Electrical
Conductor? Insulator?

Expansion
coefficient,
Temperature, T

Thermal conduction
x

Brittleness: Fracture toughness Kic , MPa.m1/2

Thermal

T1

To

Area A

Q joules/sec

Heat flux, Q/A

Stress

Mechanical

Thermal strain

Weight:

Thermal
conductivity,
(T1 -T0)/x

MAT 602 - Materials Selection in Design

Mechanical properties illustrated

Stiff
Strong
Tough
Light

All OK !

Not stiff enough (need bigger E)

Not strong enough (need bigger y )

Not tough enough (need bigger Kic)

Too heavy (need lower )

MAT 602 - Materials Selection in Design

Materials Selection

Review of materials
selection for structures
using design charts
and Ashby Diagrams.

Investigate the impact

of design and
manufacturing process
selection on materials
choice using
performance indices.

MAT 602 - Materials Selection in Design

Manufacturing

Overview of general materials manufacturing routes

applied to any material:

forming,

machining,

casting,

moulding,

fabrication, and

to materials in general.

Example Process - Die Casting

MAT 602 - Materials Selection in Design

Structure, Processing, & Properties

Properties depend on structure

ex: hardness vs structure of steel

(d)

Hardness (BHN)

6 00
5 00
4 00

(c)
(a)

(b)
4 mm

3 00
2 00

30 mm

30 mm

100
0.01 0.1

30 mm

1
10 100 1000
Cooling Rate (C/s)

Processing can change structure

ex: structure vs cooling rate of steel

MAT 602 - Materials Selection in Design

New material options

Often

a new product or the evolution of the

existing one, was suggested or made possible
by a new material.

The

number of engineering materials

available to the engineer is huge:

Approximately 100,000 are at their disposal.

Standardisation strives to reduce the number.

The continuing appearance of new materials with

novel, exploitable, properties expands the choice
further.
MAT 602 - Materials Selection in Design

Materials information for design

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.
Statistical
analysis

Data
capture

Selection of
material and process

Economic analysis
and business case

Mechanical Properties
Bulk Modulus
Compressive Strength
Ductility
Elastic Limit
Endurance Limit
Fracture Toughness
Hardness
Loss Coefficient
Modulus of Rupture
Poisson's Ratio
Shear Modulus
Tensile Strength
Young's Modulus

Test

Test data

Characterisation

4.1 55 0.06 40 24 2.3 100 0.00950 0.38 0.85 45 2.5 -

4.6 GPa
60 MPa
0.07
45 MPa
27 MPa
2.6 MPa.m1/2
140 MPa
0.026
55 MPa
0.42
0.95 GPa
48 MPa
2.8 GPa

Design data

Potential
applications

Successful
applications

Selection and implementation

MAT 602 - Materials Selection in Design

The nature of material data

Numeric: properties

measured by numbers:
density, modulus, cost
other properties

Can extrude?

Design
guide
lines

Good or bad
in sea water?

Non-numeric: properties measured by

Case
studies

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

Failure
analyses

Supporting information, specific:

what is the experience with the material?

Established
applications

Supporting information, general:

what else do you need to know?

Structured and Unstructured data

Handbooks,
data sheets

Supplier
information

FE modules

Standards
and codes
(ISO 14000)

Sector-specific
approval
(FDA, MilSpec)

Reports, papers,
the Web

MAT 602 - Materials Selection in Design

Structured data for ABS

Acrylonitrile-butadiene-styrene (ABS) - (CH2-CH-C6H4)n

General Properties
Density 1.05-1.07 Mg/m3
Price
2.1- 2.3 US $/kg
Mechanical Properties
Young's Modulus
1.1-2.9 GPa
Elastic Limit
18-50 MPa
Tensile Strength
27-55 MPa
Elongation
6-8%
Hardness - Vickers 6-15 HV
Endurance Limit
11-22 MPa
Fracture Toughness 1.2-4.2 MPa.m1/2
Thermal Properties
Max Service Temp 350 - 370 K
Thermal Expansion 70-75 x 10-6 /K
Specific Heat
1500
-1510 J/kg.K
Thermal Conductivity 0.17
- 0.24 W/m.K

Electrical Properties
Conductor or insulator?

Good insulator

Optical Properties
Transparent or opaque?

Opaque

Corrosion and Wear Resistance

Flammability
Fresh Water
Organic Solvents
Oxidation at 500C
Sea Water
Strong Acid
Strong Alkalis
UV
Wear
Weak Acid
Weak Alkalis

Average
Good
Average
Very Poor
Good
Good
Good
Good
Poor
Good
Good

MAT 602 - Materials Selection in Design

Unstructured data for ABS

What is it? ABS (Acrylonitrile-butadiene-styrene ) is tough, resilient, and easily

moulded. It is usually opaque, although some grades can now be transparent, and it
can be given vivid colours. ABS-PVC alloys are tougher than standard ABS and, in
self-extinguishing grades, are used for the casings of power tools.

Design guidelines. ABS has the highest impact resistance of all polymers. It takes
colour well. Integral metallics are possible (as in GE Plastics' Magix.) ABS is UV
resistant for outdoor application if stabilizers are added. It is hygroscopic (may need
to be oven dried before thermoforming) and can be damaged by petroleum-based
machining oils.
ABS can be extruded, compression moulded or formed to sheet that is then vacuum
thermo-formed. It can be joined by ultrasonic or hot-plate welding, or bonded with
polyester, epoxy, isocyanate or nitrile-phenolic adhesives.

Technical notes. ABS is a terpolymer - one made by copolymerising 3 monomers: acrylonitrile, butadiene and styrene. The

acrylonitrile gives thermal and chemical resistance, rubber-like butadiene gives ductility and strength, the styrene gives a glossy
surface, ease of machining and a lower cost. In ASA, the butadiene component (which gives poor UV resistance) is replaced by
an acrylic ester. Without the addition of butyl, ABS becomes, SAN - a similar material with lower impact resistance or toughness.
It is the stiffest of the thermoplastics and has excellent resistance to acids, alkalis, salts and many solvents.

Typical Uses. Safety helmets; camper tops; automotive instrument panels and other interior components; pipe fittings; home-

security devices and housings for small appliances; communications equipment; business machines; plumbing hardware;
automobile grilles; wheel covers; mirror housings; refrigerator liners; luggage shells; tote trays; mower shrouds; boat hulls; large
components for recreational vehicles; weather seals; glass beading; refrigerator breaker strips; conduit; pipe for drain-waste-vent
(DWV) systems.

The environment. The acrylonitrile monomer is nasty stuff, almost as poisonous as cyanide. Once polymerized with styrene it
becomes harmless. ABS is FDA compliant, can be recycled, and can be incinerated to recover the energy it contains.

MAT 602 - Materials Selection in Design

Case Studies

Six different case studies are considered each year.

A short 15 minute introductory lecture is given on each.

Students examine one case study in detail in a group.

Help is provided throughout using the module forum.

Five groups for each study will then prepare a short report which
outlines a suitable material and processing technique for the
part.

Each group also prepares an 8 minute presentation to explain

their choice of material and processing route.

After the presentation the visiting lecturer will offer feedback on

the options that you have presented and they will also outline
their current preferred solution to the problem.

MAT 602 - Materials Selection in Design

Case Studies used in 2015

Andy Lewis,
Biocompatibles
Keval Dattani,
RollsRoyce
Jakub Jerabek,
Schlumberger
Gerard Ward, Ford
Gavin Jackson,
Henkel
Allan Ritchie, ex
DePuy

Image-guided Transarterial Locoregional Cancer Therapy.

The fissile material in a small pressurised nuclear reactor

is uranium but what form of the material offers the highest
power output from the core and why?
Recovery of the metal inserts and the remanufacture of
steerable positive displacement motors for oil exploration.
Design a palliative kit to improve the NVH between a
diesel engine and the automatic transmission.
Life extension of steel pipes used within oil and gas
installations using adhesives.
Resorbable small finger bone fracture fixation devices.

MAT 602 - Materials Selection in Design

Case Studies used in 2015

Andy Lewis,
Biocompatibles
Keval Dattani,
RollsRoyce
Jakub Jerabek,
Schlumberger
Gerard Ward, Ford
Gavin Jackson,
Henkel
Allan Ritchie, ex
DePuy

Image-guided Transarterial Locoregional Cancer Therapy.

The fissile material in a small pressurised nuclear reactor

is uranium but what form of the material offers the highest
power output from the core and why?
Recovery of the metal inserts and the remanufacture of
steerable positive displacement motors for oil exploration.
Design a palliative kit to improve the NVH between a
diesel engine and the automatic transmission.
Life extension of steel pipes used within oil and gas
installations using adhesives.
Resorbable small finger bone fracture fixation devices.

MAT 602 - Materials Selection in Design

Case Studies used in 2015

Andy Lewis,
Biocompatibles
Keval Dattani,
RollsRoyce
Jakub Jerabek,
Schlumberger
Gerard Ward, Ford
Gavin Jackson,
Henkel
Allan Ritchie, ex
DePuy

Image-guided Transarterial Locoregional Cancer Therapy.

The fissile material in a small pressurised nuclear reactor

is uranium but what form of the material offers the highest
power output from the core and why?
Recovery of the metal inserts and the remanufacture of
steerable positive displacement motors for oil exploration.
Design a palliative kit to improve the NVH between a
diesel engine and the automatic transmission.
Life extension of steel pipes used within oil and gas
installations using adhesives.
Resorbable small finger bone fracture fixation devices.

MAT 602 - Materials Selection in Design

Case Studies in 2016

Andy Lewis, BTG
Gavin Jackson, Henkel
Francesco Battocchio,
Schlumberger
Carolyn Small, Alcoa
Chris Stevens, NGF
Europe
Allan Ritchie, ex DePuy

Design of a novel temporary metallic

coronary stent
Design of competition level off road
bicycle front forks
Drilling tools for cutting rock, cement and
steel
Manufacturing of the tooling for injection
moulding a car dashboard
Lightweight, creep resistant and stiff
timing belts for automotive applications
Design of a trochanteric nail for femoral
fracture fixation

MAT 602 - Materials Selection in Design

Examination and other assessment

The

examination will contain 3 sections (an

example is given at the end of the booklet):
Multiple Choice (25%)
Completion Answers (25%)
Long examination answers (50%)

The

long answer examination questions will

be based upon the case studies.

Each

student should make comprehensive

notes and write up each case study in
preparation for the exam.
MAT 602 - Materials Selection in Design

Recommended text books

Resources:

Materials Selection in Mechanical Design, by M.F.

Ashby

Cambridge Material Selector (CES) software Granta Design, Cambridge (Available to download
from QMPlus)
The

MAT 602 - Materials Selection in Design

No single correct solution

Design problems are almost always open-ended.

They do not have a unique or "correct" solution,

though some solutions are better than others.

They differ from the analytical problems used in

teaching mechanics, or structures, or
thermodynamics, or even materials, which generally
do have single, correct answers.

So the first tool a designer needs is an open mind: the

willingness to consider all possibilities.

MAT 602 - Materials Selection in Design