Lecture 1

MAT602 /
MTRM011

Materials Selection
in Design
Introduction

Prof James Busfield

MAT 602 / MTRM011 - Materials Selection in Design

This course considers design and how design is

related to: Metals,
ceramics, glasses
 Materials Selection
MATERIALS
 Manufacturing polymers
composites...
 Engineering Casting ,
moulding
 Design Constraints PROCESSES
powder methods,
 Costs machining...
 the Customer
Flat and dished
sheet
SHAPES
Which means: prismatic,
3-D

Understanding simultaneous engineering or Ensuring students

realise that in design, the selection of material and the choice of
manufacturing routes are interrelated.
MAT 602 / MTRM011 - The Team

Course Organiser:
James Busfield - j.busfield@qmul.ac.uk
Guest Lecturers planned for 2020 already
include:

 Andy Lewis, Boston Scientific

 Sarah Chapman, 3M
 Anna Staunton, NSG
 Ana Gallego, Blatchford Group
 Keizo Akutagawa, Racing Point F1
 Andrew Osborne, Port of London Authority

MAT 602 - Materials Selection in Design

 Course Organisation

Check
out QM+

MAT 602 - Materials Selection in Design

 Course Organisation

 There are something like 40 hours of lectures

associated with this course.
 About half of which will be delivered like a normal
lecture. For now these will be done live to all ~250
students on line using scheduled collaborate links in
QM+.
 In weeks 1 & 2 there are 4 hours of traditional live
lectures scheduled each week.
 The rest of the lectures are recorded and can be
watched in your own time.
 From the third week of term, the Monday 1pm lecture
will tell you each week what additional lectures you
should watch that week. MAT 602 - Materials Selection in Design
The schedule for the first two weeks

MAT 602 - Materials Selection in Design

The schedule for weeks 3 - 7

All
Group A

Group B
Group C

MAT 602 - Materials Selection in Design

 Course Organisation

Check
out QM+

MAT 602 - Materials Selection in Design

 Course Organisation

 I plan to record every lecture and you should be able

to play them back using the QM+ collaborate links.
 From week 3 we will start asynchronous self study
activities. These will have tutorial support and there
will be QM+ quizzes set every week from week 3 to
week 8.
 Four of these assessments are formative.
 Two of these assessments will be summative, with
each counting 15% to your overall course mark.

MAT 602 - Materials Selection in Design

 Online Forums

Online forums were first developed for use with this

module

MAT 602 - Materials Selection in Design

 Course Organisation
Teaching
 Lectures: ~18 hours live & ~18 hours recorded
 Computer Classes: ~6 hours
 Group Presentations: ~7 hours Review sessions: ~7 hours
Assessment
 1 examination paper (the format may be different this year) 40%
(combination of multiple choice & completion / short answers)
 Peer reviewed group case study with presentation and report 30%
 QM+ Introductory Quiz (about week 4) 15%
 QM+ Extending Quiz (about week 8) 15%

MAT 602 - Materials Selection in Design

 Materials World

 Metals Steels
Cast irons
Al-alloys

 Polymers Metals
Cu-alloys
Ni-alloys
 Composites Ti-alloys
PE, PP, PC

Ceramics
Alumina PA (Nylon)
 Si-Carbide
Polymers,
Ceramics,
 Natural Materials GFRP elastomers
glasses CFRP Butyl rubber
Soda-glass Neoprene
Composites
 Foams Pyrex
KFRP
Plywood

 Elastomers, and
Polymer foams Woods
 Glasses Metal foams
Natural
Foams materials
Ceramic foams
Natural fibres:
Glass foams Hemp, Flax,
Cotton

MAT 602 - Materials Selection in Design

 Types of Materials
 Metals:
 Strong, ductile
 High thermal & electrical conductivity
 Opaque, reflective.
 Polymers: 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 Thermal expansion

General
o
Weight: Density , Mg/m3

Thermal strain 

Expense: Cost/kg Cm, $/kg
Expansion
Mechanical coefficient, 
Ductile materials Stiffness: Young’s modulus E, GPa Temperature, T
Elastic limit, y Strength: Elastic limit y , MPa
Stress 

Thermal conduction
Fracture strength: Tensile strength ts , MPa x
Brittleness: Fracture toughness Kic , MPa.m1/2 To
Young’s modulus, E T1
Strain  Area A Q joules/sec
Thermal
Brittle materials Expansion: Expansion coeff. , 1/K

Heat flux, Q/A

 Tensile (fracture) Conduction: Thermal conductivity , W/m.K
Stress 

strength,  ts

 Thermal
Electrical conductivity, 
Young’s
modulus, E Conductor? Insulator?
(T1 -T0)/x
Strain 
MAT 602 - Materials Selection in Design
Mechanical properties illustrated
Stiff
Strong All OK !
Tough
Light

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)
600
Hardness (BHN)

30 mm
500 (c)
400 (b)
(a)
4 mm
300
30 mm
200 30 mm

100
0.01 0.1 1 10 100 1000
Cooling Rate (ºC/s)
• Processing can change structure
For example - 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.

Data Statistical Selection of Economic analysis

capture analysis material and process and business case

Mechanical Properties
Bulk Modulus 4.1 - 4.6 GPa

$
Compressive Strength 55 - 60 MPa
Ductility 0.06 - 0.07
Elastic Limit 40 - 45 MPa
Endurance Limit 24 - 27 MPa
Fracture Toughness 2.3 - 2.6 MPa.m1/2
Hardness 100 - 140 MPa
Loss Coefficient 0.009- 0.026
Modulus of Rupture 50 - 55 MPa
Poisson's Ratio 0.38 - 0.42
Shear Modulus 0.85 - 0.95 GPa
Tensile Strength 45 - 48 MPa
Young's Modulus 2.5 - 2.8 GPa

Test Test data Design data Potential Successful

applications applications

Characterisation Selection and implementation

MAT 602 - Materials Selection in Design

 The nature of material data
 Numeric: properties
measured by numbers:
Can extrude?
density, modulus, cost Design
…other properties guide
Good or bad Supplier
lines
in sea water? information

 Non-numeric: properties measured by Case

studies FE modules
yes - no (Boolean) or
poor-average-good type (Rankings)
Failure
analyses
Standards
 Supporting information, specific: and codes
what is the experience with the material? (ISO 14000)
Established
applications

Sector-specific
 Supporting information, general: approval
what else do you need to know? (FDA, MilSpec)

“Structured” and “Unstructured” data

Reports, papers,
Handbooks, the Web
data sheets
MAT 602 - Materials Selection in Design
 Structured data for ABS
Acrylonitrile-butadiene-styrene (ABS) - (CH2-CH-C6H4)n

General Properties •Electrical Properties

Density 1.05-1.07 Mg/m3 Conductor or insulator? Good insulator
Price 2.1- 2.3 US $/kg
•Optical Properties
Mechanical Properties Transparent or opaque? Opaque
Young's Modulus 1.1-2.9 GPa
•Corrosion and Wear Resistance
Elastic Limit 18-50 MPa
Flammability Average
Tensile Strength 27-55 MPa
Fresh Water Good
Elongation 6-8%
Organic Solvents Average
Hardness - Vickers 6-15 HV
Oxidation at 500C Very Poor
Endurance Limit 11-22 MPa
Sea Water Good
Fracture Toughness 1.2-4.2 MPa.m1/2
Strong Acid Good
Thermal Properties Strong Alkalis Good
Max Service Temp 350 - 370 K UV Good
Thermal Expansion 70-75 x 10-6 /K Wear Poor
Specific Heat 1500 -1510 J/kg.K Weak Acid Good
Thermal Conductivity 0.17 - 0.24 W/m.K Weak Alkalis 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 or seven different industry led group case studies will be set
this year
 A short introductory lecture is given on each, starting next week
 Students examine one case study in detail in a team of 6 or 7
 Help is provided throughout using the module forum
 Five or six teams for each study will then prepare a short report
which outlines a suitable material and processing technique for
the part
 Each group also prepares a short live presentation to explain
their choice of material and processing route
 After the presentation visiting lecturers 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

 Example Case Studies from 2019

Thomas Poon
Ferritic to Austenitic Stainless Transition Welding
Rolls Royce
Andy Lewis
Minimally-invasive Ablation Device to Treat Tumours
Boston Scientific
Carolyn Small
Improving fuel efficiency in aircraft by material design
Arconic
Martyn Bennett
Reducing wear debris produced by tyres
ARTIS
Sarah Chapman Reducing sound interference at drive-thru fast food
3M outlets
Paul Skinner Substituting the microplastics used to keep sheets of
NSG glass separate

MAT 602 - Materials Selection in Design

 Probable Case studies in 2020

Person, Company Potential Case Study

Andy Lewis, Boston Sclerotherapy materials for treating varicose
Scientific veins
Sarah Chapman, 3M Rain Protection for Outdoor Spaces

Anna Staunton, NSG Protecting Glass during transportation

Ana Gallego, Blatchford Sports Prosthetic leg liner

Group
Keizo Akutagawa, Racing Optimising Materials for F1 tyre treads
Point F1
Andrew Osborne, Port of Next Generation Mooring Pins for Thames
London Authority Estuary

MAT 602 - Materials Selection in Design

 The Final Assessment

 It
is not yet clear how the final assessment will
be conduced in January 2021
 It could be a conventional examination completed
in an examination hall
 It could be an open book 24hour type of
assessment submitted on line
 Or potentially some other form of assessment
 Each student should make comprehensive
notes throughout the course and write up
each case study in preparation for this final
assessment
MAT 602 - Materials Selection in Design
 Recommended Resources

 Resources:
“Materials Selection in Mechanical Design”, by M.F.
Ashby
The Cambridge Material Selector (CES) software -
Granta Design, Cambridge (Available to download for
installation to PC only from MAT602 QMPlus page)

MAT 602 - Materials Selection in Design