Contents

Preface Acknowledgements Features of the Third Edition 1 Introduction 1.1 Introduction and synopsis 1.2 Materials in design 1.3 The evolution of engineering materials 1.4 Case study: the evolution of materials in vacuum cleaners 1.5 Summary and conclusions 1.6 Further reading The 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 design process Introduction and synopsis The design process Types of design Design tools and materials data Function, material, shape, and process Case study: devices to open corked bottles Summary and conclusions Further reading

xi xii xiii 1 2 2 4 6 8 8 11 12 12 16 17 19 20 24 25 27 28 28 30 43 44 45 46 46 50 77 78 79 80 81 85 93

Engineering materials and their properties 3.1 Introduction and synopsis 3.2 The families of engineering materials 3.3 The definitions of material properties 3.4 Summary and conclusions 3.5 Further reading Material property charts 4.1 Introduction and synopsis 4.2 Exploring material properties 4.3 The material property charts 4.4 Summary and conclusions 4.5 Further reading Materials selection the basics 5.1 Introduction and synopsis 5.2 The selection strategy 5.3 Attribute limits and material indices 5.4 The selection procedure

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5.5 5.6 5.7 5.8 6

Computer-aided selection The structural index Summary and conclusions Further reading

99 102 103 104 105 106 106 110 114 117 121 126 130 133 136 140 144 147 151 154 157 160 163 168 172 172 175 176 177 180 195 202 209 215 215 216 219 220 220 223 227 230 232

Materials selection case studies 6.1 Introduction and synopsis 6.2 Materials for oars 6.3 Mirrors for large telescopes 6.4 Materials for table legs 6.5 Cost: structural material for buildings 6.6 Materials for flywheels 6.7 Materials for springs 6.8 Elastic hinges and couplings 6.9 Materials for seals 6.10 Deflection-limited design with brittle polymers 6.11 Safe pressure vessels 6.12 Stiff, high damping materials for shaker tables 6.13 Insulation for short-term isothermal containers 6.14 Energy-efficient kiln walls 6.15 Materials for passive solar heating 6.16 Materials to minimize thermal distortion in precision devices 6.17 Nylon bearings for ships rudders 6.18 Materials for heat exchangers 6.19 Materials for radomes 6.20 Summary and conclusions 6.21 Further reading Processes and process selection 7.1 Introduction and synopsis 7.2 Classifying processes 7.3 The processes: shaping, joining, and finishing 7.4 Systematic process selection 7.5 Ranking: process cost 7.6 Computer-aided process selection 7.7 Supporting information 7.8 Summary and conclusions 7.9 Further reading Process selection case studies 8.1 Introduction and synopsis 8.2 Forming a fan 8.3 Fabricating a pressure vessel 8.4 An optical table 8.5 Economical casting 8.6 Computer-based selection: a manifold jacket

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235 237 239 240 241 245 254 255 256 261 262 262 266 272 276 281 283 284 285 296 301 305 307 312 314 316 317 318 319 322 326 328 331 333 335 337 339 340 342 346 348

8.7 8.8 9

Computer-based selection: a spark-plug insulator Summary and conclusions

Multiple constraints and objectives 9.1 Introduction and synopsis 9.2 Selection with multiple constraints 9.3 Conflicting objectives, penalty-functions, and exchange constants 9.4 Summary and conclusions 9.5 Further reading Appendix: Traditional methods of dealing with multiple constraints and objectives Case studies multiple constraints and conflicting objectives 10.1 Introduction and synopsis 10.2 Multiple constraints: con-rods for high-performance engines 10.3 Multiple constraints: windings for high-field magnets 10.4 Conflicting objectives: casings for a mini-disk player 10.5 Conflicting objectives: materials for a disk-brake caliper 10.6 Summary and conclusions Selection of material and shape 11.1 Introduction and synopsis 11.2 Shape factors 11.3 Microscopic or micro-structural shape factors 11.4 Limits to shape efficiency 11.5 Exploring and comparing structural sections 11.6 Material indices that include shape 11.7 Co-selecting material and shape 11.8 Summary and conclusions 11.9 Further reading Selection of material and shape: case studies 12.1 Introduction and synopsis 12.2 Spars for man-powered planes 12.3 Ultra-efficient springs 12.4 Forks for a racing bicycle 12.5 Floor joists: wood, bamboo or steel? 12.6 Increasing the stiffness of steel sheet 12.7 Table legs again: thin or light? 12.8 Shapes that flex: leaf and strand structures 12.9 Summary and conclusions Designing hybrid materials 13.1 Introduction and synopsis 13.2 Filling holes in material-property space 13.3 The method: A B configuration scale 13.4 Composites: hybrids of type 1

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13.5 13.6 13.7 13.8 13.9 14

Sandwich structures: hybrids of type 2 Lattices: hybrids of type 3 Segmented structures: hybrids of type 4 Summary and conclusions Further reading

358 363 371 376 376 379 380 380 382 384 386 389 391 393 399 401 402 403 407 409 411 415 416 417 418 418 419 422 427 433 435 436 439 440 440 442 445 454 455 457 458 458 464

Hybrid case studies 14.1 Introduction and synopsis 14.2 Designing metal matrix composites 14.3 Refrigerator walls 14.4 Connectors that do not relax their grip 14.5 Extreme combinations of thermal and electrical conduction 14.6 Materials for microwave-transparent enclosures 14.7 Exploiting anisotropy: heat spreading surfaces 14.8 The mechanical efficiency of natural materials 14.9 Further reading: natural materials Information and knowledge sources for design 15.1 Introduction and synopsis 15.2 Information for materials and processes 15.3 Screening information: structure and sources 15.4 Supporting information: structure and sources 15.5 Ways of checking and estimating data 15.6 Summary and conclusions 15.7 Further reading Materials and the environment 16.1 Introduction and synopsis 16.2 The material life cycle 16.3 Material and energy-consuming systems 16.4 The eco-attributes of materials 16.5 Eco-selection 16.6 Case studies: drink containers and crash barriers 16.7 Summary and conclusions 16.8 Further reading Materials and industrial design 17.1 Introduction and synopsis 17.2 The requirements pyramid 17.3 Product character 17.4 Using materials and processes to create product personality 17.5 Summary and conclusions 17.6 Further reading Forces 18.1 18.2 18.3 for change Introduction and synopsis Market-pull and science-push Growing population and wealth, and market saturation

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18.4 18.5 18.6 18.7 18.8

Product liability and service provision Miniaturization and multi-functionality Concern for the environment and for the individual Summary and conclusions Further reading

Appendix A Useful solutions to standard problems Introduction and synopsis A.1 Constitutive equations for mechanical response A.2 Moments of sections A.3 Elastic bending of beams A.4 Failure of beams and panels A.5 Buckling of columns, plates, and shells A.6 Torsion of shafts A.7 Static and spinning disks A.8 Contact stresses A.9 Estimates for stress concentrations A.10 Sharp cracks A.11 Pressure vessels A.12 Vibrating beams, tubes, and disks A.13 Creep and creep fracture A.14 Flow of heat and matter A.15 Solutions for diffusion equations A.16 Further reading Appendix B Material indices B.1 Introduction and synopsis B.2 Use of material indices Appendix C.1 C.2 C.3 C.4 C.5 C.6 C.7 C.8 C.9 C.10 C.11 C.12 C Data and information for engineering materials Names and applications: metals and alloys Names and applications: polymers and foams Names and applications: composites, ceramics, glasses, and natural materials Melting temperature, Tm, and glass temperature, Tg Density,  Youngs modulus, E Yield strength, y, and tensile strength, ts Fracture toughness (plane-strain), K1C Thermal conductivity,  Thermal expansion,  Approximate production energies and CO2 burden Environmental resistance

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Appendix D.1 D.2 D.3 D.4 D.5 D.6 D Information and knowledge sources for materials and processes Introduction Information sources for materials Information for manufacturing processes Databases and expert systems in software Additional useful internet sites Supplier registers, government organizations, standards and professional societies E Exercises Introduction to the exercises Devising concepts Use of material selection charts Translation: constraints and objectives Deriving and using material indices Selecting processes Multiple constraints and objectives Selecting material and shape Hybrid materials 537 538 538 552 553 554 555 557 558 559 559 562 565 574 579 587 594 599

Appendix E.1 E.2 E.3 E.4 E.5 E.6 E.7 E.8 E.9 Index