Selecting Materials

Product function interdependence Mechanical properties Physical properties Families of materials Materials first screening

When do we select specific materials?

Customer Needs

Formulation Customer requirements Importance weights Eng. characteristics House of Quality Eng. Design Specs

Concept Design

Abstract embodiment ? Physical principles Material Geometry

Configuration Design

arrangement of parts/features (i.e. shaping materials)

Therefore, lets examine

Formulation Concept Design
materials

Interdependence - compatibility

Material Properties

Configuration Design
Parametric Design Detail Design

manufacturing processes
Manufacturing Processes

compatible materials & processes

Interdependence - capability
capable processes for the geometry

Product function is interdependent

Material Properties

Product Function Manufacturing Processes Product Geometry

Manufacturing Processes

Product Geometry

Material properties
stress

Mechanical properties
F

Mechanical properties quantities that characterize the behavior of a material in response to external, or applied forces

F/A
A

ductile ?
S ut
Sy

L L

Physical properties quantities that characterize the behavior of a material in response to physical phenomena other than mechanical forces (e.g. such as heat, electricity, radiation)

brittle
elastic plastic

strain

L L L

stiffness ?

Strength = stress at failure = (failure)

Mechanical properties

Fundamental properties
Characteristic Strength Elastic strength Stiffness Ductility Hardness Corrosion resistance Behavior strong, weak elastic then plastic flexible, rigid draws, forms easily resists surface indentation resists chemicals, oxidation Property ultimate strength yield strength modulus of elasticity % elongation, % area reduction Brinell No. galvanic series Units MPa (ksi) MPa (ksi) MPa (Mpsi) dimensionless MPa (ksi) activity number

Fundamental properties
Characteristic Fatigue resistance Conductivity (heat, electric) Creep resistance Impact resistance Density (mass) Density (weight) Temperature tolerance Behavior endures many load cycles Property endurance limit thermal conductivity electrical conductivity creep strength Charpy energy mass density weight density melting point Units MPa (Mpsi) (Btu/hr) / (F-ft), Mhos MPa (ksi)
Metals

Material families / sub-families

Materials

Plastics
Thermoplastics

Ceramics

Composites

conducts, insulates

Family (Ashby)

Ferrous

time dependent stretching shock, impact loads heavy, light softens, or melts easily

Non-ferrous

Thermosets Elastomers

Sub-family

N-m, (ft-lbs) kg/m3, (slugs/ft3) N/m3, (lbs/ft3) degrees C, F

Material sub-families / classes

Materials

Metals
Metals

Metals
Ferrous

Family

Ferrous cast iron carbon steel alloy steel stainless steel

Sub-family

Cast iron Carbon steel Alloy steel Stainless steel

Classes

Non-ferrous aluminum brass bronze copper lead magnesium nickel tin titanium tungsten zinc

Polymers
Polymers

Natural and synthetic rubbers

Polymers
No chemical reaction

Thermoplastics

Thermosets

Elastomers
butyl fluorocarbon neoprene nitrile polysulfide rubber silicone

ABS acetal acrylic nylon polycarbonate polyethylene polypropylene polystyrene vinyl

alkyd epoxy melamine phenolic polyester urethane

Cross-linking

Property profiles by family

Materials selection
prospective materials and processes

functional? manufacturable?

screening feasible materials and processes

rejected materials and processes

relative performance?

rating

best material(s) and processes

Screening: Materials first approach

Application Information
1. Applied loads

Screening: Manufact process first approach

Part Information
1. Production volume 2. Part size (overall) 3. Shape capability (features)

magnitude cyclic nature (steady, fatigue) rate (slow, impact) duration (creep) 2. Ambient conditions temperature moisture sunlight chemical liquids/vapors 3. Safety 4. Cost

boss/depression 1D boss/depression >1D holes undercuts (internal/external) uniform walls cross sections (uniform /regular) rotational symmetry captured cavities

Materials selection
prospective materials and processes

Rating: Material indices

Given the same cost/volume which is stronger?

index = Strength/cost
functional? manufacturable? rejected materials and processes

screening feasible materials and processes

Given the same cost/volume which is stiffer? index = Youngs modulus/cost

relative performance?

rating

best material(s) and processes

Summary

Ashby Chart

How can we use it?

Product function interdependence Mechanical properties Physical properties Families, sub, classes of materials Ashby charts Materials first approach Process first approach