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Technical Report · February 2015

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 FACULTY OF APPLIED SCIENCES
DEPARTMENT OF COMPUTING, ENGINEERING
AND TECHNOLOGY
EAT309 MECHANICAL DESIGN – PART 5

MATERIALS REVIEW AND SELECTION

OTSIMA ROMEO MOGBEYI (149009960)

Submit to:

Dave Knapton / Alan Fell

Hand-in date 22nd January 2015

Table of Contents
Introduction
1 Cylinder Tube
1.1 Functions
1.1.1 Constraint
1.1.2 Objectives
1.1.3 Ideal properties of material
1.2 Possible materials
1.2.1 Materials Review
1.2.2 Advantages and Disadvantages of each material
1.2.2 Selecting the Best Material
1.2.3 Performance Index
1.2.4 Environmental Factor
1.2.5 Conclusion
2.0 Piston Rod
2.1 Functions
2.1.1 Constraint
2.1.2 Objectives
2.1.3 Ideal properties of material
2.2Possible materials
2.2.1 Advantages and Disadvantages of each material
2.2.2 Selecting the Best Material
2.2.3 Performance Index
2.2.4 Environmental Factor
2.2.5 Conclusion
INTRODUCTION

The choice of materials in engineering design is a key factor to engineers. More than
40,000 to 80,000 materials are available to pick from when designing (Ashby, 1992,
p. 1). Therefore, in other to make the best product from the available materials,
proper consideration of what is expected of the design while it function, cost,
environmental implication, ethical consideration should be in mind.

For the purpose of this report, our intention is to choose from three materials the best
which will be used in manufacturing the tube and the piston rod of the hydraulic
cylinder. The function of each part is identified, what may hinder it from performing
such function (constraint), ideal material properties, objective of the design, which
include minimising both weight and cost, manufacturing process of the part from the
materials is considered and the best material which suit the design of the tube and
piston rod is selected.

CYLINDER TUBE

The piston moves to and fro from the cylinder tube. This is hollow, with a smooth
inner finish.

FUNCTION

The function of the tube is to hold pressure. The tube must therefore prevent leaks
which may reduce the pressure of the system.

CONSTRAINT

The tube should be strong enough to withstand the pressure in the system. The
constraint is therefore strength limited and corrosion resistant.

OBJECTIVES

The objective of the design is to design a cylinder tube that is lightweight with a low
price. It should also be able to perform its primary function effectively.
IDEAL PROPERTIES OF MATERIAL

 Wear resistance
 Corrosion resistance
 Lightweight
 Machinability
 Low cost.

POSSIBLE MATERIALS

Generating possible materials from Cambridge Engineering Selector CES, it is

important to first develop an equation for both the constraint and objective of the
design.

Constraint equation= Stress on tube = =

i.e, at the performance limit

Where,

Objective equation=

From density =

This implies that,

= where, m = mass, A = cross sectional area,

The area is a common attribute in both equations so we can link equation 1 and
equation 2.

That is, from equation 1,

Putting eqn 3 into eqn 2 gives,

Equation 4 is telling us about the function of the design, F, its geometry L and the
materials content .
 To get a small mass of the design, we must therefore reduce the ratio of or

maximise the inverse that is .

This is the performance index for a strength limited design.

M=

With the above equation, a graph with a gradient of 1 is plotted on CES with the y-
axis representing the tensile strength while the x- axis density. The result is shown
below.

5000

Tungsten alloys
2000 Stainless steel
Tensile strength (MPa)

Titanium alloys High carbon steel

1000
Medium carbon steel
CFRP, epoxy matrix (isotropic) Silicon nitride
Cast iron, ductile (nodular)
500 Tungsten carbides
Nickel
Silicon carbide
Cast iron, gray Silver

200 Gold

Polyamides (Nylons, PA)

100
Softwood: pine, along grain Polyoxymethylene (Acetal, POM)

Polyvinylchloride (tpPVC)
50

Lead alloys

1000 2000 5000 10000 20000

Density (kg/m^3)

CES Edu Pack 2014

The following materials where thereby picked from the numerous ones presented on
the above graph for further discussion,

 Stainless steel Type 304

  Titanium Alloys Grade 1
 Cast iron grade 60-44-18

MATERIALS REVIEW

Stainless Steel Type 304 UNS S30400 BS EN10088-1:2005

This is a widely used material for engineering purposes. Type 304 stainless steel is a
combination of various constituent with 18-20% of Chromium and 8-10% Nickel.
Other metals present include, manganese 2%, Carbon 0.08%, Phosphorus 0.045%,
Sulphur 0.030% and Silicon with 1%. This stainless steel type is easy to machine
with good weld ability and easy to form. It has a tensile strength of about 520-
720MPa. For a kilogram of this material, the cost ranges from 3.5-3.85GBP. (CES
Edu Pack 2014). Mechanical properties of this material is shown in appendix A1

ADVANTAGES

 It has excellent corrosion resistant

 It remains ductile to the lowest temperature
 Stainless steel 304 does not wear easily
 It has excellent durability in acidic environment
 In fuel, oil solvent, stainless steel 304 maintain excellent durability.
 Easily available to purchase.
 It is environmental friendly.

DISADVANTAGES

 This type of stainless steel rapidly work hardens.

 It is a little expensive.

Stainless steel grade 304 can be recycled and the energy used is not much. CO2
emission is about 1.32-1.46kg/kg (CES Edu Pack 2014).

Titanium Grade 9 UNS R56320 ISO 28401:2010

This grade of titanium provides excellent strength and corrosion resistance when
used. Titanium has strength to weight ratio of about 25% greater than the best alloys
of aluminium or steel (CES Edu Pack 2013). The following are the constituent of this
material

Content
C <0.08%
N2 <0.03%
O2 <0.15%
V 2.0-3.0%
Al 2.5-3.5%
Fe <0.25%
H2 <0.015%
Ti Balance

It has a density of 4.48g/cm^3 and a tensile strength of 621Mpa. Other mechanical

properties of interest are listed in appendix A2

ADVANTAGES

 Titanium grade 9 has excellent corrosion resistant

 It has high tensile strength and low density.
 It has lower coefficient of thermal expansion than stainless steel
 Easy to machine, weld and form.
 Lightweight

DISADVANTAGE

 Titanium is very expensive. It sells for about 14.3-15.7GBP per kilogram.(CES

2014)
 Extracting titanium from its ore is energy intensive.

Titanium grade 9 is light weight but very expensive. Its strength to weight ratio will
probably cover for its cost in its application. It is non-toxic and can be recycle
provided it is not contaminated with oxygen. The CO2 footprint when recycling is
about 6.46-717kg/kg (CES Edu Pack 2014)

Ductile Cast Iron Grade 60-40-18 ISO 400-18

Cast iron pride itself as the cheapest material available for a wide spectrum of
engineering purposes. Ductile cast iron is lightweight with excellent strength. It has a
density of 7.05-7.25g/cm^3 and tensile strength ranging from 410-830Mpa. Price per
kilogram of this material is 0.351-0.383GBP. (CES Edu Pack 2014). Properties and
composition of this material is shown in appendix A3

ADVANTAGES

 It is very cheap as compared to stainless steel and titanium.

 It has a density lower than that of stainless steel.
 It has a superior surface finish
 Ductile cast iron has a low cost of fabrication..

DISADVANTAGES

 It has limited use in salt water.

 It is difficult to weld and solder
 In acidic environment, ductile cast iron cannot be used.

SELECTING THE BEST MATERIAL

Having carefully discussed the properties, advantages and disadvantages of all three
materials, it is only imperative to choose one. Properties of a material such as its
density, young’s modulus, strength and cost define a material (Ashby, 1992 p.
56).This design therefore must take into consideration part of these properties in
ensuring that the best material is chosen for the purpose.

PERFORMANCE INDEX

For the tube design, the best material should be one with a good strength,
lightweight and modest cost. So the following properties of each material will be
analysed against material properties which needed to be maximised and minimised.

 Tensile strength
 Density
 Price

(a)To minimize the weight, for a strength design,

Performance index

For Stainless steel 304,

Titanium grade 9, =

Ductile cast iron grade 60-4018, =

(b) To minimize cost for a strength design,

Performance index=

Stainless steel 304, =

Titanium grade 9, =

Ductile cast iron 60-40-18, =

In this case, the material with the biggest result will perform better in that design
criteria. Titanium has the highest value when the performance was to minimize
weight in a strength design and the lowest in cost reduction. Ductile cast iron has
lowest in weight but perform better in cost reduction for a strength design. Stainless
steel performed fairly well in minimum weight and cost for a strength limited design.

ENVIRONMENTAL FACTOR

Overall, stainless steel has excellent durability in salt and fresh water, acceptable in
some acidic solution and they are very durable in most fuel and oil. In the primary
production of this material, CO2 footprint ranges from 4.73-5.23kg/kg. Stainless steel
is non-toxic and can be recycled. CO2 that goes into the environment as a result of
recycling ranges from 1.32-1.46kg/kg (CES Edu Pack 2014).

Extracting titanium from its ore is energy intensive. In primary production, CO2
footprint is 44.1-48.7kg/kg (CES Edu Pack 2014). Though, it can be recycled,
provided it is not contaminated with oxygen. It leaves the environment with CO2 of
6.49-7.17kg/kg in the process of recycling. In salt and fresh water, titanium grade 9
has excellent durability but limited use in some acidic environment.

Ductile cast iron grades 60-44-18 has limited use in salt water but acceptable in
fresh water. In fuel and oil, it has excellent durability. During production of ductile
cast iron, CO2 that goes into the environment is 1.7-1.8kg/kg. It can be recycled and
the process leaves the environment with carbon dioxide of 0.616-0.681kg/kg.

CONCLUSION

Ethically, it is important to consider how our design affects the environment in which
we live. Titanium grade 9 has excellent resistance to corrosion and high strength but
the cost of the material will discourage this choice. Although the strength to weight
ratio could be an advantage to the cost but the energy needed to extract titanium
from its ore is very high. The difference in weight consideration between ductile cast
iron 60-44-18 and stainless steel grade 304 is not too much when compared to the
difference in cost. The energy needed to produce stainless steel is high compared to
ductile cast iron. On the above basis, ductile cast iron grade 60-44-18 is chosen as
the material for the cylinder tube production.
PISTON ROD

The piston rod is a major part of the hydraulic cylinder. It moves to and fro from the
cylinder tube.

FUNCTION

The piston rod transfer the force (35.98KN) directly to the link attached to the cutting
blade.

CONSTRAINT

 Must not yield while in service

 Must have resistance to crack(fracture toughness)

OBJECTIVES

 Mass reduction(lightweight)
 Low cost.

IDEAL PROPERTIES OF MATERIAL

 Ability to withstand high temperatures

 Resistance to crack(fracture toughness)
 Wear resistance
 High stiffness as piston moves to and fro.
 Light weight
 Low cost
 Easily available
 Minimum environmental impact.

POSSIBLE MATERIALS

With the same performance index generated for the tube, we plot a graph of tensile
strength and density and the result is same as above. Considering the fact that a
tough material that will not yield is needed, a graph with performance index
 , was plotted. Where represent fracture toughness divided by the

young’s modulus.

The result is shown below.

1000
Fracture toughness (MPa.m^0.5)

Low alloy steel

Nickel-chromium alloys
100
Nickel-based superalloys
Zinc die-casting alloys Low carbon steel
Bronze
Brass Tungsten alloys
Non age-hardening wrought Al-alloys
Cast iron, ductile (nodular)
GFRP, epoxy matrix (isotropic)
Cast iron, gray
Wrought magnesium alloys

10
Paper and cardboard CFRP, epoxy matrix (isotropic)
Zirconia
Polyethylene terephthalate (PET)
Silicon nitride
Polyurethane (tpPUR)

Polyoxymethylene (Acetal, POM)

1 10 100 1000
Young's modulus (GPa)

CES Edu pack 2014

The following materials were chosen from the generic materials on the graph above.

 Low alloy steel

 Nickel-chromium alloys
 Low carbon steel.
MATERIALS REVIEW

Low Alloy Steel EN24T BS 970:1955

These are steels alloyed with various metals to achieve desired properties. It has a
density of about 7.8-7.9g/cm^3. A kilogram cost 0.358-0.389GBP (CES 2014). The
main constituent of this material is shown below.

Typical chemical composition of EN24T

Carbon 0.36-0.44

Silicon 0.10-0.35

Manganese 0.45-0.70

Sulphur 0.040 maximum

Phosphorous 0.035 max

Chromium 1.00-1.40

Molybdenum 0.20-0.35

Nickel 1.30-1.70

Courtesy (http://www.steelexpress.co.uk/engineeringsteel/EN24T-properties.html)

Mechanical properties of this steel is listed below

Young’s modulus 205-217Gpa

Yield strength 400-1.5e^3Mpa

Tensile strength 550-1.7Mpa

Fracture toughness 14-200Mpa

Compressive strength 400-1.5Mpa

ADVANTAGES

 Good hardenability
 It has improve strength at ordinary temperature
 Improve toughness at any minimum hardness or strength
 It has corrosion and oxidation resistance.
 Increase wear and abrasion resistance
 It is cheap
 Easily available with good machinability, formability and excellent weldability
properties.
 Excellent durability in fuel, oils and solvent.
 Environmental friendly

DISADVANTAGE

 It has limited use in acidic environment.

Low Carbon Steel EN3 ISO 9001: 2008

With a compressive strength of 250-395Mpa, low carbon steel have carbon in its
lowest amount, they are the cheapest of all structural metal. A kilogram of this
material cost 0.333-0,364GBP (CES Edu Pack 2014). Their density ranges from 7.8-
7.9g/cm^3. Some of its properties are shown in appendix B2.

ADVANTAGES

 The major advantage of this material is in its cost, they are very cheap.
 They are easily available
 They are very malleable and ductile
 Excellent durability in fuel and oil.

DISADVANTAGES
 Low carbon steel yield easily.
 The use of this material is limited to some environment. They are not
acceptable in acidic environment.
 The energy needed to produce steel is relatively low per unit weight. Carbon steel
are easy to recycle. About 0.546-0.603kg/kg of CO2 is emitted in the process of
recycling.(CES Edu Pack 2014)

Nickel-Chromium Alloy Inconel 600 UNS N06600 BS 3075

This material has excellent corrosion resistance and good mechanical strength. It
has a density of about 8.3-8.5g/cm^3 while a kilogram cost 14.3-15.8GBP. Nickel-
Chromium alloys have compressive strength of 365-460Mpa and young’s modulus
200-220Gpa (CES Edu Pack 2014).

ADVANTAGES
 High tensile strength
 Resistance to a wide range of corrosive media
 Environmentally friendly
 Good weldability , machinability and formability

DISADVANTAGE
 It is very expensive
PERFORMANCE INDEX
Material properties considered for the piston rod will include
 Fracture toughness
 Young’s modulus
 Density
 Cost
(a) Minimum weight for a stiffness design,

Performance index=

Where E is Young’s modulus and is density.

For low alloy steel EN24T and low carbon steel EN3, =

Inconel 600, =

(b)To minimize cost for a stiffness design

Performance index=

Where Cp is cost per kg.

For low alloy steel EN24T=

Low carbon steel, =

Inconel 600, =

(c) Damage tolerant design

Performance index=

Where
KIC is the fracture toughness and E is Young’s modulus

For low alloy steel EN24T=

Low carbon steel =

Inconel 600, =

Again, big is better. For a low density stiff material, low carbon steel and low alloy
steel have same value which is higher than that of Inconel 600 slightly. But with cost
reduction, low carbon steel has the advantage over low allow steel and Inconel 600.
The piston rod must be design from material that has good toughness attribute. Low
alloy steel proves to have the better value for this criterion.
ENVIRONMENTAL FACTOR

Low alloy steel EN24T has limited use in salt water but acceptable in fresh water. In
some acidic environment, this material is unacceptable. It has excellent durability in
fuel and oil.CO2 footprint in primary production is 1.93-2.13kg/kg. Low alloy steel are
recycled and CO2 footprint while recycling is 0.606-0.669kg/kg.

Inconel 600 is non-toxic and can be recycled. It has excellent durability in salt and
fresh water. Not acceptable in some acidic environment but very durable in oil and
fuel. Energy needed to produce this material is high leaving a CO2 footprint of 10.9-
12.1kg/kg in the process of primary production.
Low carbon steel EN3 is non-toxic and can be recycled. The energy needed to
produce this material is relatively low. It is however not acceptable in some acidic
environment but it has excellent durability in fuels and oils. Its use is limited in salt
water environment but acceptable in fresh water.

CONCLUSION

Inconel 600 has excellent resistance to corrosion but its production is energy
intensive compared to the other two materials. The difference in cost between
EN24T and EN3 is not too much as compared to their performance in damage
tolerance. Their production energy is also not much of a difference. Therefore, for
the piston rod, low alloy steel EN24T is chosen because it performed better in
damage tolerance and the energy needed to produce and recycle it is not high.
REFERENCES
Aalco metals limited
(Date Added: 12 December 2014)
Stainless Steel - Austenitic - 1.4301 Bar and Section
Available at http://www.aalco.co.uk/datasheets/Stainless-Steel-14301-Bar-and-
Section_34.ashx
Accessed January 5th 2015

Ashby M.F (1992) Materials Selection in Mechanical Design

Butterworth- heinemann

AZO Materials
(Date Added: Apr 28, 2008 | Updated: Jun 11, 2013)
Inconel 600 – Composition, Properties and Applications of Inconel 600 Nickel-
Chromium Alloy by Alloy Wire International
Available at http://www.azom.com/article.aspx?ArticleID=4187
Accessed January 15th 2015

AZO Materials
(Date Added: Nov 19, 2002 | Updated: Jun 11, 2013)
Titanium Alloys - Ti3Al2.5V Grade 9 and Grade 18
Available at http://www.azom.com/article.aspx?ArticleID=1728
Accessed January 15th 2015
Granta Design Limited (2014) CES Edu Pack(version 14.3.5)(Computer program)
Available at:University of Sunderland

RTI International Metals, Inc. Company

(2000)
Titanium alloy guide
Available at http://www.rtiintl.com/Titanium/RTI-Titanium-Alloy-Guide.pdf
(Accessed January 10th 2015
.

APPENDIX A1

Properties of Stainless Steel Type 304

Physical Property Value

Density 8.00 g/cm³
Melting Point 1450 °C
Thermal Expansion 17.2 x10^-6 /K
Modulus of Elasticity 193 GPa
Thermal Conductivity 16.2 W/m.K
Electrical Resistivity 0.072 x10^-6 Ω .m
Mechanical Property Value
Proof Stress 210 Min MPa
Tensile Strength 520 to 720 MPa
Elongation A50 mm 45 Min %
Compressive Strength 210 MPa

Above properties are for 1.4301 bar & section

http://www.aalco.co.uk/datasheets/Stainless-Steel-14301-Bar-and-Section_34.ashx

APPENDIX A2

Physical Properties

Table 2. Typical physical properties for Ti3Al2.5.

Property Typical Value

Density g/cm3 (lb/ cu in) 4.48 (0.161)
Melting Range °C±15°C (°F) 1704 (3099)
Volume Electrical Resistivity ohm.cm (phm.in) 124 (49)
Thermal Conductivity W/m.K (BTU/ft.h.°F) 7.6 (53)
Mean Co-Efficient of Thermal Expansion 0-300°C /°C (0-
7.9x10-6 (4.4)
572°F /°F)
Beta Transus °C±15°C (°F) 935 (1715)
 Mechanical Properties

Table 3. Typical mechanical properties for Ti3Al2.5

(data obtained for bar and plate 1” (25.4mm) thick, annealed.

Property Minimum Typical Value

Tensile Strength MPa (ksi) 621 (90) 740 (107)
0.2% Proof Stress MPa (ksi) 483 (70) 607 (88)
Elongation Over 2 Inches % 15 17
Elastic Modulus GPa (msi) 91 (13)
Hardness Rockwell C 15
Specified Bend Radius <0.070 in x Thickness 2.5
Charpy, V-notch Impact J (ft.lbf) (L-Direction 48 (35)
pipe)
Short-term Creep 1% strain MPa (ksi) (1000
400 (58)
hrs @ 250°C (480°F))
Stress Rupture MPa (ksi) (1000 hrs @ 250°C
421 (61)
(480°F))

http://www.azom.com/article.aspx?ArticleID=1728

APPENDIX A3
Metric
Physical Properties
English
Density 6.64 - 7.20 g/cc 0.240 - 0.260 lb/in³

Mechanical Properties Metric English

Hardness, Brinell 120 - 160 120 - 160
Tensile Strength, Ultimate >= 414 MPa >= 60000 psi
Tensile Strength, Yield >= 276 MPa >= 40000 psi
@Strain 0.200 % @Strain 0.200 %
Elongation at Break >= 18 % >= 18 %
Reduction of Area 5.0 % 5.0 %
Tensile Modulus 172 GPa 25000 ksi
Compressive Yield Strength >= 331 MPa >= 48000 psi
Poissons Ratio 0.275 0.275
Shear Modulus 67.6 GPa 9800 ksi
Shear Strength 496 MPa 72000 psi

Component Elements Properties Metric

Carbon, C 3.5-3.9%
Chromium, Cr <=0.050%
Copper, CU 0.020-0.50%
Iron, Fe 95%
Manganese, Mn 0.15-0.35%
Phosphorous, P <=0.050
Silicon, Si 2.25-2.27%
Sulphur, S 0.010-0.025%
Tin, Sn 0.010-0.050%

http://www.matweb.com/search/datasheet.aspx?matguid=5fd2321bcd464c1989
2c1acd09dabde8&ckck=1

APPENDIX B1

English
Metric
Hardness, Brinell 131 131
Hardness, Knoop 140 140 Converted from Brinell
hardness.
Hardness, Rockwell 68 68 Converted from Brinell
B hardness.
Hardness, Vickers 126 126 Converted from Brinell
hardness.
Tensile Strength, 470 MPa 68200 psi
Ultimate
Tensile Strength, 395 MPa 57300 psi
Yield
Elongation at Break 15 % 15 % In 50 mm
Reduction of Area 40 % 40 %
Modulus of Elasticity 205 GPa 29700 ksi Typical for steel
Bulk Modulus 140 GPa 20300 ksi Typical for steel
Poissons Ratio 0.29 0.29 Typical For Steel
Machinability 70 % 70 % Based on AISI 1212 steel. as
100% machinability
Shear Modulus 80.0 GPa 11600 ksi Typical for steel

Thermal Properties Metric English

Specific Heat 0.472 J/g-°C 0.113 Typical steel
Capacity BTU/lb-°F
Thermal 49.8 W/m-K 346 BTU- Typical steel
Conductivity in/hr-ft²-°F

Component
Elements Metric English
Properties
Carbon, C 0.17 - 0.23 % 0.17 - 0.23 %
Iron, Fe 98.78 - 99.23 % 98.78 - 99.23
%
Manganese, Mn 0.60 - 0.90 % 0.60 - 0.90 %
Phosphorous, P <= 0.040 % <= 0.040 %
Sulfur, S <= 0.050 % <= 0.050 %

http://www.matweb.com/search/datasheet.aspx?matguid=b57ab1b769db483e9
117f7570895f0ea

Appendix B2

Chemical Composition of Inconel 600

The compositional range for Inconel 600 is provided in the table below.

Element Content
Nickel (Ni) 72 % min
Chromium (Cr) 14 - 16 %
Iron (Fe) 6 – 10 %

Typical Properties of Inconel 600

Typical properties of Inconel 600 are covered in the following table.

Property Metric Imperial

Density 8.47 g/cm3 0.306 lb/in3
Melting point 1413 °C 2575°F
Co-Efficient of 13.3 µm/m.°C 7.4x10-6 in/in.°F
 (20-100°C) (70-212 °F)
Modulus of rigidity 75.6 kN/mm2 10965 ksi
Modulus of elasticity 206 kN/mm2 29878 ksi

Properties of Supplied Materials and Heat Treated Materials

Condition of Heat Treatment (After Forming)

Supply
Annealed/Spring Stress relive at 460°C (860°F) for 1hr and air cool.
Temper
Condition Approx Tensile Strength Approx Service Temp.
Annealed 600-750 87-109 ksi -200 to -330 to
N/mm2 +330°C +625°F
Spring Temper 900-1250 131-181 ksi -200 to -330 to
N/mm2 +330°C +625°F

Note – In both cases slight magnetism may occur below -120°C (-184°F)

Courtesy http://www.azom.com/article.aspx?ArticleID=4187
Wrought
Cast
Non
Density
Tensile
10000
Zinc
Nickel
Boron age-hardening
iron,
Titanium
Polyamides
1000
100
10
1
Tungsten
Alumina
Nickel-based
Silicon
Stainless magnesium
ductile
die-casting
carbide
carbide
nitride
alloys
steel
alloys
(Nylons,
superalloys
alloysPA)
alloys Al-alloys
(nodular)
wrought
(kg/m^3)
strength (MPa)

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