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Lect 1 & Lect 2 Selection of Materials: October 2018

This document discusses factors to consider when selecting materials for engineering components. It begins by explaining that selecting the right material, shape, and manufacturing process is important for minimizing costs and failures. Key factors discussed include the mechanical properties required for the application, costs of the material and processing, the desired shape and dimensions, material availability, and environmental effects. Various material classes - metals and alloys, ceramics, polymers, composites, and advanced materials - are also introduced. Stress analysis methods for axial, bending, torsional, and combined loading are reviewed for assessing yield criteria.

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39 views

Lect 1 & Lect 2 Selection of Materials: October 2018

This document discusses factors to consider when selecting materials for engineering components. It begins by explaining that selecting the right material, shape, and manufacturing process is important for minimizing costs and failures. Key factors discussed include the mechanical properties required for the application, costs of the material and processing, the desired shape and dimensions, material availability, and environmental effects. Various material classes - metals and alloys, ceramics, polymers, composites, and advanced materials - are also introduced. Stress analysis methods for axial, bending, torsional, and combined loading are reviewed for assessing yield criteria.

Uploaded by

Enriqe Puentes
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Lect 1 & lect 2 selection of materials

Presentation · October 2018


DOI: 10.13140/RG.2.2.27089.38243

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Selection of materials Lect. 1&2 (2018-2019)

Introduction to Materials Selection:


The Material Selection Problem Design of an engineering component
involves three interrelated problems: (i) selecting a material, (ii) specifying a
shape, and (iii) choosing a manufacturing process.
Getting this selection right the first time by selecting the optimal
combination your design has enormous benefits to any engineering-based
business. It leads to lower product costs, faster time-to-market, a reduction
in the number of in-service failures and, sometimes, significant advantages
relative to your competition.

Stress analysis

Design (Determine of dimension) by :


Selection of materials :(Determine
 Estimate of failure regions of yield stress) by :

 Determine applied stress at these  Estimate of failure regions


regions
 Determine applied stress at
 Calculate the dimension from these regions
applied stress and allowable
 Calculate the allowable stress
stress
then yield stress

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Selection of materials Lect. 1&2 (2018-2019)

Factors affecting the selection of materials:

(1) - Mechanical and physical properties , service requirements and


processing :

To select a suitable material for specific conditions, all mechanical and


physical properties, e.g.,
 strength,

 hardness

 toughness,

 vibration

 heat resistance, creep and stress relaxation .

 Corrosion and wear resistance,

 fatigue

 electrical and thermal conductivity etc.


 Must consider how to make the part, for example: Casting
,Machining and Welding

(2)- Cost :

(A) Cost of the material:


In most of the cases, the cost of raw material accounts about 50 % of the
finished cost. Obviously, the cost of the material is a major factor which
influences the choice of the material or process. We must note that the use of

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Selection of materials Lect. 1&2 (2018-2019)

cheaper material will not always reduce the final cost of the component or
product. Use of cheaper material may be associated with higher processing
cost due to large number of operations to be performed and also more scrap.
We can easily see that this sometimes makes the overall cost more than that
of expensive raw material in combination with low processing cost due to
lesser number of operations and lesser scrap. The type of material affects the
detailed aspect of design and hence the choice of material as well as the
process is selected at the early design state e.g. whether the material is to be
joined by spot welding, screws or rivets, must be decided at the design state.

(B) Cost of processing:


In most of the industries, the processing cost (labour cost) and other costs
such as overhead costs account for about 50% of the production cost.
Overhead cost in automatic industries is much more than the other costs. If
one can somehow reduce all such costs, the total production cost will
automatically reduce.

(3)- Component shape and dimension:


The shape and size of a component has great effect on the choice of the
processing unit which ultimately effects the choice of the material. To make
it more clear, we consider an example, let the best possible production
method is selected, under given conditions, it is die casting, obviously, now
the choice of the material becomes limited, i.e. one can only choose

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Selection of materials Lect. 1&2 (2018-2019)

materials with lower melting points, e.g. aluminum, zinc, magnesium and
thermoplastics.
There are some materials which can be finished to close tolerance while
others cannot. Obviously, the required dimensional tolerance for finished
components will, influence the choice of materials

(4)- Availability of the material:


We may find that sometimes the availability of the material becomes a
governing factor. When the desired material supply is limited, then a costly
material which is available in ample quantity may be chosen.

(5)- Application

(6) - Environment
The effect that the service environment has on the part
The effect the part has on the environment
The effect that processing has on the environment

Generally, materials engineering may be classified into the following


categories:
1) Metals and alloys.

2) Ceramics.

3) Polymers.

4) Composites.

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Selection of materials Lect. 1&2 (2018-2019)

5) Advanced materials: such as semiconductors, biomaterials, smart


materials, and Nano materials.
A. Metals and alloys:
Metals are elements which have free valence electrons which are
responsible for their good thermal and electrical conductivity. Metals readily
loose their electrons to form positive ions. The metallic bond is held by
electrostatic force between delocalized electrons and positive ions.
Note : Engineering metals are generally Alloys. There are metallic materials
formed by mixing two or more elements, such as:
 Mild steel Fe + C (C improves strength )
 Stainless steel Fe + C + Cr + Mn …etc. (Cr improves the
corrosion resistance …etc. )

Classification of metals and alloys:

 Ferrous:
Such as : Plain carbon steel, Alloy steel, Cast iron,
 Nonferrous:
Such as : Light Alloys (Al, Mg, Ti, Zn), Heavy Alloys (Cu, Pb, Ni),
Refractory Metals (Mo, Ta, W), Precious metals (Au, Ag)

B- Ceramics
• An organic components (oxides, nitrides, carbides, ..) with a combination
of ionic and covalent binding , Complex crystal lattice or amorphous ,
(Generally) High E-modulus , Brittle especially under tensile loading and
(relative) inert or very biodegradable .

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Selection of materials Lect. 1&2 (2018-2019)

C- Glasses
Close packed but disordered structure , Often network structures (silicates,
phosphates, bio-active glass, ..)

D-Polymers
Chain structures with covalent bindings , Amorphous or semi-crystalline ,
Low E-modulus
E- Composites
Combination of two or more materials from the preceding families ,
Properties can be adapted by appropriate volume fractions and distribution
of the different materials

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Selection of materials Lect. 1&2 (2018-2019)

Factors affecting the selection of materials:

(1) - Mechanical and physical properties , service requirements and


processing :

To select a suitable material for specific conditions, all mechanical and


physical properties, e.g.,
Strength:

 Applied stress such as ( axial , bending , torsion , combined stress ) ,


this stress is not depend on materials , it is depend on shape and
geometry
 Materials strength such as ultimate strength or yield stress , these type
of strength is depend on materials properties only , it is not depend on
the dimension or geometry , this strength can be obtain from tensile

test ( stress – strain curve )

When the applied stress is higher than the yield stress of the material failure

was occurs. σ applied (axial , bending , torsion or combined stress ) σ yield






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Selection of materials Lect. 1&2 (2018-2019)

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Selection of materials Lect. 1&2 (2018-2019)

 (Torsion of Rectangular section) :

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Selection of materials Lect. 1&2 (2018-2019)

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Selection of materials Lect. 1&2 (2018-2019)

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Selection of materials Lect. 1&2 (2018-2019)

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Selection of materials Lect. 1&2 (2018-2019)

13

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