19/9/2018

MATERIAL FAMILIES / SUB-FAMILIES METALS

METALS
Materials

Ferrous Non-ferrous
aluminum
Metals Plastics Ceramics Composites Family cast iron
(Ashby) brass
carbon steel
bronze
Ferrous Thermoplastics alloy steel
copper
stainless steel
lead
Non-ferrous Thermosets Sub-family magnesium
nickel
Elastomers tin
NAW 1 NAW titanium 3

tungsten
zinc

MATERIAL SUB-FAMILIES / CLASSES

POLYMER

Materials
POLYMERS

Metals
Family Thermoplastics Thermosets Elastomers
ABS alkyd butyl
Ferrous
Sub-family acetal epoxy fluorocarbon
acrylic melamine neoprene
Cast iron nylon phenolic nitrile
Carbon steel polycarbonate polyester polysulfide
Alloy steel Classes polyethylene urethane rubber
polypropylene silicone
Stainless steel
NAW 2 NAW
polystyrene 4
vinyl
 19/9/2018

POLYMERS SILICON CARBIDE

• excellent corrosion resistant
• Strong, flexible, electrically and thermally insulating, not creep-resistant, impact- • low density
resistant, lightweight, temperature-sensitive, soft, corrosion-resistant
• resistant to high temperatures
• Thermoplastic: polymers repeatedly softened by heating and hardened by
cooling • high electrical resistance
• Thermoset: polymers hardened by curing • high hardness
• Elastomers : ‘elastic polymers’, can either be thermoplastic or thermoset polymers
• low tensile strength
• low toughness difficult to shape
• products: electrical insulators, cutting tools, grinding wheel
NAW 5 NAW 7

CERAMICS THOUGHTS ABOUT THESE “FUNDAMENTAL” MATERIALS

•METALS: METALLIC BOND
Strong in compression, weak in tension, brittle, stiff, electrically and thermally • STRONG, DUCTILE
• HIGH THERMAL & ELECTRICAL CONDUCTIVITY
insulating, not impact-resistant, medium weight, very temperature tolerant, very • OPAQUE, REFLECTIVE.
hard, corrosion-resistant
•POLYMERS/PLASTICS: COVALENT BONDING  SHARING OF E’S
• SOFT, DUCTILE, LOW STRENGTH, LOW DENSITY
Ceramic
• THERMAL & ELECTRICAL INSULATORS
alumina • OPTICALLY TRANSLUCENT OR TRANSPARENT.
beryllia
diamond
magnesia •CERAMICS: IONIC BONDING (REFRACTORY) – COMPOUNDS OF METALLIC & NON-
METALLIC ELEMENTS (OXIDES, CARBIDES, NITRIDES, SULFIDES)
silicon carbide
silicon nitride • STRONG, HARD, BRITTLE, GLASSY, ELASTIC
NAW
zirconia 6 NAW • NON-CONDUCTING (INSULATORS) 8
 19/9/2018

COMPOSITES Metals

Stiff, strong, light, non-conducting, moderately corrosion-resistant, sensitive to

temperature

Natural Composites Engineering Composites

Bone Reinforced concrete beams
Wood Thermoset composites: Thermoset resins
Bamboo: Natures fiber glass due to (polyurethanes, polesters, epoxies)
pronounced fibrillar structure Glass fibers, Carbon fibers, Synthetic fibers,
which is very apparent when metalfibers, or ceramic fibers
Several uses of steel and pressed
fractured. Thermoplastic composites (polypropylene, nylon, aluminum.
Muscle and other tissue polyester,TPU,polyimide)
Glass fibers, Carbon fibers, Synthetic fibers,
NAW
metalfibers, or ceramic fibers 9 NAW

11

PROPERTY PROFILES BY FAMILY Ceramics

Examples of ceramic materials ranging from household to high performance combustion engines which utilize both
metals and ceramics.

NAW 10 NAW

12
 19/9/2018

Polymers Semiconductors

Micro-Electrical-Mechanical Systems
(MEMS)

Si wafer for computer chip devices.

Polymers include “Plastics” and rubber materials

NAW NAW

13 15

Composites

Polymer composite materials: reinforcing glass fibers in a polymer matrix.

NAW NAW 16

14
 19/9/2018

Material Selection

Different materials exhibit

different microstructures and
resultant Properties

NAW 17 NAW 19

Material Selection
How do you decide on a specific material for your application ?

NAW 18 NAW

20
 19/9/2018

MECHANICAL PROPERTIES IN DESIGN FUNDAMENTAL PROPERTIES

Designers need to know about mechanical properties…

…to choose the right material for a given component (e.g. a car’s crankshaft) or structure (e.g. a dam). Characteristic Behavior Property Units
They need to make sure that there won’t be too much deflection under load, and that the forces won’t be
high enough to cause failure. Fatigue resistance endures many load cycles endurance limit MPa (Mpsi)
thermal
Conductivity conductivity (Btu/hr) / (F-ft),
X-ray showing an artificial hip joint, conducts, insulates
(heat, electric) electrical Mhos
made of metal, which broke in two whilst conductivity
inside someone’s leg.
Creep resistance time dependent creep strength MPa (ksi)
stretching
As an engineer, you don’t want to be Impact resistance shock, impact loads Charpy energy N-m, (ft-lbs)
famous for designing a component that
Density (mass) mass density kg/m3, (slugs/ft3)
failed. heavy, light
Density (weight) weight density N/m3, (lbs/ft3)
NAW
Crack in a bicycle crank
21 NAW
Temperature tolerance softens, or melts easily melting point degrees C, F 23

FUNDAMENTAL PROPERTIES THE MATERIALS SELECTION PROCESS

1. Pick Application Determine required Properties

Characteristic Behavior Property Units
Properties: mechanical, electrical, thermal, magnetic,
Strength strong, weak ultimate strength MPa (ksi) optical, deteriorative.
Elastic strength elastic then plastic yield strength MPa (ksi)
Stiffness flexible, rigid modulus of elasticity MPa (Mpsi) 2. Properties Identify candidate Material(s)
Material: structure, composition.
% elongation,
Ductility draws, forms easily dimensionless
% area reduction
3. Material Identify required Processing
Hardness resists surface Brinell No. MPa (ksi)
indentation Processing: changes structure and overall shape
ex: casting, sintering, vapor deposition, doping forming,
Corrosion resistance resists chemicals, galvanic series activity joining, annealing.
oxidation number
NAW 22 NAW 24

3
 19/9/2018

COURSE GOAL IS TO MAKE YOU AWARE OF THE

IMPORTANCE OF MATERIAL SELECTION BY:

• Using the right material for the job.

one that is most economical and “Greenest” when life usage is
considered

• Understanding the relation between

properties, structure, and processing.

• Recognizing new design opportunities offered

by materials selection.
NAW 25 NAW 27

NAW 26 NAW 28
 19/9/2018

PROCESSING AND MATERIALS SELECTION

• PROCESSING OF MATERIALS DRAMATICALLY AFFECTS THE PROPERTIES
• STEEL: heat treatments provides many variations of steel
• ALUMINUM- heat treatments provides many variations of Al
• PLASTICS- quenching of PET (polyethylene terephthalate )(enable clear bottles for sodas
• COMPOSITES- post curing improves strengths and stiffness
• MATERIALS SELECTION
• MATERIALS ARE SELECTED FOR APPLICATIONS BASED UPON
• Cost of part (piece price)
• Material cost accounts for 50% to 90% of total part cost
• Mechanical properties
• stiffer materials for load bearing applications (tensile modulus)
• stronger materials for impact and bending applications
• electrical and thermal properties
• Shape
• forming a material to a particular shape limits material selection
• Appearance
NAW 29 NAW 31
• paintability, shininess, texture, smell, etc.

NAW 30