Material Selection

Senior Design
ME481
Fall 2017
Dr. Bardia Konh

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 1 of XX

 Materials Selection in Design
Design is…
“…the process of translating a new idea or a market need into detailed
information from which a product can be manufactured.”
M. F. Ashby, “Materials Selection in Mechanical Design”,

Material selection is critical part of almost all engineering designs

So many factors to consider:
strength, stiffness, durability, corrosion, cost, formability, etc.

This Lecture:
- Importance of material selection in design
- Exploring materials using materials property charts
- Materials selection process
- Selecting materials: materials indices
- Case studies
B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 2 of XX
 Materials Selection in Design

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 3 of XX

 The Role of Materials Selection in Design
Materials selection is a key step for a successful design
A large number of materials to select from
Recently, there has been more emphasis on the role of materials
Discovery of new and advanced materials

Advanced new materials can introduce

new products with more efficiencies,
Function lower manufacturing costs
Mechanical Exhibit desired behavior
Properties Failure
Mode
Manufacturability
Cost
Environmental
Considerations
An ability to select materials that best meet requirements of a design
Access to information and tools for comparison and selection

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 4 of XX

 Need for a new product and new materials
Development of a new materials

Soft robotics Soft multi-material actuators

Dr. Howon Lee Dr. Conor Walsh
Rutgers University Harvard University

• Soft active materials

• Biologically inspired design principles • Large bending motions

[Link]

[Link] [Link]

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 5 of XX

 Evolution of materials

[ASHBY99] - Materials Selection In Mechanical Design

[Link]
%20Materials%20Selection%20In%20Mechanical%20Design%[Link]

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 6 of XX

 Material Properties
Physical
Chemical
– Density Mechanical
– Corrosion
– Melting point – Hardness
– Oxidation
– Vapor pressure – Elastic constants
– Thermal stability
– Viscosity – Yield strength
– Biological stability
– Porosity – Ultimate strength
– Stress Corrosion
– Permeability – Fatigue
– ….
– Reflectivity – Fracture Toughness
Electrical
– Transparency – Creep
– Conductivity
– Optical properties – Damping
– Dielectric constant
– Dimensional stability – Wear resistance
– Coersive force
– Spalling
– Hysteresis
– Ballistic performance
Thermal
– …….
– Conductivity
– Specific Heat
– Thermal expansion
– Emissivity

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 7 of XX

 What do we expect from a design
The products should perform their functions effectively, safely, at acceptable cost”

DATA INFORMATION KNOWLEDGE

Data Statistical Selection of Economic analysis

capture analysis material and process and business case

Mechanical Properties
Bulk Modulus 4.1 - 4.6 GPa

$
Compressive Strength 55 - 60 MPa
Ductility 0.06 - 0.07
Elastic Limit 40 - 45 MPa
Endurance Limit 24 - 27 MPa
Fracture Toughness 2.3 - 2.6 MPa.m 1/2
Hardness 100 - 140 MPa
Loss Coefficient 0.009- 0.026
Modulus of Rupture 50 - 55 MPa
Poisson's Ratio 0.38 - 0.42
Shear Modulus 0.85 - 0.95 GPa
Tensile Strength 45 - 48 MPa
Young's Modulus 2.5 - 2.8 GPa

Potential Successful
Test Test data Allowables applications applications

Characterization Selection and implementation

[Link]

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 8 of XX

 Materials Data - Organization

• Properties for a particular material is called the “material attributes”

• Includes both structured and non-structured information
• We need to find the best match between the design requirements and the
materials attributes.

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 9 of XX

 Material stiffness

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 10 of XX

 Metals
Metal Examples of application
Ferrous Metals Carbon Steels Utensils, construction, automotive, transmission
towers …
Stainless Steels Off shore drilling rigs, naval construction,
chemical transport, food preparation, medical
instruments
Cast Irons Cylinders, pistons, motor blocks, construction,
wear resistant materials
Light Alloys Aluminum Alloys Aerospace, construction, transport, packaging,
electrical conductors
Magnesium Alloys Aerospace, automotive, sporting equipment
Titanium Alloys Aerospace, chemical industry
Copper Alloys Copper Electrical conductors
Bronze Heat exchangers, chemical industry, maritime
industry
Brass Pressure vessels, fittings
Nickel Alloys Aerospace, currency

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 11 of XX

 Interactions
Materials Selection Methodology
Ashby Methodology

1. Translation: express design requirements as constraints & objectives

2. Screening: eliminate materials that cannot do the job
3. Ranking: find the materials that do the job best
4. Supporting information: explore pedigrees of top-ranked candidates

Shape
Process

Functionality
Material

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 12 of XX

 Material selection

[ASHBY99] - Materials Selection In Mechanical Design

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 13 of XX

 First Step: Translation

“Express design requirements as constraints and objectives”

Using design requirements, analyze four items:
1. Function: What does the component do?
2. Objective: What essential conditions must be met?
3. Constraints: What is to be maximized or minimized?
4. Free variables: Which design variables are free?
– Which can be modified?
– Which are desirable?

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 14 of XX

 Example: Materials for a Light, Strong Tie

Function:
Support a tension load
Objective:
Minimize mass
Constraints:
Length specified
Carry load F, w/o failure
Free variables:
Cross-section area
Material

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 15 of XX

 Example: Materials for a Light, Strong Tie

Objective:

Constraints:

Rearrange to eliminate free variable:

Minimizing weight by minimizing

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 16 of XX

 Second Step: Screening
Eliminate materials that cannot do the job
Need effective way of evaluating large range of material classes and
properties

Metals Steels Cast Ceramics Alumina

irons Al-alloys Cu- Si-carbide Si-nitride
alloys Ti-alloys Ziconia

Polymers PE, PP,

Hybrids Composites
PC, PS, PET, PVC,
Sandwiches Lattices
PA (Nylon)
Segmented
Polyester Epoxy

Elastomers Isoprene
Glasses Soda glass
Butyl rubber
Borosilicate Silica
Natural rubber
glass Glass ceramic
Silicones EVA

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 17 of XX

 Comparing Material Properties

Material Bar Charts Material Property Charts

Good for elementary selection
(e.g., find materials with large modulus)

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 18 of XX

 Screening Example
Heat Sink for Power Electronics
Function:
Heat Sink
Constraints:
1. Max service temp > 200 C
2. Electrical insulator
R > 1020 μohm cm
3. Thermal conductor
T-conduct. λ > 100 W/m K
4. Not heavy
Density < 3 Mg/m3
Free Variables:
Materials and Processes

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 19 of XX

 Heat Sink Screening: Bar Chart
temp > 200 C

200 ºC

R > 1020 µ ohm cm

λ > 100 W/mK

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 20 of XX

 Third Step: Ranking

“Find the materials that do the job best”

- What if multiple materials are selected after screening?
- Which one is best?
- What if there are multiple material parameters for evaluation?

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 21 of XX

 Single Property Ranking Example
Overhead Transmission Cable
Function:
Transmit electricity
Objective:
Minimize electrical Resistance
Constraints:
Length L and section A are specified
Must not fail under wind or ice-load
Required tensile strength > 80 MPa Electrical resistivity
Free variables:
Material choice
>> Screen on strength, rank on resistivity

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 22 of XX

 Single Property Ranking Example
Overhead Transmission Cable

Screening on strength eliminates polymers, some ceramics

Ranking on resistivity selects Al and Cu alloys

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 23 of XX

 Advanced Ranking: The Material Index

Use this method

1. Identify function, constraints, objective and free variables
List simple constraints for screening
2. Write down equation for objective -- the “performance equation”
If objective involves a free variable (other than the material):
Identify the constraint that limits it
Use this to eliminate the free variable in performance equation

3. Read off the combination of material properties that maximizes

performance -- the material index
4. Use this for ranking

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 24 of XX

 Optimized Selection

Using Material Indices & Property Charts: Strength

Example:
Tension Load,
strength limited
- Maximize: M = σ/ρ
- In log space:
log σ = log ρ + log M
- This is a set of lines
with slope=1
- Materials above line are candidates

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 25 of XX

 Material Indices & Property Charts

Stiffness
Example:
Stiff beam
- Maximize: M = Ε1/2/ρ
- In log space:
log E = 2 (log ρ + log M)
- This is a set of lines
with slope=2
- Candidates change with objective

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 26 of XX

 Considering Multiple Objectives/Constraints
With multiple constraints:
Solve each individually
Select candidates based on each
Evaluate performance of each
Select performance based on most limiting
May be different for each candidate
With multiple objectives:
Requires utility function to map multiple metrics to common performance
measures
Method for Early Technology Screening
Design performance is determined by the combination of:
Shape / Materials / Process
Underlying principles of selection are unchanged:
- BUT, do not underestimate impact of shape or the limitation of process
B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 27 of XX
 Ashby Method for Early Material Selection:

Four basic steps

1. Translation: express design requirements as constraints & objectives
2. Screening: eliminate materials that cannot do the job
3. Ranking: find the materials that do the job best
4. Supporting information: explore pedigrees of top-ranked candidates

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 28 of XX

 Other Materials Selection Charts

• Modulus-Relative Cost • Facture Toughness-Density

• Strength-Relative Cost • Conductivity-Diffusivity
Modulus-Strength • Expansion-Conductivity
• Specific Modulus-Specific • Expansion-Modulus
Strength • Strength-Expansion
• Fracture Toughness- • Strength Temperature
Modulus
• Wear Rate-Hardness
• Fracture Toughness-
• Environmental Attack Chart
Strength
• Loss Coefficient-Modulus

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 29 of XX

 Summary

• Material affects design based on

- Geometric specifics
- Loading requirements
- Design constraints
- Performance objective
• Effects can be assessed analytically
• Keep candidate set large as long as is feasible
• Materials charts give quick overview; software can be used to more
accurately find options
• Remember, strategic considerations can alter best choice

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 30 of XX

 Defining the Design requirements
Function Objective Constraint
"What does "What is to be maximized "What specific requirements
component do?" or minimized?" must be met?"
Any engineering The designer has an The objective must be
component has objective (to make it achieved subject to
one or more as cheap as possible, constraints (e.g. the
functions (to or as light as possible, dimensions are fixed; the
support a load, to or as safe as possible component must carry the
contain a pressure, or some combination given load without failure, it
to transmit heat, of these). should function in a certain
etc.). temperature range, etc.

Free variables: What is the designer free to change?

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 31 of XX

 1. List the constraints (e.g. no buckling, high stiffness) of the
problem and develop an equation for them, if possible.
2. Develop an equation of the design objective in terms of functional
requirements, geometry and materials properties (objective function).
3. Define the unconstrained (free) variables.
4. Substitute the free variable from the constraint equation into the
objective function.
5. Group the variables into three groups, functional requirements (F),
geometry (G) and materials functions (M), to develop the performance
metric (P):

6. Read off the materials index, M, in order to maximize the

performance metric (P).

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 32 of XX

 Materials Selection Charts
•The performance metric of a design is limited by the materials.
•Performance metric is a function of multiple properties f(multiple
properties)
•Charts Property 1 versus Property 2 (P1 vs P2)
•It can be plotted for classes and subclasses of materials (Classes: metals,
ceramics, polymers, composites) (Sub-Classes: engineering ceramics,
porous ceramics etc.)
•Combinations of properties are important in evaluating usefulness of
materials.
•Strength to Weight Ratio: f /
•Stiffness to Weight Ratio: E/
•The properties have ranges
•E(Cu) = few % (purity, texture, etc.)
•Strength of Al2O3 can vary by a factor of 100 due to (porosity, grain
size, heat treatment, etc.)

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 33 of XX

 Materials Indices
Materials indices are specific functions derived from design
equations that involve only materials properties that can be used in
conjunction with materials selection charts
•e.g. strong, light tie rod in tension–minimize ρ/σy
•e.g. stiff, light beam in bending –minimize ρ/E1/2
•e.g. stiff, light panel in bending -minimize ρ/E1/3

Derivation of MI’s

B. Konh, T. Sorensen, A Trimble ME 481 – Fall 2017 34 of XX