Material Selection

Introduction

 The objective of manufacturing operations is to

make products or components that adequately
perform their intended task

In the past...

Today..
Common alloys that have been in use for a
century or more have been much improved due
to advances in metallurgy and production
processes.

Metals

Poor material selection

Poor material selection

Constant re-evaluation of the Material Selection

Process

New materials are continually being developed; others are being

phased-out and prices are always subject to change
Constraints:
Environmental impact
Recycling
Worker health and safety

Constant re-evaluation of the Material Selection

Process

Improvements:
Weight reduction
Energy savings
Corrosion resistance
Etc

Product liability actions as a result of improper material use

Example: Car Industry

Material Selection &

Manufacturing Processes

 The interdependence between materials and

their processing must also be recognized.

New processes <-> New materials

- lower production costs
- improved product quality

Change in material <-> Change in manufacturing process

- Improper processing of a well-chosen material can
definitely result in a defective product.

The Design Process

Design

First step in the manufacturing process

What do we produce?

What properties must

it have?

What conditions will it

be used in?

What will it be made

of?

How many do we
make?

Three Stages Where Design Takes Place

CONCEPTUAL

FUNCTIONAL

PRODUCTION

Conceptual Design Stage

MAIN QUESTION:
What purpose does the product intend to fulfill?

CONSIDERATION OF CONCEPTS:
Practical? Sound? Could be improved?

CONSIDERATION OF RESOURCES:
Are there materials with the properties that can fulfill the purpose of the
product?
If not, is there an alternative concept or material that can be considered given
cost and time restrictions?

Functional (Engineering) Design Stage

Workable Design &
Manufacturing Plan

Analysis

Prototype Evaluation

geometric features
and dimensions
materials for each
component
appearance
cost
reliability
producibility
serviceability

functions &
performance
requirement of each
component
materials analysis,
selection &
specification

full evaluation of
working model
may lead to changes
before full production
as similar to
production model as
possible
materials
manufacturing
techniques

Production Design Stage

MAIN QUESTION:
Is the solution compatible with current production speeds & quantities?
Can new parts be made economically, and of the desired quality?

Early Stages of Manufacturing:

Changes in materials &
processes suggested

Changes may be costly

Highlights importance of
good material selection
and product evaluation

Later Stages of Manufacturing:

Emergence of new materials & processes

may result to improved performance or lower

costs
candidates must be evaluated thoroughly
less is known about the new materials &
process in terms of properties and
reliability
product failure & liability cases could emerge

Procedures for Material

Selection

Nearly every engineered item goes through a

sequence of activities that includes:
1.
2.
3.
4.
5.
6.

Design
Material Selection
Process Selection
Production
Evaluation
Possible redesign or modification

One method for approaching design and material selection is the case-history
method.

Case-history method
1.
2.

Evaluate what has been done in the past, or what the competitor is currently
doing
then, either duplicate or modify

Issues with this method:

1.
2.

How similar is similar?

This approach tends to preclude the use of new materials, new technology,
and any manufacturing advances that may have occurred since the
formulation of the original solution

BEWARE...
Other design and selection activities occur during the modification of an existing
product, generally in an effort to reduce cost, improve quality, or overcome a
problem or defect that has been encountered. However, in the process, other
original design requirements are overlooked, and are then compromised.

MAIN POINT!
It is important to consider all aspects, and all alternatives, when going through the
manufacturing process.

Major areas of consideration

In making decisions, the needs of the product must be fully defined. What are the
requirements? These will fall on three major areas:
1.
2.
3.

Shape or geometry considerations

Property requirements
Manufacturing concerns

Some shape or geometry considerations

This will have a strong influence on decisions relating to the proposed method or
methods of fabrication
1. What is the relative size of the component?
2. How complex is its shape? Are there any axes or planes of symmetry? Are
there any uniform cross sections? Could the component be divided into several
simpler shapes that might be easier to manufacture?
3. How many dimensions must be specified?

Some shape or geometry considerations

4. How precise must these dimensions be? Are all precise? How many are
restrictive, and which ones?
5. How does this component interact geometrically with other components? Are
there any restrictions imposed by the interaction?
6. What are the surface-finish requirements? Must all surfaces be finished? Which
ones do not?
7. How much can each dimension change by wear or corrosion and the part still
function adequately?

Some shape or geometry considerations

8. Could a minor change in part geometry increase the ease of manufacture or
improve the performance (fracture resistance, fatigue resistance, etc.) of the part?

Some considerations for mechanical properties

1. How much static strength is required?
2. If the part is accidentally overloaded, is it permissible to have a sudden brittle
fracture, or is plastic deformation and distortion a desirable precursor to failure?
3. How much can the material bend, stretch, twist, or compress under load and
still function properly?
4. Are any impact loadings anticipated? If so, of what type, magnitude, and
velocity?
5. Can you envision vibrations or cyclic loadings? If so, of what type, magnitude,
and frequency?

Some considerations for mechanical properties

6. Is wear resistance desired? Where? How much? How deep?
7. Will all of the above requirements be needed over the entire range of operating
temperature? If not, which properties are needed at the lowest extreme? At the
highest extreme?

Some considerations for physical properties

(electrical, magnetic, thermal, and optical)
1. Are there any electrical requirements? Conductivity? Resistivity?
2. Are any magnetic properties desired?
3. Are thermal properties significant? Thermal conductivity? Changes in dimension
with change in temperature?
4. Are there any optical requirements?

Some considerations for physical properties

(electrical, magnetic, thermal, and optical)
5. Is weight a significant factor?
6. How important is appearance? Is there a preferred color, texture, or feel?

Some environmental concerns

1. What are the lowest, highest, and normal temperatures the product will see?
Will temperature changes be cyclic? How fast will temperature changes occur?
2. What is the most severe environment that is anticipated as far as corrosion or
deterioration of material properties is concerned?
3. What is the desired service lifetime for the product?

Some environmental concerns

4. What is the anticipated level of inspection and maintenance during use?
5. Should the product be manufactured with disassembly, repairability, or
recyclability in mind?

Some manufacturing concerns

1. How many of the components are to be produced? At what rate?
2. What is the desired level of quality compared to similar products on the market?
3. What are the quality control and inspection requirements?
4. Are there any assembly (or disassembly) concerns? Any key relationships or
restrictions with respect to mating parts?
5. What are the largest and smallest section thicknesses?

Some manufacturing concerns

6. Have standard sizes and shapes been specified wherever possible (both as
finished shapes and as starting raw material)? What would be the preferred form
of starting material (plate, sheet, foil, bar, rod, wire, powder, ingot)?
7. Has the design addressed the requirements that will facilitate ease of
manufacture (machinability, castability, formability, weldability, hardenability)?
8. What is the potential liability if the product should fail?
9. Are there any end-of-use disposal concerns?

Additional Factors to
Consider

Cost
Cost should not be considered until a material has been
shown to meet the necessary requirements.
Material Cost

Fabrication Cost

environmental impact
product lifetime
cost of disposal or recycling

Cost

Is the material too expensive to meet the marketing objectives?

Is a more expensive material justifiable if it offers improved performance?
How much additional expense might be justified to gain ease of
fabrication?

Cost Figure: cost per unit weight or cost per unit volume

Material Availability

Size

Shape

SUPPLY

Quantity

Additional Factors
Possible misuses of the product
Recorded failures of other similar products
Conditions for favorable performance

Consideration of
the Manufacturing
Process

Consideration of the Manufacturing Process

Ability to shape a material into useful objects in an economical and timely manner
1.
2.

Consider fabrication processes

Suitability of the pre-screened materials to each fabrication process
Examples:
Steel cannot be fabricated by die casting
Titanium cannot be forged by conventional drop hammers.

IMPORTANT: Minimize the number of operations involved.

Ultimate Objective

Developing the best manufacturing system

Combination of materials and process selection

Judgmental decisions required (which is best)
Decisions in one area can impose limitations in another

Material and Process Selection

Selection of materials may limit the selection of processes, and vice versa.
Each has its own performance characteristics, benefits and limitations

Overall Goal

To develop the best manufacturing system without overlooking any major

requirements
If no solution fits perfectly:

Redesign
Adjust requirements
Develop new materials and/or processes

Therefore, it is necessary for:

Decision makers to know the product, materials and processes

Necessity for different perspectives; persons of different expertises

Evolution

Study failures, reevaluate costs and material availability, examine new materials/processes,
demand improved performance

Material
Substitution

New technology and market pressure

causes new materials to be substitutes into

an existing design or manufacturing system

Substitute often brings

improved quality
reduced cost
ease of manufacture
simplified assembly
enhanced performance
However some requirements are overlook and cause more
harm than good

HSLA (High Strength Low-Alloy Sheets)

for production of lighter-weight,more fuel efficient and less
emission-producing automobiles
matched the strength of traditional body panels
thinner-gage material
corrosion resistance and rigidity is unaltered
Thinner sheets corrode in a shorter time
previously unnoticed vibrations became a significant problem

Aluminum Sheet

replaced steel panels

reduce 50% of the weight
needed special design consideration for vibration problems

Aluminum Casting
considered as alternative to cast iron for engine block and
transmission housing
Enhanced corrosion resistance
weight savings
mechanical properties must be ensured to be adequate
consideration for noise and vibration

Some Successful Substitutes

Polymeric materials
used successfully for body panels,bumpers,fuel
tanks,pumps,and housings

Composite-material
drive shafts in place of metals

Connecting rods
Cast Metal,powder metallurgy products and composite
materials

Engine components
ceramic and reinforced plastic components

Magnesium
used in instrument panels and steering wheels

Fiber reinforced polymer

cargo beds for pickup trucks

Design requirements

first to consider when making material substitution in a

successful product

EFFECTS OF PRODUCT
LIABILITY ON MATERIAL
SELECTION

Product Liability, court awards, Rising

insurance cost
made manufacturers employ the very best procedures in
material selection and processing

Causes of negligence in material selection

and processing
1. Failure to know and use the latest and best information
about the materials being specified
2. Failure to foresee,and account for,all reasonable uses of
the product

3. Use of materials for which there were insufficient or

uncertain data, particularly with regard
to long-term properties
4. Inadequate and unverified quality control procedures
5. Material selection made by people who were completely
unqualified

Examples of Product Liability cases

Exploding Coca-Cola

In 1944, waitress Gladys Escola was stocking Coca-Cola bottles

when one suddenly exploded in her hand. The explosion gave
Escola a deep cut in the palm of her hand and severed numerous
nerves and muscles. Famous attorney Melvin Belli represented
Escola at trial. The jury ultimately returned their verdict in Escolas
favor. The case was a major factor in the development of product
liability law in the US.
Accessed Nov. 10, 2015

http://pauledlundlaw.com/2013/10/07/4-famous-product-liability-lawsuits/

Examples of Product Liability Cases

General Motors Inc. (GM) Faulty Ignition

Switch

These faulty ignition switches could shut off the engine

during driving, disable power steering and brakes, and
prevent airbags from inflating.
linked to at least 13 deaths and 31 car accidents
Accessed Nov. 10, 2015. http://www.investopedia.com/slide-show/5-largest-us-product-liability-cases/

Aids to Material Selection

Because of the immense number of existing

engineering materials, engineers need handbooks
and other resources as extensive guides or
comprehensive references in material selection.

ex: Materials Selection in Mechanical Design, ASM Metals Reference

Book, Smithells Metal Reference Book, Modern Plastics, Industrial
Ceramics, and ASMs Advanced Materials and Processes, SAE
Handbook, ASME Handbook, etc.

As mentioned a while ago, it important to have

knowledge about the costs of a material.
Costs associated with various processing
operations are more difficult to obtain and can vary
greatly from one company to another.

Materials Selection Charts (also called Materials Property

Charts)
Youngs Modulus - Density chart

Accessed Nov. 10, 2015. http://www-g.eng.cam.ac.uk/125/now/mfs/tutorial/non_IE/charts.html

Materials Selection Charts

Youngs Modulus - Cost chart

Accessed Nov. 10, 2015. http://www-materials.eng.cam.ac.uk/mpsite/interactive_charts/stiffness-cost/NS6Chart.html

Materials Selection Charts

Strength - Cost chart

Accessed Nov. 10, 2015. http://www-materials.eng.cam.ac.uk/mpsite/interactive_charts/strength-cost/NS6Chart.html