Analysis of material

performance requirements
The material performance requirements
can be divided into 5 broad categories:
 Functional requirements
 Process-ability requirements
 Cost
 Reliability requirements
 Resistance to service conditions
 The Materials Selection Process
 Application —› determine required Properties
Properties: mechanical, electrical, thermal, magnetic,
optical
 Properties —› determine candidate Material(s)
Material: microstructure, composition
 Material —› determine required Processing
Processing: to change microstructure and overall
shape ex: casting, sintering, vapour deposition,
doping, forming, joining, annealing
 Properties are a link between materials
science and materials engineering
 Structure  Service
◦ Atomic bonding Performance
◦ Crystal structure ◦ Stresses
◦ Corrosion
◦ Defect Structure
◦ Temperature
◦ Microstructure
◦ Radiation
◦ Macrostructure ◦ Vibration

Material
Material Science Properties Material Engineering
 From structure
to properties

 Comparison of crystal
structures for (a) aluminium
(face-centered-cubic) and (b)
magnesium (hexagonal close-
packed).
From structure to properties
Less porous
What material do I select for a
particular application?

 1. The general type of material is

appropriate (yang sesuai).
 2. The best specific material within the
category must be found.
Gas pressure can be 14 MPa for
indefinite periods
When do we select specific materials?

Customer Needs
Formulation

- Customer requirements
- Importance weights
- Eng. characteristics
Concept Design - House of Quality
- Eng. Design Spec’s

- Abstract embodiment
?
- Physical principles
- Material arrangement of parts/features
- Geometry Configuration (i.e. shaping materials)
Design
 Therefore, let’s examine…

Formulation

Concept Design
materials manufacturing
processes
Configuration Design

Parametric Design

Detail Design
Interdependence - compatibility

Material
Properties

Manufacturing compatible
Processes materials & processes
Interdependence - capability
capable processes
(kemampuan proses)
for the geometry

Manufacturing Product
Processes Geometry
Product function is interdependent

Material
Properties

Product
Function

Manufacturing Product
Processes Geometry
Example: turbine blades
 Material properties: creep and
corrosion/oxidation requirements, but
toughness and fatigue resistance are
also important factors.
 Manufacturing process: single crystal
casting.
 Product geometry: streamline with
cooling system inside
Example: turbine blades
Example: turbine blades
 In a single-crystal casting simulation, the
different colours represent different grain
orientations of the metal.
 The cast metal starts solidifying at the cool
end while the dendrites of the crystal grow
towards the heated end (the pigtail, or green
swirl-shaped area), eventually growing into a
single crystal.
 These castings are often used in turbine-
blade manufacture.
Example: turbine blades
Example: turbine blades
 Jet engine (turbine blades) simulation
 Material properties

 Mechanical properties
quantities that characterize the
behavior of a material in response to
external, or applied forces

 Physical properties
quantities that characterize the
behavior of a material in response to
physical phenomena other than mechanical forces
…(e.g. such as heat, electricity, radiation)
 Mechanical properties
F
stress
 F/A
A
ductile ?
L L  L
S ut

Sy

brittle
elastic plastic
y f L  L
strain   
L
stiffness ?
Strength = stress at failure = (failure)

E

Mechanical properties
 Fundamental properties

Characteristic Behavior Property Units

Strength strong, weak ultimate strength MPa (ksi)
Elastic strength elastic then plastic yield strength MPa (ksi)
Stiffness flexible, rigid modulus of elasticity MPa (Mpsi)
% elongation,
Ductility draws, forms easily dimensionless
% area reduction
Hardness resists surface Brinell No. MPa (ksi)
indentation
Corrosion resistance resists chemicals, galvanic series activity
oxidation number
 Fundamental properties

Characteristic Behavior Property Units

Fatigue resistance endures many load cycles endurance limit MPa (Mpsi)
thermal
Conductivity conductivity (Btu/hr) / (F-ft),
conducts, insulates
(heat, electric) electrical Mhos
conductivity
Creep resistance time dependent creep strength MPa (ksi)
stretching
Impact resistance shock, impact loads Charpy energy N-m, (ft-lbs)
Density (mass) mass density kg/m3, (slugs/ft3)
heavy, light
Density (weight) weight density N/m3, (lbs/ft3)
Temperature tolerance softens, or melts easily melting point degrees C, F
Elastic Moduli
 Young Modulus (E): describes tension or
compression
 Shear Modulus (G) : describes shear
 Bulk Modulus (K) : describes treeaxial stress,
the effect of hydrostatic pressure
 Poisson’s Ratio (u) : negative ratio of the lateral
strain to the axial strain in axial loading
G = 3/8 E
K≈E
u = 0.25  0.35
K1C = Y σ √π cY = geometry factor
 Material families / sub-
families
Materials

Metals Polymers Ceramics Composites Family

(Ashby)

Ferrous Thermoplastics

Non-ferrous Thermosets Sub-family

Elastomers
Material sub-families /
classes
Materials

Metals
Family

Ferrous
Sub-family

Cast iron
Carbon steel
Alloy steel Classes
Stainless steel
Metals
Metals

Ferrous Non-ferrous
cast iron aluminum
carbon steel brass
alloy steel bronze
stainless steel copper
lead
magnesium
nickel
tin
titanium
tungsten
zinc
Metals
 High moduli (E)
 Can be made stronger by: alloying, heat or
mechanical treatment
 Easy to deform, specially in high
temperature
 Poor resistance to corrosion
 Good electrical & thermal conductivity
Metals
 Cast iron (grey, white, malleable, nodular)
 Carbon steel (low, medium, high)
 Alloys steel (low alloys, tool, stainless)
 Light alloys (zinc, aluminum, magnesium,
titanium)
 Heavy alloys (copper, lead, nickel)
 Refractory metals (tungsten, tantalum,
molybdenum)
 Precious metals (gold, silver, platinum)
 Natural and

Polymers synthetic rubbers

Polymers

Thermoplastics Thermosets Elastomers

ABS alkyd butyl

acetal epoxy fluorocarbon
acrylic melamine neoprene
nylon phenolic nitrile
polycarbonate polyester polysulfide
polyethylene urethane rubber
polypropylene silicone
polystyrene
vinyl
Polymers
No chemical reaction

Cross-linking
 Polymers
 Low moduli
 Large elastic deflection
 Creep at room temperature
 Resistance to corrosion
Polymers
 Partially crystalline (polyamides,
acetals, polyathenes)
 Amorphous (PVC, polycarbonates,
polysterenes)
 Epoxy (phenolics, polyesters, aminos)
 Rubbers (natural, nitrile, butyl, styrene,
silicones)
Ceramics
Ceramics
alumina
beryllia
diamond
magnesia
silicon carbide
silicon nitride
zirconia
Ceramics
 NaturalCeramics = rocks, ore
 Constructional = porcelain,
stoneware, earthenware
 Electronics = semiconductors, ferrites,
capacitor
 Engineering Ceramics = alumina,
carbides, nitrides, zirconia, graphene
 Glasses = soda, borosilicates,
pyroceramics
Ceramics
 High moduli
 Hard
 Brittle
 Strong
 Low density
 Resistance to corrosion & abrasion
 Low electrical & thermal conductivity
Composites
Composites

carbon fiber
ceramic
matrix
glass fiber
Kevlar
metal
matrix
Composites
 Composites (natural, fiber, particulate,
dispersion)
 Metal-Metal Composite
 Metal-Ceramic Composite
 Metal-Polymer Composite
 Ceramic-Ceramic Composite
 Ceramic-Polymer Composite
 Polymer-Polymer Composite
Composites
 Depends on the type of composites
 Can be low density
 Can be strong & stiff
 Can be tough
Composites
Manufacturing process

Carbon fiber Style 282

bidirectional.
Araldite epoxy resin with
HY956 additive.
 Composites
College Park Foot

Otto Bock Advantage Ossur Flexwalk

Pie protésico dinámico

2004

Pie protésico dinámico

2005
 Composites

Marlon Cameron
Shirley Clapp

Ossur Otto Bock

Cheeta C-Leg
Flex-Foot
Date of birth: April 21, 1978 Date of birth: Sep 15, 1986
Hometown: Thatcher, Utah
Current Home:San Diego, CA
Properties, Symbols & Unit
 Density : ρ Kg/m3 , g/cm3
 Elastic Modulli : E, G, K Gpa
 Strength : σy, σu, σb MPa
 Fracture toughness : K1C MPa.m0.5
 Hardness : BHN,VHN, etc.
 Thermal conductivity : λ, k W / (m K)
 Thermal diffusivity : a m2/s
 Specific heat : Cp J /(kg K)
 Meltng point : Tm oK
 Thermal exp. coeff. : α K-1
Property profiles by family
Processing route
 A proper processing route to
manufacture a specific part or component
has to be finalized that calls for a through
methodology for the selection of a
suitable manufacturing process.
 The manufacturing requirements are
expressed as constraints on material,
shape, size, tolerance, roughness, and
other process-related parameters.
Processing route
 The constraints are used to screen out
processes that are incapable of meeting
them, using process selection diagrams.
 The surviving processes are then ranked
according to economic measures and
then the top ranked candidates are
explored for supporting information to be
enabled as final choice.
Processing
route
This figure
schematically
outlines the steps
to select a suitable
manufacturing
process for a given
part provided the
material and the
shape of the part
are finalized
Process-Material matrix
 Next figure represents a typical process-
material matrix indicating the general
compatibility between manufacturing
process and engineering material.
 The processes are also broadly classified as
shaping, joining and finishing.
 The dot indicates that the pair of the
material and the process is compatible.
 For example, sand casting or die casting
process cannot be used for processing of
composite materials
M F Ashby,
Material
Selection in
Mechanical
Design,
Butterworth-
Heinemann,
1999.
Process-Shape matrix
 Next figure presents a broad classification of
different shapes that are commonly encountered
in product design.
 Various manufacturing processes are capable of
making these shapes. For example, a typical
turning operation creates axisymmetric shapes
while extrusion, drawing and rolling make
prismatic shapes – both circular and non-circular.
 The sheet forming processes can make flat or
dished shapes. Certain manufacturing processes
can make three-dimensional shapes
Process-Shape matrix

M F Ashby, Material Selection in Mechanical

Design, Butterworth-Heinemann, 1999.
Process-Shape matrix
 Next figure depicts a typical Process vis-
à-vis Shape compatibility chart indicating
the ability of various manufacturing
processes in producing different shapes.
 Often a single process is unable to give
the final shape of a product and it is
necessary to combine two or more
processes.
M F Ashby, Material Selection
in Mechanical Design,
Butterworth-Heinemann,
1999.
Process-Mass bar-chart
 Next figure shows the typical mass-range of
components that each process can make.
Large components can be built up by joining
smaller ones. For this reason the ranges
associated with joining are shown in the
lower part of that figure.
 It can be noted that sand casting process, for
example, is capable of producing large
component while die casting or investment
casting processes can make relatively smaller
sized parts.
M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.
Process-Section thickness bar-chart
 The selection of a manufacturing process
also depends on the section thickness of the
part to be made.
 Each process has its limit over the range of
the section thickness, which it can produce.
 For example, surface tension and the typical
nature of heat flow limit the minimum
section and slenderness of gravity-die cast
shapes. Bulk deformation processes cover a
wider range of section thickness.
Process-Section thickness bar-chart
 Limits on forging pressures also set a lower limit
on the section thickness and slenderness that can
be forged.
 Powder forming methods are more limited in the
section thicknesses they can create, but they can
be used for ceramics and very hard metals that
cannot be shaped in other ways.
 Special techniques such as electro-forming, plasma
spraying allow manufacturing of slender shapes.
 Next figure depicts the typical manufacturing
processes and the range of section thickness that
each process can manufacture.
M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.
Process – Dimensional Tolerance
bar-charts
 Tolerance and surface roughness that a
specific manufacturing process can
provide is an important characteristic.
Manufacturing processes vary in the levels
of tolerance and roughness they can
achieve economically.
 Next figure shows the process vis-à-vis
range of achievable dimensional tolerance.
M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.
Process – Dimensional Tolerance
bar-charts
 Next figure shows the process vis-à-vis range of
minimum achievable surface roughness bar charts.
 For example, die casting process with the
permanent metallic dies can give better surface
finish compared to the same achievable in sand
casting.
 Machining is capable of delivering high
dimensional accuracy and surface finish when the
process parameters are controlled properly.
 Grinding can be adopted to achieve very high
tolerance while such precision and finishing
operations are generally expensive.
M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.
Economic criteria for selection
 The choice of the process also depends on the
batch size that is required to produce.
 Often manual processing is suitable when the
quantity to be produced is low. However, the cost
to manufacture increases with the increase in
batch size e.g. the manual cost that warrants
automated manufacturing process for medium to
large batch size.
 Next figure typically represents the broad
relation between various manufacturing processes
and the corresponding economic batch size
M F Ashby, Material Selection in Mechanical Design, Butterworth-Heinemann, 1999.