MATERIALS SELECTION

Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering

Chapter Two
M
M
ethods of
ethods of
M
M
aterials
aterials
S
S
election
election
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Some of the more common and analytical methods of materials Some of the more common and analytical methods of materials
selection are: selection are:
1. 1. Cost versus Performance Cost versus Performance
2. 2. Weighted Property Indices Weighted Property Indices
3. 3. Value Analysis Value Analysis
4. 4. Failure Analysis Failure Analysis
5. 5. Benefit Benefit- -Cost Analysis Cost Analysis
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
1. Cost 1. Cost vs vs Performance Performance
Because Because COST COST is so important in selecting materials, it is logical to is so important in selecting materials, it is logical to
consider cost at the start of the material selection process consider cost at the start of the material selection process
Usually, a target cost is set to eliminate the materials that ar Usually, a target cost is set to eliminate the materials that are very e very
expensive expensive
The final choice is a trade The final choice is a trade- -off between off between COST COST and and PERFORMANCE PERFORMANCE
Overall, cost is the most important criterion in selecting a mat Overall, cost is the most important criterion in selecting a material erial
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Cost is a most useful parameter when it can be related to a crit Cost is a most useful parameter when it can be related to a critical ical
material property that controls the performance of the design material property that controls the performance of the design
Such a Such a cost cost vs vs performance performance index can be used for optimising the index can be used for optimising the
selection of a material selection of a material
However, the cost of a material expressed in $$$ / kg may not al However, the cost of a material expressed in $$$ / kg may not always be ways be
the most valid criterion the most valid criterion
It depends on the material function: whether it is used as a It depends on the material function: whether it is used as a load bearing load bearing
or just as or just as space filling space filling
It is also very important to emphasise that there are many ways It is also very important to emphasise that there are many ways to to
compute costs compute costs
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Total life-cycle cost is the
most appropriate cost to
consider. This cost consists
of:
The initial material costs +
manufacturing costs +
operation costs +
maintenance costs
Consideration of factors
beyond just the initial
materials cost leads to
relations such as shown in
Figure 2
Yield Strength (MPa)
$$ $$
Min. Cost
A: Manufacturing Costs
B: Other Costs
Total Cost
Figure 2: Relations between cost factors and a
material property
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Cost per unit property method Cost per unit property method
This method is suitable for initial screening in situation where This method is suitable for initial screening in situation where one one
property stands out as the most critical service requirement. property stands out as the most critical service requirement.
In this case, it is possible to estimate how much various materi In this case, it is possible to estimate how much various materials to als to
provide this requirement will cost provide this requirement will cost
Cost / unit tensile ($$/ Cost / unit tensile ($$/ MPa MPa) strength is usually one of the most ) strength is usually one of the most
important criteria important criteria
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
By introducing the density of the material and the market price, By introducing the density of the material and the market price, the cost the cost
of buying 1 of buying 1 MPa MPa of strength, C, can be calculated: of strength, C, can be calculated:
P: material price / unit weight P: material price / unit weight
: density : density
: tensile strength : tensile strength

P
C =
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Materials with lower cost/ unit strength are preferable. Materials with lower cost/ unit strength are preferable.
Since manufacturing costs are a significant factor in evaluating Since manufacturing costs are a significant factor in evaluating
materials, it can be considered in the cost /unit property analy materials, it can be considered in the cost /unit property analysis by sis by
considering P as the cost of material + manufacturing and finish considering P as the cost of material + manufacturing and finishing ing
costs costs
Limitations of this method
It considers It considers only one property only one property as the most critical and ignoring other as the most critical and ignoring other
properties properties
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Since comparison of materials is a fundamental part of material Since comparison of materials is a fundamental part of material
selection selection
A basis material can be selected and the other candidate materia A basis material can be selected and the other candidate materials ls
compared against it compared against it
The relative cost / unit property, RC, is then given by: The relative cost / unit property, RC, is then given by:
i: candidate material, b: basis material i: candidate material, b: basis material
If RC < 1: If RC < 1: the candidate material is less expensive than the basis the candidate material is less expensive than the basis
material material
i
b
b
i
b
i
P
P
RC

=
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Relationships to determine the relative cost per unit property f Relationships to determine the relative cost per unit property for strength or strength
and stiffness are given in Table 2 and stiffness are given in Table 2
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
2. Weighted Property Method 2. Weighted Property Method
In most applications, the selected material should satisfy In most applications, the selected material should satisfy more than one more than one
functional requirement functional requirement
In this method each material requirement (or property) is assign In this method each material requirement (or property) is assigned a ed a
certain weight (which depends on its importance to the performan certain weight (which depends on its importance to the performance of ce of
the design) the design)
This method attempts to: This method attempts to:
1. 1. Quantify how important each desired requirement is by determinin Quantify how important each desired requirement is by determining g
a a weighting factor ( weighting factor ( ) )
2. 2. Quantify how well a candidate material satisfies each requiremen Quantify how well a candidate material satisfies each requirement t
by determining a by determining a scaling factor ( scaling factor ( ) )
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Weighted Properties Method Weighted Properties Method
Find weighting factors
of properties of
candidate materials
Convert properties of
different materials into
scaled properties
Find the Performance
Index ()
=
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
2.1. Ranking of Attributes 2.1. Ranking of Attributes
Attributes are characteristics that can be described to distingu Attributes are characteristics that can be described to distinguish one ish one
item from another item from another
Some attributes are more important that others. Determining the Some attributes are more important that others. Determining the
relative importance of the various properties assigned to these relative importance of the various properties assigned to these
attributes is therefore necessary if this method is to be used attributes is therefore necessary if this method is to be used
There are two steps for ranking attributes: There are two steps for ranking attributes:
rank in order of importance with no consideration of how important
one attribute is to another
a weight is assigned to the importance of each attribute
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
2.2. Weighting factors 2.2. Weighting factors
It is desirable to quantify the relative importance of the attri It is desirable to quantify the relative importance of the attributes butes
One attribute may be very much more important than another, whil One attribute may be very much more important than another, while e
others may be quite similar in importance others may be quite similar in importance
The relative importance is shown by using a point scale that The relative importance is shown by using a point scale that does not does not
exceed 100 points exceed 100 points
e.g; if strength is 4 times as important as cost, it will be rep e.g; if strength is 4 times as important as cost, it will be represented resented
by an 80 / 20 division by an 80 / 20 division
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
Weight 4 times as important as strength, strength is 4 times as Weight 4 times as important as strength, strength is 4 times as important important
is as cost, corrosion is 2 /3 the importance of strength, etc is as cost, corrosion is 2 /3 the importance of strength, etc
Weighting of attributes
Property 1/2 1/3 1/4 1/5 ratio weight
Strength 1 20 60 50 80 1.0 0.14
Density 2 80 4.0 0.58
Corrosion 3 40 0.66 0.10
Colour 4 50 1.0 0.14
Cost 5 20 .25 0.04
Total 6.91 1.00
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
We can also use the We can also use the Digital Logic Method Digital Logic Method
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
The number of attributes that should be listed vary between 5 The number of attributes that should be listed vary between 5 - - 10 10
This method combine properties with different units. This limita This method combine properties with different units. This limitation is tion is
overcome by the use of a overcome by the use of a scaling factor scaling factor
The relative merit of each property of the candidate material ma The relative merit of each property of the candidate material may be y be
incorporated by assigning the value of 100 (%) to the best mater incorporated by assigning the value of 100 (%) to the best material in ial in
that property category that property category
MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
For a given property, the scaling factor ( For a given property, the scaling factor ( ) for a given candidate ) for a given candidate
material is: material is:
For properties that should have maximum values (strength, toughn For properties that should have maximum values (strength, toughness ess ) )
For properties that should have low values (density, cost corrosion )
100
max
=
list the in value
property of value numerical

100 =
property of value numerical
list the in value lowest

MATERIALS SELECTION
Ali Ourdjini, UTM - 2005 Faculty of Mechanical Engineering
The best material may either have the largest value of the given The best material may either have the largest value of the given
property or the smallest property or the smallest
For example; For example;
High Strength is given 100 High Strength is given 100
Low density or low corrosion rate are given 100 Low density or low corrosion rate are given 100
2.3. Performance Index 2.3. Performance Index
The material performance index ( The material performance index ( ) is calculated: ) is calculated:
The material with the highest The material with the highest is considered to be the best is considered to be the best


=