Chapter 1: Introduction

Dr. Abdul Shakoor

shakoor@uetpeshawar.edu.pk
 Materials Science & Engineering in a Nutshell
Materials Engineering
Performance
Designing the structure to
achieve specific properties
of materials.

Structure Processing

Processing
Properties
Structure
Materials Science
Properties
Investigating the relationship
between structure and properties Performance
of materials.
 Materials in Design
Selection of material for a given application is an extremely important part
of a design Process
Design:
A process of translating a new idea or market need into the detailed
information from which a product can be manufactured
The Design Process:
Problem
Concept
Selection
Realization
Each stage requires decision about materials and process for making it
Normally the choice of material is dictated by design
But sometime it is the other way around: a new product or the evolution of
the existing one is made possible by a new material
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Market Pull Versus Technology Push

New Materials Enable New Designs

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 Motivation for Selection
40,000-100,000 materials are available to Engineers in
recent days
Selection can be made on experience but it may not take
into account new developments taking place
The 20th Century has been a period of unprecedented
evolution of materials. This will continue in the 21st
Century
A systematic procedure based on a rational approach is
required for selection of materials
Selecting materials in mechanical design requires more
than consideration of their mechanical properties
Other factors in the Design Process include:
Cost Analysis
Process Selection
Environmental issues
Aesthetics 5
 Important Design Considerations
Failure in Service: mostly either mechanically or by
corrosion
Ductile Collapse:
Above yield stress, fracture properties are not important. Example of
ductile materials include?
Fatigue
Catastrophic or Brittle Failure
Which one is better?
Stiffness
Cost
Space filling (i.e. to lower cost per unit volume)
Surface Durability:
Corrosion
Wear

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 Physical Properties:
Conductivity
Magnetic
Etc
Aesthetics:
Texture and feel
Color and decorations

Although in a design process a material is chosen to satisfy a

predominant requirement for one property; the selected
material must possess a combination of properties
(sometimes conflicting such as low weight and cost)
A trade-off is normally required to get an optimum solution
There is often no unique solution

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Important Material Properties

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Design limiting material properties
Economic Cost
Recyclability
General Density
Mechanical Elastic moduli
Strength
Hardness
Fracture toughness / Fatigue
Damping capacity
Thermal Melting point / Glass transition temperature
Thermal conductivity / diffusivity / expansion
Specific heat / shock resistance
Electrical Conducting / non conducting
Environmental Corrosion / oxidation / wear

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Materials Selection Check List:

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 Materials Available
The broad group of materials available are:

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 Evolution of Engineering Materials
Throughout history materials have limited design of engineering components
and systems

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Evolution of Engineering Materials
Weight of the materials used in components/assemblies are
reduced with growing sophistication

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Case study: The evolution of materials in Vacuum Cleaners

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 Manufacturing
Goal of manufacturing: to create products and components
that perform properly.
Due to advances in materials science, there is a wide array of
available materials
The increase in the number of choices has often
led to improper or poor materials selection
Sometimes, a more expensive alloy is chosen
when a cheaper alloy would have been sufficient
Design and material engineers have the responsibility of
proper materials selection.
 Introduction
Material selection processes should be
constantly reevaluated
Materials selection concerns are always changing
Environmental pollution
Recycling
Energy
Health or safety constraints
Geopolitical issues
Introduction
Materials in many
products have changed
over the years

Figure 9-2 a) (Left) A traditional two-wheel

bicycle frame (1970s vintage) made from
joined segments of metal tubing,
b) (Right) a top-of-the-line (Tour de France
or triathlon-type) bicycle with one-piece
frame, made from fiber-reinforced polymer-
matrix composite. (Courtesy of Trek Bicycle
Corporation, Waterloo, WI.)
 9.2 Material Selection and Manufacturing
Processes
Material and manufacturing
processes are extremely (Material)
interdependent
Change in a material will likely
cause a change in the
manufacturing process needed
A successful product has gone
through both proper material
selection and processing
Figure 9-4 Schematic showing the
selection interrelation among material,
properties, processing, and
performance.
 9.2 Material Selection and Manufacturing
Processes
Material and manufacturing
processes are extremely (Material)
interdependent
Change in a material will likely
cause a change in the
manufacturing process needed
A successful product has gone
through both proper material
selection and processing
Figure 9-4 Schematic showing the
selection interrelation among material,
properties, processing, and
performance.
 9.3 The Design Process
Design is the first stage in manufacturing
processes
What it is
What properties must it possess
What material
How to make it
How many to make
What conditions will it see during use
 Steps for Design
1. Conceptual
Several concepts may be considered
2. Functional
Workable designs are developed
Detailed plan for manufacturing
Prototyping
3. Production
Full production
Production speeds and quantities
 Procedures for Material Selection

General sequence of product design

designmaterial selectionprocess
selectionproductionevaluationredesign
Case-history method
Evaluates what has been done in the past
Modification of an existing product
Evaluates the current product and manufacturing techniques
Changes or improves upon features of the existing product
Development of a new product
Follows the full sequence of product design above
 Geometric Considerations
Relative size
Shape complexity
Specified dimensions
Precision
Component interaction
Surface-finishes
Tolerances
Tolerances due to environmental or usage concerns
Minor changes to improve manufacture or performance
 Mechanical Properties
Static strength
Brittle fracture
Plastic deformation
Allowable bend, stretch, twist, or compress
Impact loadings
Vibrations or cyclic loadings
Wear resistance
Operating temperatures
 Physical Properties (Electrical, Magnetic,
Thermal, and Optical)
Electrical requirements
Conductivity, resistivity
Magnetic
Thermal conductivity
Thermal expansion
Optical requirements
Weight
Appearance (color, texture, feel)
 Environmental Considerations
Operating temperatures
Corrosion
Erosion
Lifetime
Fatigue
Expected level of maintenance
Disassembly
Repairability
Recyclability
 Manufacturing Concerns
Quantity
Production rate
Level of quality
Quality control and inspection
Assembly concerns
Section thickness
Standard sizes and shapes
Liability if product failure occurs
End-of-use disposal
 Proper Materials Selection
All factors and service conditions must be met
Absolute requirements
No compromise possible
Relative requirements
Compromises can be made
Good, better, best are all acceptable
 Additional Factors to Consider
Handbook data is valuable in determining materials
Note the conditions under which values for materials
were obtained
Cost is often one of the biggest additional factors
Often, compromises between material properties and cost
must be made
Material availability
Are there any possible misuses on the part of the
consumer?
Have there been failures for similar products?
Materials usage history
Material standardization
Consideration of the Manufacturing Process
Overall attractiveness
Physical properties
Mechanical properties
Formability
Economical concerns
All processes are not compatible with all
materials
 Ultimate Objective
Develop a combination of material and
processes that is the best solution
Material or manufacturing selection normally
imposes restrictions or limitations on the
other
Economics, environment, energy, efficiency,
recycling, inspection, and serviceability are
important deciding factors
 Decision Models

Figure : Alternative flow chart showing

Figure : Sequential flow chart showing parallel selection of material and
activities leading to the production of a part process.
or product.
 Decision Models

Figure 9-6 Alternative flow chart

Figure 9-5 Sequential flow chart showing showing parallel selection of material
activities leading to the production of a part and process.
or product.
 Compatibility
Figure : Compatibility
chart of materials and
processes. Selection of
a material may restrict
possible processes.
Selection of a process
may restrict possible
materials.
 Materials Substitution
Care should be taken so that all requirements
are still met
The total picture should be considered so that
any possible compromises can be determined
Aluminum sheets have replaced steel for weight
reduction, but vibration problems require special
design considerations
Material Substitutions
 Material Substitutions
Causes of product failure
Failure to know and use the best materials
information
Failure to account for all reasonable material uses
Use of materials with insufficient data
Inadequate quality control
Material selection made by unqualified people
 Aids to Material Selection
There is an enormous amount of resources available for
materials selection
Metals Handbook, published by ASM International
ASM Metals Reference Book
Handbooks are available for specific classes of materials
American Metal Market provides material costs
Materials Selection in Mechanical Design by M. F. Ashby
Computer software
Select a Material with Rating Chart
1. List all required material properties for a product to be
designed.
2. Screen all required properties and identify those absolute
properties that must be considered for the product as Go-
No-Go properties.
3. Rate each candidate material on a scale such as 1 to 5 or 1
to 10 for each required property.
4. Define weighted factor for each required property based on
its significance.
5. Multiply property rating by its weighted factor and sum the
results for each materials
6. Select the material that satisfies the Go-No-Go screen
and has the highest sum of the relative rating numbers.
Select a Material with Rating Chart
Material Go-No-Go Relative rating number - R SR Sr SR/r
(=rating number x weighting factor)

Weldability Stiffness Stability Fatigue Tensile

1 4 5 4 14

A 14

B 14

C 14
Select a Material with Rating Chart
Advantages:
Potential materials can be compared in a
uniform, unbiased manner
The best candidate can often be selected
There is less chance to overlook a major
requirement by placing all the requirement on a
single sheet.
Example: Selection of a Material:
 Solution
Finding Go-No-Go property: weldability
- S: satisfactory
- U: unsatisfactory
Calculating: R = Relative rating number, and r =
weighting factor.
Relative rating number R = property rating number x
weighting factor
Set materials property rating number (1 5):
excellent = 5, very good = 4, good = 3, fair = 2,
poor = 1
weighted factor for each materials property:
- Stiffness : 1
- Stability: 4
- Fatigue: 5
- Tensile strength: 4
Select a Material with Rating Chart
Material Go-No-Go Relative rating number - R SR Sr SR/r
(=rating number x weighting factor)

Weldability Stiffness Stability Fatigue Tensile

1 4 5 4 14

A 14

B 14

C 14
 Solution (cont.)
Rating chart for selecting
material
Weldability Stiffness Stability Fatigue Tensile SR Sr SR/Sr
Strength

Go-No-Go (1) (4) (5) (4)

screening
X S 3x1 3x4 2x5 3x4 37 14 2.64

Y U 3x1 5x4 3x5 5x4 58 14 4.14

Z S 3x1 3x4 5x5 2x4 48 14 3.43

 Conclusion:
Based on the chart below, material Y has
the highest rating number. However,
because it does not have satisfactory
weldability and this is an "absolute"
requirement, it should not be selected.
Material Z should be used.
 Summary
Proper materials selection is vital to a
products success
The design engineer and materials engineer
are responsible for materials selection
Materials and process selection go hand-in-
hand
Data should be used to validate materials
selection
 Case-Study / Presentation # 1
ME 5391: Applications and Selection of Materials

A thorough knowledge of different materials available is essential to

select proper materials for a designed product. This case
study/presentation will bring us update on the different materials types
available for design Following is a list of materials on which presentation
will be prepared:

Ferrous Alloys - Plain Carbon Steels

Ferrous Alloys - Alloy Steels
Non-Ferrous Alloys
Polymers (Excluding Elastomers)
Elastomers
Engineering (or Technical) Ceramics
Traditional Ceramics and Glasses
Composites
Natural Materials

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 The presentation should include the definition, sub-classes introduction to
the properties, specific examples, trade names, applications,
microstructures, general processing methods, cost and availability of the
materials class selected.

Individual presentation of 15 minutes will be made followed by Question

and Answer session.

A short hand-out should be provided by the presenter to the entire class.

The audience has to take notes during the presentation since the contents
presented will be considered as part of the course.

The presentation will be held after the regular lectures.

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