Materials Selection & Design: Lecture Topics .

Department of Materials Engineering
ENG1050 & MCD4220 Engineering Materials Week 9A
Materials Selection & Design
www.monash.edu.au
john.forsythe@monash.edu
Lecture topics..
Materials Selection screening process Material Selection Charts Performance Index Design Guidelines Materials Selection vaulting pole, spark plug
www.eng.monash.edu.au
Learning Outcomes
Understand the process of material selection Understand the process of obtaining the performance Index Select an appropriate material using a Material Selection Chart Describe the materials used in a spark plug explain why they were selected for their application
Basic material properties

Mechanical properties
General Weight: Expense: Mechanical Stiffness: Ductile materials
Stress Elastic limit,
Thermal expansion
Density , Mg/m3
Thermal strain
Cost/kg Cm, $/kg
Youngs modulus E, GPa Elastic limit y , MPa
Strength:
Expansion coefficient, Temperature, T
Fracture strength: Tensile strength ts , MPa Brittleness: MPa.m1/2 Thermal Expansion: Expansion coeff. , 1/K Conduction: Thermal conductivity , W/ m.K Electrical Conductor? Insulator? Fracture toughness Kic ,
Thermal conduction
x
Youngs modulus, E Strain
T1
Area A
Heat flux, Q/A
To
Q joules/sec
Brittle materials
Stress
* Tensile (fracture) strength, *

Youngs modulus, E Strain
Thermal conductivity, (T1 -T0)/x
Mechanical Properties
Stiff Strong Tough Light
All OK !
Not stiff enough (need bigger E)
Not strong enough (need bigger y )
Not tough enough (need bigger Kic)
Too heavy (need lower )
Materials Information for Design

The goal of design: To create products that perform their function effectively, safely, at acceptable cost What do we need to know about materials to do this? More than just test data.
Data capture Statistical analysis Selection of material and process Economic analysis and business case
$
Test Test data Design data Potential applications Successful applications
Characterisation
Selection and implementation

Data Organisation
Kingdom Family Class Member Attributes
Density Mechanical props. Thermal props. Electrical props. Optical props. Corrosion props. Supporting information -- specific -- general
Ceramics Polymers
Steels Cu-alloys Al-alloys Ti-alloys Ni-alloys
Materials
Metals Natural Foams
Composites Zn-alloys
1000 2000 3000 4000 5000 6000 7000 8000
A material record
Modulus of Materials
Steel Copper WC
Youngs modulus, GPa
CFRP Alumina Aluminium Zinc Lead PEEK PP PTFE Glass GFRP Fibreboard
Metals
Polymers
Ceramics
Composites
Selection rarely dependent on a single parameter Often consider the weight of the article
Department of Materials Engineering www.eng.monash.edu.au
Materials Selection
Materials properties LIMIT performance. Usually a COMBINATION of properties are important eg. strength-to-weight ratio; f / Stiffness-to-weight ratio; E /
Materials Property Chart

1000 Ceramics Youngs modulus E, (GPa) 100 Composites 10 Woods Metals 1 Foams 0.1 Elastomers 0.01 0.1 10 1 Density (Mg/m3) 100 Polymers
Modulus - Density
Youngs modulus (GPa)
Density (Mg/m3)
Methodology for Materials Selection
Selection has 4 basic steps 1. Translation of design requirements into a material specification 2. Screening out of materials that fail constraints 3. Ranking by ability to meet objectives; material indices 4. Search for supporting information for promising candidates
Material Specification
Translation Analyse: Function Constraints Objectives Free variables
What does the component do ? What essential conditions must be met ? What is to be maximised or minimised ? Which design variables are free ?
Design requirements
From which we obtain Screening criteria: go / no-go criteria (usually many) Ranking criteria: an ordering of the materials that go
Material Index
STRUCURAL INDEX
p = f (F) f(G) f (M)
performance functional requirement eg. tensile load,
geometric parameters MATERIAL PERFORMANCE INDEX
Material for a Paul Vault

Function?
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Constraints length fixed Objectives maximum flexibility for amount of material

lightweight rod
Free Variable Material Radius
Material for a Vaulting Pole

radius r, length l assuming solid rod, held at one end built-in cantilever
mass = density () volume ( r2 l) mass = r2 l minimize mass

r is a free variable and is eliminated
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M = E 1/2 / material index Taking logs on both sides log M = log E log log E = 2 log + 2 log M

log E = 2 log + 2 log M A plot of log E vs log will yield a family of straight lines all having a slope of 2 The lines are termed design guidelines ALL materials that lie on these lines will perform equally well in terms of stiffness-per-mass Materials lying above the line will perform better than one below selection zone
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13

4 3 2 1
The selection
1 Wood: Cheap, light, but variable 2 CFRP: The best choice, more control of design 3 Beryllium: cost (and toxicity) rules it out 4 Ceramics: But fracture toughness inadequate

Process: Position design line with a small group of materials above it These are the material with the largest values of M These materials potentially offer the best choice, but must satisfy other design criteria eg. toughess, cost
Material Woods CFRP GFRP Ceramics
M(GPa)1/2/(Mg/m3) 5-8 4-8 2-3.5 4-8
Comments Cheap, but natural variability As good as wood, more control of properties Cheaper than CFRP, but low M, thus heavier Good M, but tougness low
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Material Selection Chart

May impose additional property limits eg E 10GPa
Materials Selection Chart
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Materials Selection
Material for a pauling vault: Traditionally wood, but CFRP even better
What are modern vaulting poles made from?
Materials Selection Charts
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Materials Selection: Insulator for Automotive spark plug
delivers spark to ignite petrol vapour / air mix very high voltage required vast number of firing repetitions huge numbers needed ease of manufacture cost
Components 3 main parts

central shaft including electrode
insulator
body including electrode

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Performance
spark gap section of spark plug, showing the spark gap which must withstand the aggressive high temperature environment
Composition of Components
Insulator : ave high electrical resistivity and reasonable thermal conductivity h
Central Shaft : mild steel, steel nut Cu insert to conduct heat away from electrode i alloy tip N
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Spark plug insulator

Specification Function Objectives Constraints
Spark-plug insulator
Minimise material cost Good electrical insulator Breakdown V > 20 MV/m Tolerate temp. > 600 C Resist thermal shock of 100 C Material
Free variables
Spark plug insulator

Constraints: Good insulator; Thermal Strain = T Vmax > 2.107 V/m; (1)
Insulator Youngs modulus
Tmax > 873 K
Temperature change T-expansion coefficient
Stress:
=E
Elastic limit
(2)
Body shell
Fracture when:
= el in tension
(3)
Central electrode
Combining (1) to (3) gives allowable T-shock:
Impose T > -100K as a constraint, then minimise material cost

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Materials for spark-plugs

Search region
Thermal shock resistance, T (C)
Selection: Alumina
Additional constraints:
Good insulator Breakdown potential > 20 MV/m Maximum service temperature > 873 K
Approximate material cost ($/kg)

Summary
Material Selection Charts provide an effective process of comparing many materials at the same time The many demands placed on the spark plug results In the selection of several materials
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Resources
Ashby, M. F. , Materials selection in mechanical design [electronic resource] / Michael F. Ashby.2nd ed.Publisher:Oxford ; Boston : ButterworthHeinemann, c1999.Material type:[electronic resource] / Chapter 4
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Department of Materials Engineering

ENG1050 & MCD4220 Engineering Materials Week 9A