MecE 360: Engineering Design II

Section 3: Materials

Class Notifications
Jason Carey will be providing information about graduate
opportunities
B and A group meeting sign-up outside of 10-227
Quiz 1: early Feb
I posted: old A3 and soln online
Class notes purchased through MECE club for $20
Many extra examples, detailed notes
Teams are notified of projects
Relaxed design specifications as long as explained
5 pages of writing: figure out story, and write
Keys success : bearing, connections, fatigue, creativity

Objectives
Initial considerations
Materials, loading, failure
Presentation on designing materials

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Outline

Material considerations
Uncertainties in material properties (+/- 30%)
Basic engineering materials
Selecting the right material
Ashby charts
Manufacturing processes

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Material Considerations

(p.3-2)

1. Availability and cost

It is very possible that the perfect material exists
for you design - but at what cost.
Titanium: high specific strength (strength/density).
But costs $8.20/ kg vs. $1.50/kg for Al.
2. Strength
Critical for stress related failure (Section 5).

applied

y ,C ,T
n

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Material Considerations
3. Rigidity/stiffness
Designs are often limited by the amount of deflection
between mating components for alignment and proper
mating.
Deflection is dependent on elastic modulus (E) and
geometry.
4. Hardness and ductility
Is scratch resistance or large deformation important?
Contact problems: wear

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Material Considerations
5. Resistance to fatigue
Steel and aluminium have different fatigue behaviour.

6. Manufacturability and machinability

How easy is it to build?
3D printing: only certain materials

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Material Considerations
7. Resilience
The energy before yielding is important for combined
loading, temperature effects.
8. Friction coefficient
Different applications require different surfaces or
mediums for proper functions, e.g. bearings low, and
clutches high
9. Weight
Some designs are weight critical: consider polymers,
wood, foams, aluminium or titanium.

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Uncertainty

(p.3-3)

140

Number of test

120
100
80
60
40
20
0
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
Sy (kpsi)

Uncertainty and variability in material properties are

inherent due to microstructure variability
Assessed through experimental testing.

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Engineering Materials

Metals: Magnesium

Polymer: electrospun polyethylene oxideGarcia and Hernandez 2014

Ceramic: alumina
Carbon-reinforced-composite

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Metals

(p.3-6)

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Polymers

(p.3-7)

Different behaviour based on microstructure/chain linking

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Polymers

Properties change
significantly with
increasing temperature
Modulus drops
Should not used above
glass transition
temperature

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Composite Materials

(p.3-9)

In general, composites consist

of two or more materials
Fiber-reinforced polymers (FRP)
long fibers in resin matrix
fibers strength, brittle
resin toughness,
rigidity, protection of
fibers
Lamina is transverse isotropic material
Properties proportional to fiber volume fraction

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Composite Materials
Several laminae combined form a laminate
Laminates can be quasi-isotropic
Laminate layup can
be tailored to meet
specific strength and
stiffness requirements

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Ceramics
Only for compressive
loading
Poor in tension,
cracks propagate
catastrophically
Reinforced with steel,
or fibre reinforced
polymers
Good thermal and
electrical insulators
More later

(p.3-8)

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Comparison
Material

(p.3-10)

Advantages

Disadvantages

Steel

Strength, stiffness, ductility, strength and corrosion

resistance adjustable with alloying elements

Heavy

Aluminum

Lightweight, high ductility, corrosion resistant

Low strength and stiffness

Brass

Corrosion resistant, good wear properties

Heavy, cost

Titanium

Good strength over wide temperature range,

corrosion resistant, lightweight

Poor machinability, cost

Polymers

Lightweight, corrosion resistant, easy to form and

manufacture, versatile, impact resistance, shock
and vibration absorbance, low friction and wear,
recyclable (thermoplastics)

Low strength and stiffness, small

temperature changes cause
large change in properties, poor
recyclability (thermosets)

Lightweight, high specific strength and stiffness,

corrosion resistant, flexible design and versatility

Brittle, expensive, poorly

characterized (codes/standards),
quality strongly affected by
manufacturing, poor recyclability

FRP
Composites

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Material Selection

(p.3-16)

1. Decision matrix
Simple, basic design
Need specifications/requirements
Select material that best meets the specs
See previous sections for example
2. Ashby charts
Advanced methodology
Allows for optimization
Need information on function, objective, constraints
examples will be presented in Seminar #3
Ive never seen this in a 460 report, attempt to incorporate here

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Material Selection:
Ashby Charts

Used with permission: Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.

Material Selection:
Ashby Charts
Three basic elements are required for the selection charts:

Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.

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Material Selection:
Ashby Charts

Performance (p) of a component

based on the requirements of the design
Designs will have three requirements:
1. functional
2. geometric
3. materials property
These are associated to a function (equation)
(which are assumed be independent of each other)

Functional
Geometric Material

p f
, F ,
, G ,
, M
requirements parameters properties

p f1 F f 2 G f 3 M

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Comments

Example: All the materials

lying on a line of constant
E1/2/r perform equally well
as a light stiff beam.
Those above the line are
better, those below, worse.
A material with M = 8 in
these units gives a beam
which has one quarter the
weight of one with M = 2.
Example in seminar

Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.

Designing Next Generation

Protection Materials

Jamie Hogan
Assistant Professor
Mechanical Engineering
University of Alberta

38

Take Away

Exposure to brittle materials

Failure depends on microstructure, stress-state and strain-rate

Talk about how to design microstructures to control failure

Example: fragmentation for body armor applications

300 um

PADB4C-Microstructure

50 um

PADB4C- Fragments

Materials in Defense Applications

bankspower.com

www.galls.com

Big question: Why is one system better than the other?

1.

Requires fundamental understanding of material failure (experiments and models)

2.

Manufacturing processes to produce tailored microstructures (processing)

Approaches to Materials Design

10 um
Twinning in Mg (Dixit)

Boron Carbide Microstructure

Microstructures and material properties (K1c, , E, ) + identification of failure mechanisms

Material Science: alter microstructure property performance (test, test, test)

Mechanics: microstructure/properties mechanisms (models) performance

Philosophy: see it (experiments), understand it (models), control it (processing)

Failure Mechanisms in Brittle Materials

Failure: Defects nucleate mechanisms, which lead to macro-cracks, and often to catastrophic failure

Defects: grain boundaries, secondary phases, initial cracks (we want to identify key defects)

Objective: Control failure mechanisms by designing the defect populations (microstructure design)

Impact Failure of Brittle Materials

Failure Processes (time and space):

1.

Fracture

2.

Granular flow

3.

Plasticity

4.

Phase transformations (amorphization)

Fig. Impact into PAD B4C at 930 m/s

500 microns

Manifest in fragmentation

Hypothesis: controlling fragmentation will

lead to improved performance

Fig. Ballistic fragments for PAD B4C at 930 m/s

Material: boron carbide

1. See it:
Microstructure Characterization
and Experimentation

Boron Carbide Material

Composition: B4C (or B12C3): rhombohedral (bucky balls)

High hardness (Mohs 9.5) and low density (2.5 g/cm3)

Silicon carbide (SiC): 3.2 g/cm3

Manufacturing: grow boron crystal, ball milled, hot-press

with carbon and aluminum nitride additives

Yields defects (serve as fracture sites).

Not all defects are bad

PADB4C- Microstructure

10 um

Boron Carbide Defect Microstructure*

Hot Pressing Direction

Globules (ellipsoids): graphitic disks

Spherical features: graphite/pores

Bright phases: aluminum nitride

Q: What processing defects initiate failure?

Hogan et al. JACS 2014

Strength and Failure

Dynamic Compressive Failure

Unconfined Configuration

2.5 mm

Bi-Axial Confined Configuration

2.5 mm
2 Mfps, exposure= 500 ns

5 Mfps, exposure= 110 ns

Strain rates: ~10-3 (MTS) and ~10+3 s-1 (Kolsky bar) and Stress-states: compression, confined, tension (BD)

Crack speeds set deformation time scales: 2,000 +/- 300 m/s (left) vs. 510 +/- 130 m/s (right)

Deformation mode changes with confinement: need to understand this

Hogan et al. JACS 2014

Strength: Confinement Effects

Hot Pressing Axis

Unconfined Configuration
Hot Pressing Axis

Confined Configuration

We can use strength measurements to guide us on package design

Hogan et al. Acta 2015

Rate-Dependent Strength

Kimberley et al. 2013 scaling relation for

strength as a function of strain rate*

Dynamic strength of brittle materials

is controlled by fracture

Governed by microstructure features

and properties

This example: can control strength by

controlling fracture through design of
defect populations

Fractography: Failure Mechanisms

2. Understand it:
Compressive Brittle
Fragmentation Model

2. Understand It: Theoretical and

Computational Modeling
Inputs From Experiments
Crack growth Kinetics

Flaw Orientation distribution

Flaw Size distribution

Initial Damage

Crack Nucleation

Brittle Failure Model

Self-Consistant
Scheme

Flaw Density
Damage Evolution

Irreversible
Damage Strain

Anisotropic Damage

Crack Growth

Crack Coalescence

Stiffness
Definition

Flow Behavior
Granular Flow
EOS

Micromechanics

Evolution as a
function of Damage

Flaw Density (#/m2)

and Spacing

Influence of Bulking
Visco-Plastic Flow

Porosity

Figure
Figure
11.
9.Orientation
Inclusion number/area
of inclusionsfraction
in relation
vs. to
the hot pressing
inclusion
axis
size
(AR
distribution.
is the aspect ratio).

Fig. Mind-map for brittle failure

Incorporate the physics in the model: properties and microstructure

2. Strength and Fragmentation

Micro-Mechanical Models
Flaw Size Dependence

1000 s-1

6 m
10 m
20 m
40 m

2
1.5

1.5
1

10

0.5

0.5
0
0

0.002

0.004
Strain

0.006

0
0.008

Normalized Size

Stress (GPa)

2.5

2.5

Tr(Damage)

10
10
10
10
10

3
Grady 2006
Glenn and Chudnovsky 1986
Zhou et al. 2006
Levy and Molinari 2010
Mod. Grady (vc c)

Spinel

PAD B4C

0
-1

PAD SiC-N
-2

10

Basalt
-4

10

-3

10

-2

10

-1

10

Stony meteorite
0

10

Normalized Strain Rate

We can use simple models to inform about materials design

10

3. Control it:
Materials Design

Ballistic Performance Curve

We designed microstructures for controlled strength and

fragmentation outcomes

Probability of Penetration

PS B4C
HP B4C

0.8
0.6

Pressureless sintered (PS)

0.4
0.2
0
0.7

Hot-pressed (PAD-B4C)

0.75

0.8

0.85

0.9

0.95

1.05

Normalized Velocity
Highlights power of simple model to inform design decisions
Remember: consider physics of problems (whats important
and what isnt)

5. Summary

Take Away

Exposure to brittle materials

Failure depends on microstructure, stress-state and strain-rate

Talk about how to design microstructures to control failure

Example: fragmentation for body armor applications

Length: 5 mm

Fig. Impact into PAD B4C at 1000 m/s

Compressive failure of boron carbide

Acknowledgements

Support of the Materials in Extreme Dynamic Environments

Collaborative Research Alliance through Cooperative Agreement
Number W911NF-12-2-0022.

Support from ARL (ITOL 2015-2443)

NSERC Engage

CFI for ultra-high-speed camera

Lukasz Farbaniec, Debjoy Mallick, Matt Shaeffer, Nitin

Daphalapurkar, Ravi Sastri, Jim McCauley, KT Ramesh

Undergraduate support: Will Wagers, Erez Krimsky

James Hogan email: jdhogan@ualberta.ca

Bonus Work for ME 360

Assigned as 5%+ on quiz #1

Develop 1 ppt slide:

Choose an industrial application that interests you

Select a material within that application

Show its microstructure, material properties

Address why it is used in this application

Be creative

Due before Quiz 1- assignment box will be created

Next Topic

Unit # 2: Initial Considerations

Section 4: Loading and deflections
Static
Cyclic
Impact
Beam deflection
Section 5: Failure criteria