MATERIAL SELECTION

Material selection is a step in the process of designing any physical object. In the context of product
design, the main goal of material selection is to minimize cost while meeting product performance
goals. Systematic selection of the best material for a given application begins with properties and
costs of candidate materials.

Materials which can be used to make an electric scooter:-

1. Aluminium alloys
2. Copper alloys
3. Brass alloys
4. Copper chromium alloys
5. Cast iron alloys
6. Lead and lead alloys
7. Carbon steels
8. Stainless steels
9. Alloy steels

1) Aluminium alloys
Aluminium alloys have been the dominant materials used for airframe structures until the
increasing trend in the use of polymer–matrix composites. Aluminium alloys possess a
number of very attractive characteristics that, together with their light weight, make them
extremely attractive for many applications. Aluminium is the dominating material in aircraft
industries and 66% of total empty weight of newest passenger aircraft by Airbus is made of
aluminium alloys. Since aluminium comprises 8% of the Earth’s crust by weight, the overall
reserves are adequate to cope with anticipated demands for the foreseeable future. Cost
differentials with respect to competing materials will probably dictate the extent to which
aluminium will be used. The cost includes the price of the electrical energy needed for the
extraction of the metal from its minerals, and this may be greatly reduced in the future since
aluminium can be recycled for many applications.

2) Copper alloys
Copper alloys are metal alloys that have copper as their principal component. They have
high resistance against corrosion. The best known traditional types are bronze, where tin is a
significant addition, and brass, using zinc instead. Both these are imprecise terms, both
having been commonly referred to as lattens in the past.

3) Brass alloys
A brass is an alloy of copper with zinc. Brasses are usually yellow in colour. The zinc content
can vary between 18% to about 40%; as long as it is kept under 15%, it does not markedly
decrease corrosion resistance of copper. Brasses can be sensitive to selective leaching
corrosion under certain conditions, when zinc is leached from the alloy, leaving behind a
spongy copper structure. Brasses with a copper content greater than 63% are the most
ductile of any copper alloy and are shaped by complex cold forming operations. If the copper
content is less than 63% the brasses can be extensively hot worked by rolling, extrusion,
forging and stamping.
4) Copper chromium alloys
Copper chromium alloys were developed for aircraft engines and heat-resistant materials.
Co–Cr alloys show excellent mechanical properties such as strength and toughness,
castability, corrosion resistance, and wear resistance. Their corrosion resistance is better
than that of stainless steel; their wear resistance is better than that of stainless steel and Ti
alloys; but their plasticity and workability are lower than those of stainless steel and Ti
alloys. They were initially used for cast alloys because working them was difficult.

5) Cast iron alloys

Cast iron, an alloy of iron that contains 2 to 4 % carbon, along with varying amounts of
silicon and manganese and traces of impurities such as sulphur and phosphorus. It is made
by reducing iron ore in a blast furnace. The liquid iron is cast, or poured and hardened, into
crude ingots called pigs, and the pigs are subsequently remelted along with scrap and
alloying elements in cupola furnaces and recast into molds for producing a variety of
products. Most cast iron is either so-called gray iron or white iron, the colours shown by
fracture. Gray iron contains more silicon and is less hard and more machinable than is white
iron.

6) Lead and lead alloys

The mechanical or structural properties of lead and lead alloys are relatively poor compared
to other metals. Lead offers useful properties such as good corrosion resistance,
malleability, energy absorption and electrical conductivity. However, it is often used in
conjunction with other, structurally superior, materials to produce an effect that neither
could achieve separately. For example, sheet lead is bonded to steel for chemical tank
linings, noise and radiation shielding or as a lining for chemical or nuclear facility piping. Lead
alloy solder applied to copper or steel is used in roofing applications.

7) Carbon steels
Carbon steels can be further categorized into three groups depending on their carbon
content which are low carbon steel, medium carbon steel and high carbon steel. The carbon
steel is the cheapest among other types of steel. It has good properties of high stiffness,
easy to machine and joint. However, it has poor resistance to corrosion. Carbon steel is dull,
with a matte finish that is comparable to a cast iron pot or wrought iron fencing.

8) Stainless steels
Stainless steels are not normally used to manufacture tools. With over 11% chromium, steel
is about 200 times more resistant to corrosion than mild steel. It has high strength
properties and high aesthetical appeal compare to carbon steel. Stainless steel generally
costs larger than compare to carbon steel and alloy steel.

9) Alloy steels
Alloy steel has greater strength, hardness, hot hardness, wear resistance, hardenability, or
toughness compared to carbon steel. However, they may require heat treatment in order to
achieve such properties. If compared based of the cost of the steel, the alloy steel are at the
average cost when compared to the carbon steel and stainless steel.