Material Selection

MATERIALS SELECTION
by
Teddy Sjafrizal
Teddy Sjafrizal @2015
MATERIALS SELECTION
Page 1
MAIN CONSIDERATIONS
The interaction between function, material,
shape, and process lies at the heart of the
material selection process
The selection of a material and process cannot
be separated from the choice of shape.
We use the word shape to include the external,
and internal, (e.g honeycomb ).
To make the shape, the material is subjected to
processes (e.g casting, forging, machining,
polishing and joining processes)
Function dictates the choice of both material and
shape.
Process is influenced by the material:
( formability, machinability, weld ability, heattreatability, etc)
Process interacts with shape the process
determines the shape, the size, the precision
and, the cost.
MATERIALS SELECTION
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MECHANICAL PROPERTIES
MATERIALS SELECTION
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MECHANICAL PROPERTIES
MATERIALS SELECTION
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MATERIAL SELECTION
GUIDELINESS
MATERIALS SELECTION
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MATERIAL SELECTION
GUIDELINESS
MATERIALS SELECTION
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MATERIAL SELECTION STEPS

TRANSLATING
Function
:
What does component do?
Constraints
:
What non-negotiable conditions must be
met?
What negotiable but desirable conditions ?
Objective
:
What is to be maximized or minimized?
Free variables :
What parameters of the problem is the
designer free to change?
SCREENING : eliminates candidates that
cannot do the job at all
MATERIALS SELECTION
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MATERIAL SELECTION STEPS

RANK : measure how well a candidate that has passed the
screening step can do the job. Performance is sometimes limited
by a single property, sometimes by a combination of them
SUPPORTING INFORMATION : it is descriptive, graphical or
pictorial, details of its corrosion behavior in particular
environments, information of availability and pricing, experience of
its environmental impact
MATERIALS SELECTION
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CASE STUDY
Known :
The heat sink must be a good electrical insulator, meaning a resistivity e > 1019
.cm. But to drain heat away from the chip as fast as possible, it must also
have the highest possible thermal conductivity, .
Translating .
Function
Heat Sink
Constraints
Material must be good insulator, or e >

1019 .cm
All dimensions are specified
Objective
Maximize thermal conductivity
Free variables
Choice of Material
MATERIALS SELECTION
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CASE STUDY
Screen :
Resistivity
e > 1019 .cm.
Rank :
Maximum thermal
conductivity.
Result :
Aluminium Oxide
MATERIALS SELECTION
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MATERIAL INDICES
Material indices when objectives are coupled to constraints
.
MATERIALS SELECTION
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A schematic E- chart showing guidelines for the three material indices for stiff,
lightweight design.
MATERIALS SELECTION
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CASE STUDY
Minimize mass
Function
Column (supporting compressive loads)
Constraints
Length L specified
Must not buckle under design loads
Must not fracture if accidentally struck
Objective
Minimize the mass, m

Maximize slenderness
Free variables
Diameter of legs, 2r
Choice of material
Maximize slenderness
MATERIALS SELECTION
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PROCESS SELECTION
MATERIALS SELECTION
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PROCESS SELECTION
Function
What must the process do

? Shappe? Join ? Finish ?
Constraints
What material, shape, size,

precision , must it provide ?
Objective
What is to be maximed or
minimized ? ( cost ? Time ?
Quality ? )
Free
variables
Choice of process
Process chain options
MATERIALS SELECTION
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PROCESS SELECTION
Case study : Forming a FAN
Function
Fan
Constraints
Material : Nylon
Shape : 3D solid
Mass: 0.1 -0.2 kg
Minimum section : 4 mm
Precision : 0.5mm
Roughness : < 1 m
Batch size : 10,000
Objective
Minimize cost
Free variables
Choice of process
Result
Process
Comment
Injection
Molding
Meets all design constraints
Compression
molding
May need further finishing operations
MATERIALS SELECTION
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The processmaterial
compatibility matrix
MATERIALS SELECTION
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The processshape compatibility

matrix
MATERIALS SELECTION
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The processmass range chart
MATERIALS SELECTION
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The processsection thickness

chart
MATERIALS SELECTION
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The processtolerance chart
MATERIALS SELECTION
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The processsurface
roughness chart
MATERIALS SELECTION
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Material Selection

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Material Selection

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MATERIALS SELECTION

Teddy Sjafrizal @2015

Teddy Sjafrizal @2015

Teddy Sjafrizal @2015

Teddy Sjafrizal @2015

Teddy Sjafrizal @2015