Selection Process Overview

At concept (preliminary) level

Analyze material requirements (from PDS)
Conditions of service and operating environment
Translate conditions to material properties
Screen for candidate materials
Compare reqd properties with a materials database to
select candidate materials
During embodiment phase
Analysis of candidate materials in terms of
tradeoffs in performance, cost, manufacturability

Material Selection and Design
Selecting an appropriate material is a critical part of almost all
engineering designs.
A methodology for selecting materials and processes which is
driven by design, uses as inputs the functional requirements
of the design.
There are many factors to consider
Mechanical Properties:
Strength, stiffness, ductility, fracture toughness , fatigue, creep
Physical Properties:
Density, melting point, thermal/electrical conductivity
Other
Cost, corrosion, formability, etc

Material Selection
Basic Methods

Translation:
express design requirements as constraints
and objectives.
Screening:
eliminate materials that cannot do the job.
Ranking:
find materials that best do the work using
performance indices.
Research Supporting Info:
handbooks, expert systems, web, etc.



Translation
(express design requirements as constraints and objectives)

Function: What does the component do?
Objective: What essentials conditions must be met?
Constraints: What is to be maximized or minimized?
Free Variables: Identify which design variables are
free?
Which can be modified?
Which are desirable?

Screening
(Eliminate materials that cannot do the job)

Need an effective way to evaluate a large
range of material properties and classes.
Methods to evaluate materials
Material Bar Charts
Material Property Charts
(for example, density vs. Youngs Modulus)


Material Bar Charts
Metals Polymers Ceramics Hybrids
PEEK
PP
PTFE
WC
Alumina
Glass
CFRP
GFRP
Fibreboard
Steel
Copper
Lead
Zinc
Aluminum
Material Selection Charts
Screening Example:
Heat Sink for Power Electronics
Retain materials with:
1. Max service temp >200 C
2. Good insulator, or R >10
19
ohm.cm
3. Good T-conductor or T-conduct. >100 W/m.K
Function:
Heat sink
Constraints:
operate at 200 C
be electrical insulator
conduct heat well

Free variable:
Choice of material

Therefore
200
0
C
Screening using Bar Charts
(max service temperature >200
o
C)
Metals Polymers Ceramics
Composites
PEEK
PP
PTFE
WC
Alumina
Glass
CFRP
GFRP
Fibreboard
Steel
Copper
Lead
Zinc
Aluminium
Screening using Property Charts
R=10
19
=100
Screening using Material Property Charts
(>100W/m.K,
e
>10
19
.cm)
Ranking
(find the materials that do the job best)
What if multiple materials remain after screening?
Which one is best?
What if there are multiple material parameters for
evaluation?

Use the Material Performance Index

Start with Translation
Rank on Objectives because objectives define performance
metrics

Example: Tie Rod

Function:
Support a tensile load
Objective:
Minimize mass
Constraints:
Required length (L)
Load carrying capability w/o failure
Free Variables:
Cross-sectional area
Material


Write design requirements as equations.
Objective
m = A*L*
Constraint
F/A <
y

Eliminate free variable
m FL (/
y
)
therefore, minimize weight by maximizing
y
/

Using the Performance Index
Method
1) Identify function, constraints, objective and free
variables (as before)
2) Write equation for objective (the Performance
Equation)
3) Define combination of material properties that
maximize performance (the Material Index)
4) Use these for ranking
The Performance Equation
(

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|

\
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.
|

\
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.
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\
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=
P , properties
Material
G , parameters
Geometric
,
F ts, requiremen
Functional
P
or P= f (F,G,M)
Use constraint to eliminate free variable

Performance equation for Tie Rod example

m FL (/
y
)
Example: material for stiff, light beam
Function:
Support a bending load
Objective
Minimize mass
Constraints
Length
Carry load F with minimal deflection
Free Variables
Cross-sectional area
Material
F
Deflection,
Beam has length = L and area = A
Objective:
m = AL
Constraint:


3
L
CEI F
S =

Beam Example cont

Objective:
m = AL
Constraint:


Solve for m substitute
and rearrange.

3
L
CEI F
S =

=
2 / 1 2 / 1
2 / 5
2 / 1
4

C
L F
m
Material Indices
Minimize weight by minimizing


or by maximizing

|
.
|

\
|
2 / 1
E

|
|
.
|

\
|

2 / 1
E
Material Index Calculation Process Flow
Tie Rod
Beam
Shaft
Column
Function



Stiffness specified


Fatigue limit


Geometry specified
Constraints
Minimize cost


Minimize weight


Maximum energy
Storage


Minimum
eco-impact
Objective
Strength specified
Could be mechanical,
thermal, electrical
(Each combination has a characterizing material index)
(

2 / 1
E
M
Index
Material Index Examples
An objective defines a performance metric
For example mass or resistance
Equation for performance metric contains
material properties
Sometimes a single property*
Sometimes a combination*

*either is a material index

Material Index Examples
Material Indices for a Beam
Loading

Stiffness
Limited
Strength
Limited
Tension E/
f
/
Bending E
1/2
/

f
2/3
/
Torsion G
1/2
/
f
2/3
/
Objective:
minimize mass

Performance Metric:
mass
Maximize indices
Optimized Selection using Material Indices
and Property Charts
Example:
Tension load,
strength limited
Maximize: M = /
In log space:
log = log + log M
This is a set of lines
with slope =1
Materials above the
line are candidates