Materials

and
Fabrication
Selection
Chapter outline:
Classes of materials (categories of materials)

Materials selection criteria

Material properties

Commonly used materials of construction

Materials fabrication steps

Economic selection of materials

Analysis of failure for metals (types of failure,

finding primary cause of failure and initiate
corrective action to prevent repetition).
Classes of materials
Materials selection criteria
The most important characteristics (criteria) to
be considered when selecting a material of
construction are:
1. Mechanical and physical properties

2. Corrosion resistance

3. Ease of fabricationforming, welding, casting

4. Availability in standard sizes

1. Mechanical and physical
properties
a. Strengthtensile strength;
b. Stiffness:
c. Toughnessfracture
resistance;
d. Hardnesswear resistance;
e. Fatigue resistance;
f. Creep resistance.
Tensile Strength (UTS)
is a measure of the basic strength of a material. It is
the maximum stress that the material will withstand,
measured by a standard tensile test.

Stiffness
the ability to resist bending and buckling. It is a
function of the elastic modulus of the material and
the shape of the cross-section of the member.

Toughness
The ability to absorb impact energy.
It is a measure of the materials resistance to crack
propagation or measure of ductility.
 Hardne
ss
is an indication of a materials ability to resist wear or
scratching. This will be an important property if the
equipment is being designed to handle abrasive
solids, or liquids containing suspended solids which
are likely to cause erosion.
Fatigue
Failure which is likely to occur in equipment subject
to cyclic loading; for example, rotating equipment,
such as pumps and compressors, and equipment
subjected to temperature or pressure cycling.

Creep
Creep is the gradual extension of a material under a
steady tensile stress, over a prolonged period of time.
It is usually important only at high temperatures.
orrosion resistance

The conditions that cause corrosion can arise in a

variety of ways.
It 1.
is Uniform
convenient to classify corrosion into the following
corrosion;
categories:
2. Galvanic corrosiondissimilar metals in
contact;
3. Pittinglocalized attack;
4. Intergranular corrosion;
5. Stress corrosion;
6. Erosioncorrosion;
7. Corrosion fatigue;
8. High-temperature oxidation and
Intergranular
corrosion
Stress corrosion
Erosioncorrosion
Increase in the rate of deterioration or corrosion
because of relative movement between a corrosive
fluid and the metal surface.

Factors affecting rate of corrosion:

1. Nature of metal.

2. Surface film.

3. Velocity.
Erosioncorrosion
Hydrogen embrittlement
loss of ductility caused by the absorption
(and reaction) of hydrogen in a metal
Ex: Hydrogen reforming plants

H2 embrittlement severity depends on:

1. Partial pressure of hydrogen

2. Temperature
LECTION FOR CORROSION RESISTANCE
In order to select the correct material of construction,
the process environment to which the material will be
exposed must be clearly defined. In addition to the
main corrosive chemicals present, the following factors
must be considered:
1. Temperatureaffects corrosion rate and mechanical
properties;
2. Pressure;
3. pH;
4. Presence of trace impurities
5. The amount of aerationdifferential oxidation cells;
6. Stream velocity and agitationerosion-corrosion;
 Acceptable Corrosion
Rates

ipy = inch per year

mpy = mills per year ( 1 mill = 10-3

inch)
mmonly used material of construction

on and steel

loy steel

ckel and its alloys

opper and its alloys

ead

uminum
 II- NONMETALS
A. Plastic materials
B. Ceramic materials
A. PLASTICS AS MATERIALS OF CONSTRUCTION FOR
CHEMICAL
They PLANTS
can be divided into two broad classes:

1. Thermoplastic materials, which soften with

increasing temperature; for
example, polyvinyl chloride (PVC) and polyethylene.

2. Thermosetting materials, which have a rigid, cross-

linked structure; for
example, the polyester and epoxy resins.
FAILURE-MODE EFFECT ANALYSIS
[FMEA]
Reasons for failure

1. Design deficiency

2. Materials problem

3. Overload (abuse)
Failure analysis steps