CH3349 - Lecture-03 Material Selection-1

Lecture-03
Material
Selection-1
References:
• Mahmood M. Farag, “Materials and Process Selection for Engineering Design,” CRC Press, 2013
©2024 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
CONTENT
1.1 Introduction
1.2 Performance Requirements
1.3 Material Selection Process
1.4 Activity
Course Outcomes
Emphasis
Course Outcomes Total
Very high High Medium Low
Design pressure vessels using ASME
CLO1 standards and emphasis on safety and 65.0 65.0
resource sustainability.
Use readily available software (e.g. Excel)

CLO2 to carryout design calculations and 10.0 10.0
material selections
Practice leadership, cooperation, and 10.0

CLO3 10.0
accountability in a teamwork setting.
Produce a standard technical report for a 15.0

CLO4 15.0
chemical equipment design.
0.0
Total 65.0 0 15 20 100.0
Learning Outcomes
At the end of this lecture, you should be able to
– Explain the classification of materials
– Describe the factors considered in material selection
– Explain the methods for material selection
– Select materials using Ashby charts
Introduction:
Interrelations of Design, Materials, and Processing to Produce a Product:
Relation of Materials Selection to Design:
• An incorrectly chosen material can lead not only to part failure but also to excessive
life-cycle cost.
• At the concept level of design, essentially all materials and processes are
considered in broad detail.
• The materials selection charts and methodology developed by Ashby are highly
appropriate at this stage.
• Depending on the importance of the part, materials properties may need to be known
to a high level of precision.
• Material and process selection is a progressive process of narrowing from a large

universe of possibilities to a specific material and process.
General Criteria for Selection:
Materials are selected based on four general criteria:
– Performance characteristics (properties)
– Processing (manufacturing) characteristics
– Environmental profile
– Business consideration
Business Issues:
• Availability:
– Are there multiple sources for the supply of materials?
– What is the likelihood of availability in the future?
– Is the material available in the forms needed?
• Size limitations and tolerances on available material shapes and form
• Excessive variability in properties
• Low environmental impact, including ability to recycle the material
• Cost
Performance
Requirements:
Material Properties:
• Performance requirements of a material are usually expressed in terms of
physical, thermal, mechanical, electrical, or chemical properties.
• Structure determines properties.
• At the atomic level, materials scientists are concerned with basic forces between
atoms, which determine the density, inherent strength, and Young’s modulus.
Classification of Materials:
• We can divide materials into:
✓ Metals
✓ Ceramics, and
✓ Polymers
• An engineering material is a material that is used to fulfill some technical

functional requirement, as opposed to being used just for decoration.
• Structural materials are typically used to resist forces or deformations in

engineering structures
Material Classification Hierarchy
Materials Kingdom All materials
Family Metals, polymers, etc.
Class For metals: steels, aluminum alloy
Subclass Steels: plain carbon, low alloy
Member Polymer grade

Source:
George Dieter, Linda Schmidt,” Engineering Design,” McGraw-Hill, 2012
Commonly Used
Structural Engineering
Materials:
Short List of Material Properties
Example:
• Selecting a material with a low rate of corrosion in the environment of concern is the obvious first step
to preventing corrosion.
Mechanical Properties
Stress-Strain Curve
Mechanical Properties (1)
• Ultimate tensile strength, u, is the maximum tensile stress that a material can withstand in
the tension test, measured by load divided by the original area of the specimen. For brittle
materials it is the same as their fracture strength, but for ductile materials it is larger by a
factor of 1.3 to 3 because of strain-hardening.
• Modulus of elasticity (Young’s modulus), E, is the slope of the stress-versus-strain curve
where it initially shows linear behaviour. A material with a high E is stiffer than a material with
a lower E and resists deformation by bending or twisting to a greater extent.
• Ductility is the opposite of strength. It is the ability of a material to plastically deform before it
fractures.
• Fracture toughness, KIc, is a measure of the resistance of a material to the propagation of a
crack within it.
• Fatigue properties measure the ability of a material to resist many cycles of alternating
stress. Fatigue failure, in all of its variations (high-cycle, low-cycle, and corrosion fatigue) is
the number one cause of mechanical failure.
Mechanical Properties (2)
• Damping capacity is the ability of a material to dissipate vibrational energy by
internal friction, converting the mechanical energy into heat.
• Creep is the time-dependent strain that occurs under constant stress or load in
materials at temperatures greater than half of their melting point.
• Impact resistance is the ability of a material to withstand sudden shock or

impact forces without fracturing.
• Hardness is a measure of the resistance of the material to surface indentation.
• Wear rate is the rate of material removal from two sliding surfaces in contact.
Guide for Selection of Material
B. A. Miller, “Materials Selection for Failure Prevention,” Failure Analysis and Prevention, ASM
Handbook, vol. 11, ASM International, Materials Park, OH, 2002, p. 35.
Specification of Materials:
• The material properties required in a part usually are formalized through
specifications.
• Designer depends on generally accepted specifications established through

organizations such as the Society of Automotive Engineers (SAE), ANSI, ASTM,
ASME, API, or ISO.
• Often companies find that using common standards which are “consensus
standards” agreeable to a wide sector of a material producing industry, do not
provide the material quality they need for particularly sensitive manufacturing
operations.
Examples:
Examples:
Examples:
Ashby Chart/
Diagrams
• Ashby has created materials selection charts that are very useful in
comparing many materials during conceptual design.
• These charts are based on a large computerized material property

database.
• Ashby chart, for example, displays the elastic modulus (E) of polymers,
metals, ceramics, and composites plotted against density ().
Ashby Charts
18 Charts available for material selection. 9 of the Charts are
• Young's modulus against density
• Strength against density
• Fracture toughness against density
• Young's modulus against strength
• Specific modulus against specific strength
• Fracture toughness against Young's modulus
• Fracture toughness against strength
• Loss coefficient against Young's modulus
• Thermal conductivity and thermal diffusivity
Ashby Materials Selection Chart
Material
Selection Process:
Materials Selection for a New Product or
New Design:
i. Define the functions that the design must perform and translate these into
required materials properties (e.g. stiffness, strength, etc.) .
ii. Define the manufacturing parameters (e.g. no. of parts, size, complexity,
tolerance, surface finish, quality level, etc.).
iii. Compare the needed properties and parameters against a large materials
property database.
iv. Investigate the candidate materials in more details, particularly for trade-offs in
product performance, cost, fabricability, and availability in the grades and sizes.
v. Develop design data and/or a design specification.
Material Substitution in an Existing
Design:
i. Characterize the currently used material in terms of performance, manufacturing
requirements, and cost.
ii. Determine which properties must be improved for enhanced product function.
Often failure analysis reports play a critical role in this step
iii. Search for alternative materials and/or manufacturing routes.
iv. Compile a short list of materials and processing routes and use these to estimate
the costs of manufactured parts.
v. Evaluate the results of STEP-4 and make a recommendation for a replacement

material.
Two Different Approaches to Materials
Selection
• There are two approaches to settling on the material-process combination for a part:
– Material-first approach
– Process-first approach
• In the material-first approach, the designer begins by selecting a material class and
narrowing it down as described previously.
• With the process-first approach, the designer begins by selecting the manufacturing
process, guided by the same factors.
Materials Selection in
Embodiment Design:
Cost of Materials
• The basic cost of a material depends upon:
– Scarcity:
• As determined by either the concentration of the metal in the ore or the

cost of the feedstock for making a polymer
– The cost and amount of energy required to process the material
– The basic supply and demand for the material
• Cost is such an overpowering consideration in many materials selection

situations that we need to give this factor additional attention.
Price Ranges for Different Materials Purchased in Bulk at
2007
K. T. Ulrich and S. D. Eppinger, Product Design and Development, 4th ed., McGraw-Hill, New York, 2007.
Relative Prices of Various Steel Products
Cost Structure of Materials:
• The cost structure for pricing many engineering materials is quite complex.
• True prices can be obtained only through quotation from vendors.
• Reference sources typically give only the nominal or baseline price.
• The actual price depends upon a variety of price extras in addition to the base price.
• Price extras are assessed for any changes from standard chemical composition, for
vacuum melting or degassing, heat treatments, and so on.
Service Considerations*
* Dennis R. Moss, Michael M. Basic, “Pressure Vessel Design Manual,” Butterworth-Heinemann, 4th Edition, Year: 2013, pp. 34.
Miscellaneous Design Considerations*
* Dennis R. Moss, Michael M. Basic, “Pressure Vessel Design Manual,” Butterworth-Heinemann, 4th Edition, Year: 2013, pp. 35.
Material
Selection
Guide*
Example-E1:
Which material property would you select as a guide in material selection if the chief
performance characteristic of the component was:
a. strength in bending;
b. resistance to twisting;
c. the ability of a sheet material to be stretched into a complex curvature;
d. ability to resist fracture from cracks at low temperatures;
e. ability to resist shattering if dropped on the floor;
f. ability to resist alternating cycles of rapid heating and cooling?
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Lecture-03

1.2 Performance Requirements

1.3 Material Selection Process

Use readily available software (e.g. Excel)

Practice leadership, cooperation, and 10.0

Produce a standard technical report for a 15.0

At the end of this lecture, you should be able to

– Explain the classification of materials

– Describe the factors considered in material selection

– Explain the methods for material selection

– Select materials using Ashby charts

• Material and process selection is a progressive process of narrowing from a large

Materials are selected based on four general criteria:

– Performance characteristics (properties)

– Processing (manufacturing) characteristics

– Are there multiple sources for the supply of materials?

– What is the likelihood of availability in the future?

– Is the material available in the forms needed?

• Size limitations and tolerances on available material shapes and form

• Excessive variability in properties

• Low environmental impact, including ability to recycle the material

• Structure determines properties.

• An engineering material is a material that is used to fulfill some technical

• Structural materials are typically used to resist forces or deformations in

Family Metals, polymers, etc.

Class For metals: steels, aluminum alloy

Subclass Steels: plain carbon, low alloy

Member Polymer grade

• Impact resistance is the ability of a material to withstand sudden shock or

• Hardness is a measure of the resistance of the material to surface indentation.

• Designer depends on generally accepted specifications established through

• These charts are based on a large computerized material property

• Young's modulus against density

• Strength against density

• Fracture toughness against density

• Young's modulus against strength

• Specific modulus against specific strength

• Fracture toughness against Young's modulus

• Fracture toughness against strength

• Loss coefficient against Young's modulus

• Thermal conductivity and thermal diffusivity

v. Develop design data and/or a design specification.

iii. Search for alternative materials and/or manufacturing routes.

v. Evaluate the results of STEP-4 and make a recommendation for a replacement

• As determined by either the concentration of the metal in the ore or the

– The cost and amount of energy required to process the material

– The basic supply and demand for the material

• Cost is such an overpowering consideration in many materials selection

• True prices can be obtained only through quotation from vendors.

• Reference sources typically give only the nominal or baseline price.

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