2 Materials in Design

What Design Engineers need to know about Materials
& Properties of Material
M S Dasgupta, BITS Pilani M. S. Dasgupta, BITS Pilani, Pilani campus

1
Factors/Criteria in Material Selection
– Function
– Mechanical Properties
– Failure Modes
– Manufacturability
– Cost
– Environmental Considerations
2
Material ↔ Design
Properties of a newly discovered material can

suggest new product
eg: High-purity silicon : Transistor
Need for a new product can demand the

development of a new material
eg: Space Technology: Lightweight Composites
3
Important classes of materials (6)
– Metals  Ceramics
– Polymers  Glasses
– Elastomers  Composites
 A good design exploits and brings out the

true potential of materials selected.
4
Key Material Properties for Design
• General: • Thermal
– Cost – Thermal Conductivity
– Density – Thermal Diffusivity
• Mechanical – Specific Heat
– Elastic Modulus – Melting Point
– Strength – Glass Temperature
– Toughness – Thermal Expansion Coefficient
– Fracture Toughness – Thermal Shock Resistance
– Damping Capacity – Creep Resistance
– Fatigue Endurance Limit • Corrosion/Oxidation
• Wear – Corrosion Rate
– Archard Wear Constant – Parabolic Rate Constant
5
Material Stereotypes
• Metals • Ceramics/Glasses
– High Moduli – High Moduli, Hard,
– Can undergo Abrasion/Corrosion
resistant
• Alloying, Heat Treatment
– Cutting Tools
– Formed by Deformation – Retain Strength at
– Ductile High Temperature
• Yields before fracture – Brittle
– Prey to Fatigue, – Prey to high contact
Corrosion stresses, low
tolerance for cracks
6
Material Stereotypes
 Polymers and Elastomers  Composites
 Low Moduli, High Strength  High Moduli, Strength,

» High Elastic Deflection Lightweight
• Snap fits  Can be Tough
 Corrosion Resistant  Optimal performance
 Easy to Shape at room temperature
 Minimize Finishing  Expensive
Operations  Difficult to Form/Join
 Temperature Dependent
Properties
7
Material Index
• Combination of material properties which
characterize performance in a given
application
 Functional   Geometeric   Material 
p  f  ,  ,  
 Needs, F   Parameters, G   Characteristics, M 
p  f1 ( F ) f 2 (G ) f 3 ( M )
8
Modulus-Density charts
Longitudal
wave speed
9
Other Materials Selection Charts
• Strength-Density • Facture Toughness-

• Modulus-Relative Cost Density
• Strength-Relative Cost • Conductivity-Diffusivity
• Specific Modulus-Specific • Expansion-Conductivity
Strength • Expansion-Modulus
• Fracture Toughness- • Strength-Expansion
Modulus • Strength Temperature
• Fracture Toughness- • Wear Rate-Hardness
Strength • Environmental Attack
• Loss Coefficient-Modulus Chart
Ashby charts, Cambridge Engineering Selector (CES) 10
Environmental Attack Chart
11
Manufacturing & Material Selection
Manufacturability
• Castability
• Formability/Workability
• Machinability
• Coatability
• Heat Treatment
12
CLASSIFICATION OF FERROUS ALLOYS
FERROUS
STEELS CAST IRON
GRAY
LOW ALLOY HIGH ALLOY IRON
DUCTILE
IRON
LOW MEDIUM HIGH
CARBON CARBON CARBON WHITE
IRON
PLAIN HIGH TOOL MALLEABLE

PLAIN HEAT PLAIN IRON
STRENGH TREATABLE
LOW ALLOY
STAINLESS
13
Nomenclature: AISI/SAE
Carbon Steels In percentage

10xx Plain Carbon
11xx Resulfurized
12xx Resulfurized and
rephosphorized
Manganese steels
13xx Mn 1.75
Nickel steels
23xx Ni 3.5
25xx Ni 5.0
Nickel Chromium Steels
31xx Ni 1.25 Cr 0.65-0.80
32xx Ni 1.75 Cr 1.07
33xx Ni 3.50 Cr 1.50-1.57
14
34xx Ni 3.50 Cr 1.50-1.57
BIS CLASSIFICATION SYSTEM
• The Bureau of Indian Standards (BIS) was set up after

the enactment of the Bureau of Indian Standards Act,
1986.
• It operates a product certification scheme, and has till
date granted more than 30,000 licenses to
manufacturers covering a whole lot of industries
ranging from agriculture to electronics.
• The certification entitles to use the ISI (Indian
Standards Institution) mark, which is considered the
symbol of quality in India.
15
1. Standard Steels:
a) Fe 290 (New) St 290 (Old)
Structural steel sheets for plain drawn or
enameled parts, tubes of oil well casing,
steam etc.,
Ultimate Tensile strength of 290 N/mm2.
b) FeE 220 (New)
Ultimate Tensile strength of 290 N/mm2.
Structural steel of yield strength of 220N/mm2.
2. Plain Carbon Steel:
50C4 (New) C50 (Old)
Plain carbon steel. Average carbon content in
hundredths of a percent.
4 denotes the grade (as per the requirement).
16
BIS CLASSIFICATION Continued
• Alloy steel: 20 Cr18 Ni25 Mn25 *

20 0.2% Carbon
Cr18 18% Chromium
Ni25 2.5% Nickel
Mn25 0.25% Manganese
17

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2 Materials in Design

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What Design Engineers need to know about Materials

& Properties of Material

M S Dasgupta, BITS Pilani M. S. Dasgupta, BITS Pilani, Pilani campus

Properties of a newly discovered material can

Need for a new product can demand the

 A good design exploits and brings out the

 Polymers and Elastomers  Composites

 Low Moduli, High Strength  High Moduli, Strength,

• Strength-Density • Facture Toughness-

STEELS CAST IRON

PLAIN HIGH TOOL MALLEABLE

Carbon Steels In percentage

• The Bureau of Indian Standards (BIS) was set up after

• Alloy steel: 20 Cr18 Ni25 Mn25 *

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