Material Selection in Industry

Selecting the Appropriate Materials

• The presentation covers material selection and testing.
• The objective of the material selection process is to select the material most suitable for a specific application.
• Material selection is a crucial step in the design of physical objects.

Today's Objectives

• Recap the equipment in the material lab for various industries.
• Understand the material selection process and its importance in various industries.
• Complete an in-class assignment to practice the material selection methodology.

Materials Lab in Industry

• The presentation highlights the applications and testing capabilities within the materials lab that are used in industry.
• Shows pictures of different machines within the lab, for example, a testing machine.
• The presentation makes reference to certain brands of equipment (e.g., Tinius Olsen).

Why a Materials Lab is Required

• Conducting tests to determine the strength of the material being used.
• Testing design modifications to ensure the accuracy of machining processes.
• Checking the safety and clarity of vehicle parts (like headlight lamps).
• Testing the thermal resistance of rocket parts.
• Studying the effects of vibrations on airplane parts.
• Understanding the interactions between chemicals and plastic materials.
• Determining the weather resistance of fittings and materials.

Type of Tests Needed

• The presentation details different types of tests used to evaluate materials. This includes tensile, compression, hardness, bending, crack strength, impact, creep, corrosion, thermal investigation, friction, magnetism, electrical properties, clarity and light properties, accuracy and dimensional measurements, and vibration and fatigue .
• These tests are crucial in understanding the suitability of a material for a given application.

Material Selection Methodology (In Brief)

• The process involves identifying desired material properties and comparing them to real engineering materials. The process identifies the best match.

Material Selection Methodology (In Detail)

• The process consists of four main steps: translation, screening, ranking, and considering supporting information and local conditions.

Material Selection Methodology (Example)

• A business owner wants to hire someone.
• The job requirements are analyzed, and essential skills are identified.
• Basic criteria, like a valid driving license, are applied (screening).
• More complex criteria, such as experience or work history, are also used to rank candidates (ranking).
• References and interviews are used to gather more information on the top candidates (supporting information and local condition).

Translation (Methodology in Detail)

• Design requirements are translated into material specifications, including function, constraints, objective, and free variables.
• Distinguishing between "hard" and "soft" constraints is useful, where absolute requirements vs negotiable attributes are identified.

In-Class Assignment

• Students will be divided into groups for assignments.
• Each group will focus on a specific application.
• Teams need to perform a full material selection analysis in their respective area of application.
• The assignment begins with the Translation Stage.

Screening (Methodology)

• Screening eliminates candidates that are unable to meet the job requirements.
• Limits are determined from constraints like temperature tolerances, and optical requirements.
• Ashby charts/Material property charts are used to determine relevant materials that meet the requirements.

Screening (Ashby Charts)

• These charts visually present various materials' properties, helping to determine suitability based on parameters like stiffness and conductivity.
• Materials display in "Families" or groupings of related materials.

In-Class Assignment

• The use of Ashby charts is explicitly mentioned for selecting appropriate materials.

Ranking (Methodology)

• Identifying criteria of excellence for ranking candidates.
• Optimization may not always yield the best results. The balance or "sweet spot" between properties might be the best solution.
• Screening identifies candidates capable of performing the job; ranking identifies the best amongst those.

In-Class Assignment

• Rank the screened materials based on the given constraints and desired objectives.

Supplementary Information (Methodology)

• Assessing the top-ranked material's strengths, weaknesses, reputation, and overall "credit rating" is essential for the final decision.

Local Conditions (Methodology)

• Considering local availability and vendors is crucial.
• Inquiring about the existence of specific equipment or expertise is also important.

In-Class Assignment (Supporting Information and Local Conditions)

• Real-world examples (e.g., Carbon fiber, Aluminum, Aluminum nitride) are referenced.
• Students need to consider local availability to understand the feasibility and practicality of using particular materials.

Quick Recap

• Briefly summarizes the steps in material selection:
  • Translate design requirements into attributes
  • Identify materials based on constraints
  • Rank materials based on relevant objective criteria
  • Seek out supportive information for best candidates
  • Select the final material based on this analysis

This quiz covers the crucial processes of material selection and testing, integral to designing physical objects. Understand the importance of choosing the right materials for specific applications and gain insights into the equipment used in materials labs across industries. Engage with an in-class assignment to solidify your knowledge.