Kutz M. Handbook of materials selection

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Handbook of

Materials

Selection

HandbookofMaterialsSelection.EditedbyMyerKutz

Handbook of

Materials

Selection

Edited by

MYER KUTZ

Myer Kutz Associates, Inc.

JOHN WILEY & SONS, INC.

This book is printed on acid-free paper. 嘷⬁

served.

Published simultaneously in Canada.

No part of this publication may be reproduced, stored in a retrieval

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& Sons, Inc., 605 Third Avenue, New York, NY 10158-0012, (212)

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This publication is designed to provide accurate and authoritative in-

formation in regard to the subject matter covered. It is sold with the

understanding that the publisher is not engaged in rendering profes-

sional services. If professional advice or other expert assistance is re-

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Library of Congress Cataloging-in-Publication Data:

Handbook of materials selection /Myer Kutz, editor.

p. cm.

Includes bibliographical references.

ISBN 0-471-35924-6 (cloth : alk. paper)

1. Materials—Handbooks, manuals, etc. I. Kutz,

Myer.

TA403.4.H368 2001

620.1

⬘1—dc21 2001046821

Printed in the United States of America.

10987654321

To Merrilyn, Bill, and David

The Future Is Yours

vii

CONTENTS

Preface xi

Contributors xv

PART 1 QUANTITATIVE METHODS OF MATERIALS SELECTION

1. Quantitative Methods of Materials Selection 3

Mahmoud M. Farag

PART 2 MAJOR MATERIALS

2. Carbon and Alloy Steels 27

Bruce L. Bramﬁtt

3. Stainless Steels 67

James Kelly

4. Aluminum Alloys 89

J. G. Kaufman

5. Copper and Copper Alloys 135

Konrad J. A. Kundig

6. Selection of Titanium Alloys for Design 201

Matthew J. Donachie

7. Nickel and Its Alloys 235

T. H. Bassford and Jim Hosier

8. Magnesium and Its Alloys 259

Robert S. Busk

9. Corrosion and Oxidation of Magnesium Alloys 267

D. Eliezer and H. Alves

10. Selection of Superalloys for Design 293

Matthew J. Donachie and Stephen J. Donachie

11. Plastics: Thermoplastics, Thermosets, and Elastomers 335

Edward N. Peters

12. Composite Materials 357

Carl Zweben

viii CONTENTS

13. Smart Materials 401

James A. Harvey

14. Overview of Ceramic Materials, Design, and Application 419

R. Nathan Katz

PART 3 FINDING AND MANAGING MATERIALS INFORMATION AND

DATA

15 How to Find Materials Properties Data 441

Patricia E. Kirkwood

16. Sources of Materials Data 457

J. G. Kaufman

17. Managing Materials Data 475

Deborah Mies

18. Information for Materials Procurement and Disposal 505

J. H. Westbrook

PART 4 TESTING AND INSPECTION

19. Testing of Metallic Materials 519

Peter C. McKeighan

20. Plastics Testing 545

Vishu Shah

21. Characterization and Identiﬁcation of Plastics 591

Vishu Shah

22. Professional and Testing Organizations 615

Vishu Shah

23. Ceramics Testing 623

Shawn K. McGuire and Michael G. Jenkins

24. Nondestructive Inspection 649

Robert L. Crane and Ward D. Rummel

PART 5 FAILURE ANALYSIS

25. Failure Modes: Performance and Service Requirements for Metals 705

J. A. Collins and S. R. Daniewicz

26. Failure Analysis of Plastics 775

Vishu Shah

27. Failure Modes: Performance and Service Requirements for Ceramics 787

Dietrich Munz

28. Mechanical Reliability and Life Prediction for Brittle Materials 809

G. S. White, E. R. Fuller, Jr., and S. W. Freiman

CONTENTS ix

PART 6 MANUFACTURING

29. Interaction of Materials Selection, Design, and Manufacturing Processes 831

Ronald A. Kohser

30. Production Processes and Equipment for Metals 847

Magd E. Zohdi, William E. Biles, and Dennis B. Webster

31. Metal Forming, Shaping, and Casting 925

Magd E. Zohdi, Dennis B. Webster, and William E. Biles

32. Plastic Parts Processing I 969

William E. Biles

33. Plastic Parts Processing II 993

Dean O. Harper

34. Composites Fabrication Processes 1037

Michael G. Bader

35. Advanced Ceramics Processing 1113

Lisa C. Klein

PART 7 APPLICATIONS AND USES

36. Spacecraft Applications of Advanced Composite Materials 1131

Kevin R. Uleck, Paul J. Biermann, Jack C. Roberts, and

Bonny M. Hilditch

37. Selection of Materials for Biomedical Applications 1165

Michele J. Grimm

38. Selecting Materials for Medical Products 1195

Sherwin Shang and Lecon Woo

39. Materials in Electronic Packaging 1223

Warren C. Fackler

40. Advanced Materials in Sports Equipment 1253

F. H. Froes

41. Materials Selection for Wear Resistance 1275

Andrew W. Phelps

42. Diamond Films 1287

Andrew W. Phelps

43. Advanced Materials in Telecommunications 1303

Glen R. Kowach and Ainissa G. Ramirez

44. Using Composites 1343

Hans J. Borstell

x CONTENTS

45. Composites in Construction 1369

Ayman S. Mosallam

46. Design for Manufacture and Assembly with Plastics 1423

James A. Harvey

INDEX 1437

PREFACE

Invention is often born of the need, or just the desire, to improve something.

This simple statement (a restatement, in a way, of the old saw ‘‘necessity is the

mother of invention’’) is the driving force behind the development of the Hand-

book of Materials Selection. The audience for this handbook consists of prac-

ticing engineers and the people who work with them, all of whom need to

determine what materials they might specify, order, and use to make something

better, whether it’s a dental implant, an electronic package, an airplane, or a

highway overpass. The choices are not always as clear cut, nor are they as

straightforward, as they once were. In the past, one material (e.g., steel) or a

class of materials (e.g., metals) might have been all an engineer would have

needed to consider for a particular application. But now different classes of

materials compete for consideration, in order that a manufactured part or assem-

bly be as inexpensive, or as light, or as long-lasting as possible, to name just a

few factors that might have to be taken into account. So whereas an engineer

might have turned in the past to a single supplier’s materials properties tables

to make a selection, now he or she might ﬁrst turn to the engineer’s most trusted

information source—colleagues, whose collective expertise can be brought to

bear on an improved materials selection procedure.

So an important purpose of a publication such as this handbook is to assemble

a collection of experts to provide advice to an engineer. If a handbook is to do

this job effectively, its assigned experts should have a wide range of professional

experience. They should have worked in a variety of settings. In keeping with

this concept, the Handbook of Materials Selection is the product of the efforts

of over 50 contributors who have experience in ﬁve different environments: a

little over 40 percent are from mainly industrial backgrounds; a little under 30

percent are U.S. university faculty members, many with some experience in

industry, while another 10 percent are, or have been until recently, on the faculty

of academic institutions in Egypt, Israel, Germany, and England; the rest work

at U.S. government installations or at research institutes, both private and uni-

versity afﬁliated.

Whatever their background and experience may be, the contributors to this

handbook have written in a style that reﬂects practical discussion informed by

real-world experience. The intent is for readers to feel that they are in the pres-

ence of experienced engineers, materials specialists, teachers, researchers, and

consultants who are well acquainted with the multiplicity of issues that govern

the selection of materials for industrial applications. At the same time, the level

is such that students and recent graduates can ﬁnd the handbook as accessible

as experienced engineers.

As much as practicable, contributors have employed visual displays, such as

tables, charts, and photographs, to illustrate the points they make and the ex-