Kutz M. Handbook of materials selection

Подождите немного. Документ загружается.

xii PREFACE

amples they draw on. They have discussed current trends in the speciﬁcation,

availability, and use of materials. Also, wherever appropriate, discussion enables

readers to look into the near-term future.

Nevertheless, no information resource, I mean no handbook, no shelf of

books, not even a web site or a portal on the Internet (not yet, at least), can

hope to inspire every new product whose successful introduction and long ser-

vice life are predicated on innovative and adroit materials selection, much less

inspire every new version of existing products that is cheaper, lighter, or ﬂashier

than its predecessors because of a clever material substitution. Why, then, de-

velop a one-volume Handbook of Materials Selection? The powerful premise

driving this 1,500-page handbook is that, in terms of materials selection, what

works now, as well as what has failed in the past, can serve as an experiential

platform on which practicing engineers can employ the modern multidisciplinary

training they now receive.

My intention has been to create a practical reference for engineers wanting

to explore questions about selecting materials for speciﬁc industrial applications.

In my view, there are two sets of useful questions worth exploring. One set

covers practical examples of the what, why, and how of materials selection:

What materials have been used in particular industrial applications?

Why were these materials selected?

Were the materials processed in special ways?

How did material properties relate to performance in service?

Were there any problems initially, and did any develop later?

What precautions are recommended?

What were the key tradeoffs between properties and performance?

What were the limitations imposed by the selected materials?

A second set of questions relates to a practicing engineer’s particular design

situation:

What materials might have the characteristics that meet the needs of the

application I’m working on?

Where would I ﬁnd information about such materials?

What processing techniques might I use to create parts or components from

these materials?

How do I take into account properties and manufacturing processes in the

design process?

How would I conﬁrm that the materials I specify and purchase have the

properties I’m looking for?

How does the organization I’m working for go about supplying the materials

required by the design I’m proposing, and what limitations may be imposed

on my selection by such factors as cost, environmental degradation, etc.?

PREFACE xiii

The emphasis in the handbook is on practical issues rather than on basic

science, on design and manufacturability issues, on where to ﬁnd properties

information, much of which is now electronic, and on instructive applications

and case studies where engineers have taken advantage of distinctive properties

offered by different classes of materials. Metals, nonmetallic materials, including

plastics and ceramics, and composites get equal coverage, as appropriate.

In order to answer such questions as the ones I have posed above, I arranged

the contents of the handbook in seven parts. The ﬁrst part, just one chapter long,

but important nonetheless and a good introduction to the ﬁeld of materials se-

lection, is on quantitative methods that a practitioner can apply to materials

selection problems. The second part covers the range of major materials—

metallic, nonmetallic, and composite, from the tried and true to the new and

novel—that engineers use nowadays to make things. A couple of these chapters

deal speciﬁcally with the potential problems that practitioners should be aware

of when selecting particular materials.

The third part of the handbook covers sources of materials data, including a

librarian’s advice on ﬁnding, as well as evaluating the reliability of, such data,

methods for managing the data that an organization has acquired, and how the

data are used for procuring materials. Once you’ve obtained a material, what

exactly do you have? The fourth part of the handbook deals with the issue of

testing—what equipment is used to determine the properties of the different

classes of materials, what standards govern test procedures, and what organi-

zations are in the business of providing testing services.

What about the life expectancy of the thing you’ve designed and made from

the material you selected? Another important factor in materials selection is

knowing how different classes of materials fail, which is the subject of the

chapters that comprise the ﬁfth part of the handbook. The ﬁnal aspect of ma-

terials selection involves knowing about the manufacturing processes used to

make things from available classes of materials, which is the subject of the

chapters that make up the sixth part of the handbook.

The handbook’s last, and largest, section, which sets it apart from other hand-

books in the materials ﬁeld, includes 11 chapters that deal not only with a broad

range of industrial applications, but also with design and assembly issues in-

volved in using composites and plastics, as well as chapters on materials that

provide improved wear resistance. The applications chapters cover aerospace,

medical, electronic, telecommunications, sports, and construction industries.

A few chapters in this handbook, which are not more than a few years old,

have been repurposed from the second edition of another Wiley publication that

I have developed, the Mechanical Engineers’ Handbook. For the most part, how-

ever, the contributions in the Handbook of Materials Selection were cooked to

order, so to speak. All of them are miracles, and I am eternally grateful to the

busy men and women who took the time and trouble to write them.

My thanks to Wiley’s internal and external production personnel for their

speed and diligence. They, too, are in the business of making something better.

Special thanks to my acquiring editor, Bob Argentieri, who shepherded the proj-

ect through the corporate labyrinth. Not long after I drove down to Manhattan

with the handbook manuscript in ﬁle folders in two cartons on the back seat of

xiv PREFACE

my car, Bob and his wife, Anne, had their third child. She will grow up in a

world changed and improved by the materials-selection decisions that engineers

make every day. I hope this handbook helps to make some of those decisions

the best that they can be.

YER

UTZ

Albany, NY

CONTRIBUTORS

H. Alves

Department of Chemical Engineering

University of Dortmund

Dortmund, Germany

Michael G. Bader

School of Mechanical and Materials

Engineering

University of Surrey

Guildford, Surrey, UK

T. H. Bassford

Inco Alloys International, Inc.

Huntington, West Virginia

Paul J. Biermann

Applied Physics Laboratory

The Johns Hopkins University

Laurel, Maryland

William E. Biles

Department of Industrial Engineering

University of Louisville

Louisville, Kentucky

Hans J. Borstell

Milledgeville, Georgia

Bruce L. Bramﬁtt

Bethlehem Steel Corporation

Homer Research Laboratories

Bethlehem, Pennsylvania

Robert S. Busk

Hilton Head, South Carolina

J. A. Collins

Department of Mechanical Engineering

Ohio State University

Columbus, Ohio

Robert L. Crane

Air Force Wright Laboratory

Materials Directorate

Nondestructive Evaluation Branch

Wright Patterson Air Force Base

Dayton, Ohio

S. R. Daniewicz

Department of Mechanical Engineering

Mississippi State University

Starkville, Mississippi

Matthew J. Donachie

Rensselaer at Hartford

Hartford, Connecticut

Stephen J. Donachie

Special Metals Corporation

New Hartford, New York

D. Eliezer

Department of Materials Engineering

Ben-Gurion University of the Negev

Beer-Sheeva, Israel

Warren C. Fackler

Telesis Systems

Cedar Rapids, Iowa

Mahmoud M. Farag

The American University in Cairo

Cairo, Egypt

S. W. Freiman

Ceramics Division

Materials Science and Engineering

Laboratory

National Institute of Standards and

Technology

Gaithersburg, Maryland

xvi CONTRIBUTORS

F. H. Froes

Institute for Materials and Advanced

Processes (IMAP)

University of Idaho

Moscow, Idaho

E. R. Fuller, Jr.

Ceramics Division

Materials Science and Engineering

Laboratory

National Institute of Standards and

Technology

Gaithersburg, Maryland

Michele J. Grimm

Bioengineering Center

Wayne State University

Detroit, Michigan

Dean O. Harper

Department of Chemical Engineering

University of Louisville

Louisville, Kentucky

James A. Harvey

Under the Bridge Consulting

Corvallis, Oregon

Bonny M. Hilditch

Applied Physics Laboratory

The Johns Hopkins University

Laurel, Maryland

Jim Hosier

Inco Alloys International, Inc.

Huntington, West Virginia

Michael G. Jenkins

University of Washington

Seattle, Washington

R. Nathan Katz

Department of Mechanical Engineering

Worcester Polytechnic Institute

Worcester, Massachusetts

J. G. Kaufman

Kaufman Associates, Inc.

Columbus, Ohio

James Kelly

Southﬁeld, Michigan

Patricia E. Kirkwood

Paciﬁc Lutheran University

Tacoma, Washington

Lisa C. Klein

Department of Ceramic and Materials

Engineering

Rutgers University

Piscataway, New Jersey

Ronald A. Kohser

Department of Metallurgical

Engineering

University of Missouri-Rolla

Rolla, Missouri

Glen R. Kowach

Agere Systems

Murray Hill, New Jersey

Konrad J. A. Kundig

Randolph, New Jersey

Shawn K. McGuire

Stanford University

Stanford, California

Peter C. McKeighan

Southwest Research Institute

San Antonio, Texas

Deborah Mies

MSC.Software Corporation

Santa Ana, California

Ayman S. Mosallam

Division of Engineering

California State University

Fullerton, California

Dietrich Munz

Universita¨t Karlsruhe

Institut fu¨r Zuverla¨ssigkeit und

Schadenskunde im Maschinenbau

Karlsruhe, Germany

Edward N. Peters

General Electric Company

Selkirk, New York

CONTRIBUTORS xvii

Andrew W. Phelps

University of Dayton Research Institute

Dayton, Ohio

Ainissa G. Ramirez

Agere Systems

Murray Hill, New Jersey

Jack C. Roberts

Applied Physics Laboratory

The Johns Hopkins University

Laurel, Maryland

Ward D. Rummel

D&W Enterprises

Littleton, Colorado

Vishu Shah

Consultek

Brea, California

Sherwin Shang

Baxter Healthcare Corporation

McGaw Park, Illinois

Kevin R. Uleck

Department of Aerospace Engineering

University of Maryland

College Park, Maryland

Dennis B. Webster

Department of Industrial and

Manufacturing Systems Engineering

Louisiana State University

Baton Rouge, Louisiana

J. H. Westbrook

Brookline Technologies

Ballston Spa, New York

G. S. White

Ceramics Division

Materials Science and Engineering

Laboratory

National Institute of Standards and

Technology

Gaithersburg, Maryland

Lecon Woo

Baxter Healthcare Corporation

Round Lake, Illinois

Magd E. Zohdi

Department of Industrial and

Manufacturing Systems Engineering

Louisiana State University

Baton Rouge, Louisiana

Carl Zweben

Devon, Pennsylvania

PART 1

QUANTITATIVE METHODS OF

MATERIALS SELECTION

HandbookofMaterialsSelection.EditedbyMyerKutz

CHAPTER 1

QUANTITATIVE METHODS OF

MATERIALS SELECTION

Mahmoud M. Farag

The American University in Cairo

Cairo, Egypt

1 INTRODUCTION 3

2 INITIAL SCREENING OF

MATERIALS 4

2.1 Analysis of Material Performance

Requirements 4

2.2 Quantitative Methods for Initial

Screening 7

3 COMPARING ALTERNATIVE

SOLUTIONS 11

3.1 Weighted-Properties Method 11

4 SELECTING THE OPTIMUM

SOLUTION 13

5 CASE STUDY IN MATERIAL

SELECTION 13

5.1 Material Performance

Requirements 14

5.2 Initial Screening of Materials 14

5.3 Comparing Alternative Solutions 14

5.4 Selecting the Optimum Solution 15

6 MATERIALS SUBSTITUTION 19

6.1 Pugh Method 19

6.2 Cost–Beneﬁt Analysis 20

7 CASE STUDY IN MATERIALS

SUBSTITUTION 21

8 SOURCES OF INFORMATION

AND COMPUTER-ASSISTED

SELECTION 21

8.1 Computerized Materials

Databases 22

8.2 Computer Assistance in Making

Final Selection 22

8.3 Expert Systems 23

REFERENCES 24

1 INTRODUCTION

It is estimated that there are more than 40,000 currently useful metallic alloys

and probably close to that number of nonmetallic engineering materials such as

plastics, ceramics and glasses, composite materials, and semiconductors. This

large number of materials and the many manufacturing processes available to

the engineer, coupled with the complex relationships between the different se-

lection parameters, often make the selection of a materials for a given component

a difﬁcult task. If the selection process is carried out haphazardly, there will be

the risk of overlooking a possible attractive alternative material. This risk can

be reduced by adopting a systematic material selection procedure. A variety of

quantitative selection procedures have been developed to analyze the large

amount of data involved in the selection process so that a systematic evaluation

HandbookofMaterialsSelection.EditedbyMyerKutz

4 QUANTITATIVE METHODS OF MATERIALS SELECTION

can be made.

1–11

Several of the quantitative procedures can be adapted to use

computers in selection from a data bank of materials.

12–15

Experience has shown that it is desirable to adopt the holistic decision-making

approach of concurrent engineering in product development in most industries.

With concurrent engineering, materials and manufacturing processes are consid-

ered in the early stages of design and are more precisely deﬁned as the design

progresses from the concept to the embodiment and ﬁnally the detail stages.

Figure 1 deﬁnes the different stages of design and shows the related activities

of the material and manufacturing process selection. The ﬁgure illustrates the

progressive nature of materials and process selection and deﬁnes three stages of

selection—namely initial screening, developing and comparing alternatives, and

selecting the optimum solution. Sections 2, 3, and 4 of this chapter discuss these

three stages of material and process selection in more detail, and Section 5 gives

a case study to illustrate the procedure.

Although the materials and process selection is often thought of in terms of

new product development, there are many other incidents where materials sub-

stitution is considered for an existing product. Issues related to material substi-

tution are discussed in Section 6 of this chapter.

Unlike the exact sciences, where there is normally only one single correct

solution to a problem, materials selection and substitution decisions require the

consideration of conﬂicting advantages and limitations, necessitating compro-

mises and trade-offs; as a consequence, different satisfactory solutions are pos-

sible. This is illustrated by the fact that similar components performing similar

functions, but produced by different manufacturers, are often made from differ-

ent materials and even by different manufacturing processes.

2 INITIAL SCREENING OF MATERIALS

In the ﬁrst stages of development of a new product, the following questions may

be posed: What is it? What does it do? How does it do it? To answer these

questions it is necessary to specify the performance requirements of the different

parts involved in the design and to broadly outline the main materials perform-

ance and processing requirements. This allows the initial screening of materials

whereby certain classes of materials and manufacturing processes may be elim-

inated and others chosen as likely candidates.

2.1 Analysis of Material Performance Requirements

The material performance requirements can be divided into ﬁve broad categories,

namely functional requirements, processability requirements, cost, reliability,

and resistance to service conditions.

Functional Requirements

Functional requirements are directly related to the required characteristics of the

part or the product. For example, if the part carries a uniaxial tensile load, the

yield strength of a candidate material can be directly related to the load-carrying

capacity of the product. However, some characteristics of the part or product

may not have simple correspondence with measurable material properties, as in

the case of thermal shock resistance, wear resistance, reliability, etc. Under these

conditions, the evaluation process can be quite complex and may depend upon

2 INITIAL SCREENING OF MATERIALS 5

Fig. 1 Stages of design and the related stages of materials selection.