Materials and Process Selection for Engineering Design

About the book

Main Features of the 3rd Edition

Since the publication of the second edition in 2009, changes have occurred in the fields of materials and manufacturing.
Nanostructured and smart materials now appear more frequently in products. Composites are now used in manufacturing essential
parts of civilian airliners and even the whole aircraft, as in Boeing Dreamliner 787. Biodegradable materials are increasingly used
instead of traditional plastics as more emphasis is placed on how products affect the environment and as society is also willing to
accept a more expensive but echo friendly goods. Companies are now manufacturing more of their products in-house rather than
outsourcing to assure quality and reduce cost. These changes have been reflected in the curricula and courses of materials and
manufacturing in a variety of engineering programs and schools.

Experience in using the 2nd edition as a textbook for junior and senior engineering students has shown that although they have
completed a first course in materials, they still need practical information on the treatment, behavior and use of engineering
materials in various applications. The appendices in Part IV have been revised and expanded to provide such information.

Twenty two new cases studies and design examples were also added throughout the book as experience has also shown that case
studies are helpful in explaining engineering concepts in addition to increasing student interest in the subject and encouraging active
learning. A list of expected outcomes has also been added at the beginning of each part of the book to enhance the use of the 3rd
edition as textbook.

Several new sections were also added and the content of many others changed to reflect the recent developments in engineering
materials and manufacturing. The main new features in the 3rd edition include:

 House Of Quality (HOQ) as a tool for identifying customer needs and relating them technical characteristics of the product
(Chapters 1, 5 and 9)
 Environmental considerations, including environmental impact of products, environmentally responsible designs,
environmental impact assessment of materials and processes, and recyclability issues (Chapters 1, 5 and 8)
 Product safety and reliability considerations, including failure mode and effects analysis, design for Six Sigma, product
reliability and safety, and product liability legislation (Chapters 2 and 5)
 Using nontraditional and advanced materials in engineering products, including layered structures as a replacement to
steel sheets, using polymers in mechanical design, and technical and economic feasibility of using carbon nanotubes
(Chapters 6, 9, 10 and 11) 
 Manufacturing considerations, including product manufacture in industry, manufacturing processes selection, automation
of manufacturing processes, and computer integrated manufacturing (Chapter 7)
 Selecting engineering products on the basis of benefit/cost ratio and cost-effectiveness analysis (Chapter 8)
 Using MATLAB in materials selection and materials substitution (Chapters 9 and 10)

Preface to the second edition

Introducing a new engineering product or changing an existing model involves making designs, reaching economic decisions,
selecting materials, choosing manufacturing processes, and assessing its environmental impact. These activities are interdependent
and should not be performed in isolation from each other. This is because the materials and processes used in making the product
can have a large influence on its design, cost, and performance in service. For example, making a part from injection-molded
plastics instead of pressed sheet metal is expected to involve large changes in design, new production facilities and widely different
economic and environmental impact analysis.

Experience has shown that in most industries it is easier to meet the increasing challenge of producing more economic and yet
reliable, aesthetically pleasing and environmentally friendly product if a holistic decision making approach of concurrent engineering
is adopted in product development. With concurrent engineering, materials and manufacturing processes are considered 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
stage.

The objective of this book is to illustrate how the activities of design, materials and process selection, and economic and
environmental analysis fit together and what sort of tradeoffs can be made in order to arrive at the optimum solution when
developing a new product or changing an existing model.

The book starts with an introductory chapter which briefly reviews the stages of product development in industry, recycling of
materials, and life cycle costing. The subject matter is then grouped into three parts. Part I consists of three chapters which discuss
the performance of materials in service. After a review of different types of mechanical failures and environmental degradation, the
materials that are normally selected to  resist a given type of failure are then discussed. Part II consist of three chapters which deal
with the effect of materials and manufacturing processes on design. The elements of industrial and engineering design are first
explained, followed by a discussion of the effect of material properties and manufacturing processes on the design of components.
Part III consists of four chapters which are devoted to the selection and substitution of materials in industry. After a brief review the
economics and environmental aspects of materials and manufacturing processes, several quantitative and computer assisted
methods of screening, comparing and ranking of alternative solutions, and selecting the optimum solution are presented. The final
chapter presents five widely different detailed case studies in materials selection and substitution.

The book is written for junior and senior engineering students who have completed a first course in engineering materials; however,
first year graduate students and practicing engineers will also find the subject matter interesting and useful. In order to enhance the
value of the text as a teaching device, a variety of examples and open ended case studies are given to explain the subject matter
and to illustrate its practical application in engineering. Each chapter starts with an introduction, which includes its goals and
objectives, and ends with a summary, review questions, suggestions for student projects, and selected references for further
reading. SI units are used throughout the text, but Imperial units are also given whenever possible. Tables of composition and
properties of a wide variety of materials, conversion of units, and glossary of technical terms are included in appendices. Power
Point presentations and solution manual are made available to instructors.

Biographical note
Dr. Mahmoud Farag received a B.Sc. degree in mechanical engineering from Cairo University and a M.Met. and Ph.D. from
Sheffield University, UK. He is currently professor of engineering at the American University in Cairo (AUC).

Dr. Farag’s area of academic interest is in engineering materials and manufacturing and has published three engineering textbooks,
edited one book, and written several engineering book-chapters. He has also authored and co-authored about 100 papers in
academic journals and conference proceedings on issues related to the effect of microstructure on the behavior of engineering
materials. His current research interests include studying the behavior of nano-structured materials, with emphasis on NiTi alloys,
natural fiber reinforced plastics, biodegradable composite materials, and using quantitative methods in selecting materials and
processes for engineering applications. In addition to his academic work, Dr. Farag has a wide industrial and consulting experience.

Dr. Farag has more than 30 years of teaching experience and has taught a variety of materials courses on different levels ranging
from introductory overview to sophomore/junior students to advanced topics to masters degree students. He also taught
manufacturing courses with heavy emphasis on how processing affects the properties of materials. One of Dr. Farag’s favorite
courses, which he created at AUC and has written textbooks for, is materials selection. This is a capstone course for
mechanical/materials engineering senior students, which integrates economic analysis with the process of product design and
material and process selection.

Dr. Farag was visiting scientist/scholar at the University of Sheffield (UK), MIT and University of Kentucky-Lexington (USA),  Aachen
Technical University (Germany), and Joint Research Center,  Commission of the European Communities (Ispra, Italy).  He  is a
member of  the American Society of Mechanical Engineers, the Materials Information Society, The Materials Information Society
ASM International (USA), the Institute of Materials, Minerals & Mining (UK),  and the Egyptian Society for Engineers. He is listed in
Marquise Who’s Who in the World, Who’s Who in Science and Engineering, and Who’s Who in Finance and Industry. Dr. Farag is a
recipient of the Egyptian State Award for promotion of Science and the First Order of Merit in Arts and Sciences.

Contact the author

Mahmoud M. Farag 
Professor of Engineering
The American University in Cairo
email: mmfarag@aucegypt.edu

Mailing Address:
Department of Mechanical Engineering
School of Sciences and engineering
The American University in Cairo
AUC Avenue, P.O. Box 74, 
New Cairo, 11835, Egypt