DESIGN FOR MANUFACTURE

MATERIAL SELECTION
By

Dr. R. PANNEER

UNIT: II MATERIAL SELECTION

TOPIC 1: Factors determining choice of materials,
TOPIC 2: Performance characteristics of materials,
TOPIC 3: Material selection process.
TOPIC 4: Evaluation methods for material selection.
TOPIC 5: Principal materials used in manufacturing.

Topic 1: Factors determining

choice of materials
Materials science and engineering plays a vital
role in this modern age of science and
technology.
Various kinds of materials are used in industry,
housing, agriculture, transportation, etc. to meet
the plant and individual requirements.
The rapid developments in the field of quantum
theory of solids have opened vast opportunities
for better understanding and utilization of
various materials.

Topic 1: Factors determining

choice of materials
The spectacular success in the field of space is
primarily due to the rapid advances in hightemperature and high-strength materials.
The selection of a specific material for a particular
use is a very complex process.
However, one can simplify the choice if the details
about (i) operating parameters, (ii) manufacturing
processes, (iii) functional requirements and (iv)
cost considerations are known.
Factors affecting the selection of materials are
summarized in Table 1 & 2

Topic 1: Factors determining

choice of materials
Table 1 Factors determining choice of materials: (Manufacturing
Processes and Functional Requirements)

Topic 1: Factors determining

choice of materials
Table 2 Factors determining choice of materials:
(Cost Considerations and Operating Parameters)

Topic 1: Factors determining

choice of materials
Table 2 Factors determining choice of materials:
(Cost Considerations and Operating Parameters)

TOPIC 2: Performance
characteristics of materials
The table below provides fairly complete listing of material
performance characteristics.
1. Physical Properties:
i. Crystal Structure
ii. Density
iii. Melting Point
iv. Vapor Pressure
v. Viscosity
vi. Porosity
vii. Permeability
viii. Reflectivity
ix. Transparency
x. Optical Properties
xi. Dimensional Stability

2. Electrical Properties:
i. Conductivity
ii. Dielectric Constant
iii. Coercive Force
iv. Hysteresis
3 Mechanical Properties:
i. Hardness
ii. Modulus of Elasticity
-Tension & Compression
iii. Poison Ratio
iv. Stress Strain curve

TOPIC 2: Performance characteristics

of materials
The table below provides fairly complete listing of material
performance characteristics.
3 Mechanical Properties:
v. Yield strength
-Tension & Compression
-Shear
vi. Ultimate strength
-Tension & Compression
-Bearing
vii. Fatigue properties
- Smooth
- Notched
- Corrosion Fatigue
- Rolling Fatigue
- Fretting

3 Mechanical Properties:
viii. Charpy Transition Temp.
ix. Fracture Toughness
x. High Temp.
- Creep
-Stress Rupture
xi. Damping Property
xii. Wear Property
- Galling, Abrasion, & Erosion
xiii. Cavitations
xiv. Spalling
xv. Ballistic Impact

TOPIC 2: Performance characteristics

of materials
The table below provides fairly complete listing of material
performance characteristics.
5 Chemical Properties:
4 Thermal Properties:
ii. Corrosion & Degradation
i. Conductivity
- Atmosphere
ii. Specific Heat
- Salt water
iii. Coeff. of Expansion
- Acids
iv. Emissivity
- Hot gases
v. Absorbtivity
- Ultra-violet
vi. Ablation Rate
iii. Oxidation
vii. Fire Resistance
iv. Thermal Stability
v. Biological Stability.
5 Chemical Properties:
vi. Stress Corrosion
i. Position in electromotive
vii. Hydrogen Embrittlement
series
viii. Hydraulic Permeability

TOPIC 2: Performance characteristics

of materials
The table below provides fairly complete listing of material
performance characteristics.
6 Nuclear Properties:
i. Half-life
ii. Cross-section
iii. Stability
7 Fabrication Properties:
i. Castability
ii. Heat Treatability
iii. Hardenability
iv. Formability
v. Machinability
vi. Weldability

 There are thousands and thousands of

materials available and it is very difficult
for an engineer to possess a detailed
knowledge of all the materials.
However, a good grasp of the
fundamental principles which control
the properties of various materials help
one to make the optimum selection of
material.

MATERIAL SELECTION PROCESS

The selection of materials on purely rational basis is
far from easy.
The problem is not only often made difficult by
insufficient or in accurate property data but is
typically one of decision making in the face of
multiple constraints without a clear cut objective
function.
Material selection usually involves one of two
different situations.
1. Selection of Materials for new product or design
2. Revaluation of existing product or design to reduce
cost, increase reliability, improve performance etc.