Because learning changes everything.

Chapter 2
Materials

Lecture Slides

© 2020 McGraw Hill. All rights reserved. Authorized only for instructor use in the classroom.
No reproduction or further distribution permitted without the prior written consent of McGraw Hill.
 Chapter Outline

2–1 Material Strength and Stiffness 42 2–11 Investment Casting 67

2–2 The Statistical Significance of 2–12 Powder-Metallurgy Process 67
Material Properties 48 2–13 Hot-Working Processes 67
2–3 Plastic Deformation and Cold 2–14 Cold-Working Processes 68
Work 50
2–15 The Heat Treatment of Steel 69
2–4 Cyclic Stress-Strain Properties 57
2–16 Alloy Steels 72
2–5 Hardness 61
2–17 Corrosion-Resistant Steels 73
2–6 Impact Properties 62
2–18 Casting Materials 73
2–7 Temperature Effects 63
2–19 Nonferrous Metals 75
2–8 Numbering Systems 64
2–20 Plastics 78
2–9 Sand Casting 66
2–21 Composite Materials 80
2–10 Shell Molding 66
2–22 Materials Selection 81

© McGraw Hill 2
 Nonferrous Metals

Aluminum.
Magnesium.
Titanium.
Copper-based alloys.
• Brass with 5 to 15 percent zinc.
• Gilding brass, commercial bronze, red brass.
• Brass with 20 to 36 percent zinc.
• Low brass, cartridge brass, yellow brass.
• Low-leaded brass, high-leaded brass (engraver’s brass), free-cutting brass.
• Admiralty metal.
• Aluminum brass.
• Brass with 36 to 40 percent zinc.
• Muntz metal, naval brass.
• Bronze.
• Silcon bronze, phosphor bronze, aluminum bronze, beryllium bronze.
© McGraw Hill 3
 Plastics

Thermoplastic – any plastic that flows or is moldable when heat is

applied.
Thermoset – a plastic for which the polymerization process is
finished in a hot molding press where the plastic is liquefied under
pressure.

© McGraw Hill 4
 Thermoplastic Properties (Table 2–3)

Su E Hardness Elongation Dimensional Heat Chemical

Name kpsi Mpsi Rockwell % Stability Resistance Resistance Processing
ABS group 2 to 8 0.10 to 0.37 60 to 110R 3 to 50 Good * Fair EMST
Acetal group 8 to 10 0.41 to 0.52 80 to 94M 40 to 60 Excellent Good High M
Acrylic 5 to 10 0.20 to 0.47 92 to 110M 3 to 75 High * Fair EMS
Fluoroplastic 0.50 to 7 ... 50 to 80D 100 to 300 High Excellent Excellent MPR†
group
Nylon 8 to 14 0.18 to 0.45 112 to 120R 10 to 200 Poor Poor Good CEM
Phenylene oxide 7 to 18 0.35 to 0.92 115R, 106L 5 to 60 Excellent Good Fair EFM
Polycarbonate 8 to 16 0.34 to 0.86 62 to 91M 10 to 125 Excellent Excellent Fair EMS
Polyester 8 to 18 0.28 to 1.6 65 to 90M 1 to 300 Excellent Poor Excellent CLMR
Polyimide 6 to 50 ... 88 to 120M Very low Excellent Excellent Excellent† CLMP
Polyphenylene 14 to 19 0.11 122R 1.0 Good Excellent Excellent M
sulfide
Polystyrene group 1.5 to 12 0.14 to 0.60 10 to 90M 0.5 to 60 ... Poor Poor EM
Polysulfone 10 0.36 120R 50 to 100 Excellent Excellent Excellent† EFM
Polyvinyl 1.5 to 7.5 0.35 to 0.60 65 to 85D 40 to 450 ... Poor Poor EFM
chloride
*Heat-resistant
grades available.
†Withexceptions.
C Coatings L Laminates R Resins E Extrusions M Moldings S Sheet F Foams P Press and sinter methods T Tubing

© McGraw Hill 5
 Thermoset Properties (Table 2–4)

Su E Hardness Elongation Dimensional Heat Chemical

Name kpsi Mpsi Rockwell % Stability Resistance Resistance Processing

Alkyd 3 to 9 0.05 to 0.30 99M* ... Excellent Good Fair M

Allylic 4 to 10 ... 105 to 120M ... Excellent Excellent Excellent CM

Amino group 5 to 8 0.13 to 0.24 110 to 120M 0.30 to 0.90 Good Excellent* Excellent* LR

Epoxy 5 to 20 0.03 to 0.30* 80 to 120M 1 to 10 Excellent Excellent Excellent CMR

Phenolics 5 to 9 0.10 to 0.25 70 to 95E ... Excellent Excellent Good EMR

Silicones 5 to 6 ... 80 to 90M ... ... Excellent Excellent CLMR

*With exceptions.
C Coatings L Laminates R Resins E Extrusions M Moldings S Sheet F Foams P Press and sinter methods T Tubing

© McGraw Hill 6
 Composite Materials

Formed from two or more dissimilar materials, each of which contributes to the
final properties.
Materials remain distinct from each other at the macroscopic level.
Usually amorphous and non-isotropic.
Often consists of laminates of filler to provide stiffness and strength and a matrix
to hold the material together.
Common filler types:

Access the text alternative for slide images.

Fig. 2–22
© McGraw Hill 7
 Material Families and Classes (Table 2–5) 1
Family Classes Short Name
Metals
(the metals and alloys of
engineering) Aluminum alloys Al alloys
Copper alloys Cu alloys
Lead alloys Lead alloys
Magnesium alloys Mg alloys
Nickel alloys Ni alloys
Carbon steels Steels
Stainless steels Stainless steels
Tin alloys Tin alloys
Titanium alloys Ti alloys
Tungsten alloys W alloys
Lead alloys Pb alloys
Zinc alloys Zn alloys

(Continued)
© McGraw Hill 8
 Material Families and Classes (Table 2–5) 2
Family Classes Short Name
Ceramics
Technical ceramics (fine ceramics
capable of load-bearing application) Alumina Al2O3
Aluminum nitride AlN
Boron carbide B4C
Silicon carbide SiC
Silicon nitride Si3N4
Tungsten carbide WC
Nontechnical ceramics (porous
ceramics of construction) Brick Brick
Concrete Concrete
Stone Stone
Glasses Soda-lime glass Soda-lime glass
Borosilicate glass Borosilicate glass
Silica glass Silica glass
Glass ceramic Glass ceramic

(Continued)
© McGraw Hill 9
 Material Families and Classes (Table 2–5) 3
Family Classes Short Name
Polymers
(the thermoplastics and thermosets
of engineering) Acrylonitrile butadiene styrene ABS
Cellulose polymers CA
Ionomers Ionomers
Epoxies Epoxy
Phenolics Phenolics
Polyamides (nylons) PA
Polycarbonate PC
Polyesters Polyester
Polyetheretherkeytone PEEK
Polyethylene PE
Polyethylene terephalate PET or PETE
Polymethylmethacrylate PMMA
Polyoxymethylene(Acetal) POM
Polypropylene PP
Polystyrene PS
Polytetrafluorethylene PTFE
Polyvinylchloride PVC
(Continued)
© McGraw Hill 10
 Material Families and Classes (Table 2–5) 4
Family Classes Short Name
Elastomers
(engineering rubbers, natural
and synthetic) Butyl rubber Butyl rubber
EVA EVA
Isoprene Isoprene
Natural rubber Natural rubber
Polychloroprene (Neoprene) Neoprene
Polyurethane PU
Silicon elastomers Silicones
Hybrids
Composites Carbon-fiber reinforced polymers CFRP
Glass-fiber reinforced polymers GFRP
SiC reinforced aluminum Al-SiC
Foams Flexible polymer foams Flexible foams
Rigid polymer foams Rigid foams
Natural materials Cork Cork
Bamboo Bamboo
Wood Wood

© McGraw Hill Source: From Ashby, M. F., Materials Selection in Mechanical Design, 3rd ed., Elsevier Butterworth- Heinemann, Oxford, 2005. Table 4–1, 49–50. 11
 Young’s Modulus for Various Materials

Access the text alternative for slide images. Fig. 2–23

© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 12
 Young’s Modulus versus Density

Access the text alternative for slide images. Fig. 2–24

© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 13
 Specific Modulus 1

Specific Modulus – ratio of

Young’s modulus to density,
E / ρ.
Also called specific stiffness.
Useful to minimize weight
with primary design
limitation of deflection,
stiffness, or natural
frequency.
Parallel lines representing
Fig. 2–24
different values of E / ρ allow
comparison of specific
modulus between materials.
© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 14
 Minimum Mass Guidelines for Young’s Modulus-Density Plot

Guidelines plot constant

values of Eβ/ρ.
β depends on type of
loading.
β = 1 for axial.
β = 1/2 for bending.

Example, for axial loading,

k = AE/l ⇒ A = kl/E Fig. 2–24

m = Alρ = (kl/E) lρ =kl2 ρ /E

Thus, to minimize mass, maximize E/ρ (β = 1)
© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 15
 The Performance Metric

The performance metric depends on (1) the functional

requirements, (2) the geometry, and (3) the material properties.

 fuctional   geometric   material  

P= , , 
 requirements F   parameters G   properties M  
P = f ( F , G, M ) (2 - 38)
The function is often separable,
P = f1 ( F ) ⋅ f 2 (G ) ⋅ f3 ( M ) (2 - 39)
f3 (M) is called the material efficiency coefficient.

Maximizing or minimizing f3 (M) allows the material choice to be

used to optimize P.
© McGraw Hill 16
 Performance Metric Example 1

Requirements: light, stiff, end-loaded cantilever beam with circular

cross section.

© McGraw Hill 17
 Performance Metric Example 4

β = ½.
Use guidelines parallel
to E1/2/ρ.
Increasing M, move up
and to the left.
Good candidates for this
example are certain
woods, composites, and
ceramics.

Access the text alternative for slide images. Fig. 2–25

© McGraw Hill Source: Adapted from Ashby, M. F., Materials Selection in Mechanical Design, 3rd ed., Elsevier Butterworth-Heinemann, Oxford, 2005. 18
 Performance Metric Example 5

Additional constraints
can be added as needed.
For example, if it is
desired that E > 50 GPa,
add horizontal line to
limit the solution space.
Wood is eliminated as a
viable option.

Access the text alternative for slide images. Fig. 2–26

© McGraw Hill Source: Adapted from Ashby, M. F., Materials Selection in Mechanical Design, 3rd ed., Elsevier Butterworth-Heinemann, Oxford, 2005. 19
 Strength versus Density

Access the text alternative for slide images. Fig. 2–27

© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 20
 Specific Modulus 2

Specific Strength –
ratio of strength to
density, S / ρ.
Useful to minimize
weight with primary
design limitation of
strength.
Parallel lines
representing different
values of S / ρ allow
comparison of specific
strength between
materials. Fig. 2–27

© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 21
 Minimum Mass Guidelines for Strength-Density Plot

Guidelines plot constant

values of Sβ/ρ.
β depends on type of
loading.
β = 1 for axial.
β = 2/3 for bending.

Example, for axial loading,

σ = F/A = S ⇒ A = F/S
Fig. 2–27
m = Alρ = (F/S) lρ
Thus, to minimize m, maximize S/ρ (β = 1)
© McGraw Hill Source: Adapted from figure by Prof. Mike Ashby, Granta Design, Cambridge, U.K. 22
 Engineering Ethics – Case Study #2: Piper Alpha

© McGraw Hill 23