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Materials Selection

  • 1.  Materials Selection

    Posted 03-12-2023 01:07
    Edited by David Sapiro 03-12-2023 01:08

    How do you go about materials selection/trade studies, particularly for new products and advanced applications? Simple Google searches often don't result in thorough lists that include technical details, and it's impossible to sift through all materials data in any database.



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    David Sapiro
    Senior Materials Engineer
    Seattle WA
    david@schonpiromaterials.com
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  • 2.  RE: Materials Selection

    Posted 03-12-2023 07:51
    Initially find the service requirements like operating stress, temperature and mechanical property.
    Then use the edupack software Ashby plot to match the material and think about what are the modifications in microstructure can be done to maximize the life time and properties of the material

    Regards,
    Sri Saran

    ---------------------------------
    Sri Saran Gunasekaran


    Manchester
    +447442114684
    ---------------------------------



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  • 3.  RE: Materials Selection

    Posted 03-13-2023 11:33

    The "material selection" in industry is a fairly involved process and amounts to the process of selecting material chemistry, processing route (casting, rolling, forging, die casting, welding, brazing, P/M, MIM etc), heat treatment, surface treatment, finishing and plating. One needs to select the entire package, not just the material chemistry.

    That said, some of the considerations for selecting material/process for a component may involve the following:

    1. Component geometry (planar, 3-D, axisymmetric etc.)
    2. General strength levels 
    3. Load application mode in service (steady, shock loading, cyclic, thermal cycling etc)
    4. Service Environment (corrosion requirement, temperature exposure etc.)
    5. Service Life 
    6. Wear Requirements (mating with other components)
    7. Lubrication Requirements
    8. Primary Failure Modes 
    9. Cost
    10. Others

    Unfortunately, materials databases do not address above factors when listing properties. 

    You may need to contact subject matter experts to guide you through this process if the component is slated for "mission critical" applications.

    Ratnesh Dwivedi, Ph.D.

    www.RKDENGG.com



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    Ratnesh Dwivedi
    President
    RKD ENGG, LLC
    Thornton PA
    6103993670
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  • 4.  RE: Materials Selection

    Posted 03-14-2023 02:28
    Edited by David Sapiro 03-14-2023 02:29

    Ratnesh, how does a subject matter expert select a material? I wouldn't expect even a SME to know ALL of the options, particularly for things that have never been made before. How does one find a material that fits with the many requirements you listed, since databases can't yet sort by all of the relevant properties?



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    David Sapiro
    Senior Materials Engineer
    Seattle WA
    david@schonpiromaterials.com
    www.schonpiromaterials.com
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  • 5.  RE: Materials Selection

    Posted 03-14-2023 08:25

    David,

    Especially in the case of things which have never been made before, it should be recognized that material selection is often an iterative process. You can recognize the limitations of databases and models up front and plan series of physical tests to confirm your selections, or you can run with your selection and have the end user conduct the physical tests after product release. Personally, I think the second option is poor engineering and generally irresponsible, but that does not mean that it is not common. Prototyping and testing should be central to any product development, it serves as the point where design, material selection, and manufacturing methods meet for the first time in "real life" and any weaknesses or oversights in any of the three are revealed. This is especially crucial in cases where the design, material selection, and manufacturing methods were selected by different people or groups.

    This does not mean that I underestimate the value of databases and models. A good model and stress analysis (FEA, etc.) is an excellent starting point. The stress results will often eliminate broad categories of materials, and materials often have their own unique fabrication methods, which substantially narrows the variables. If the FEA eliminates all practical (may also be read "affordable" or "readily available") materials, then the design must be rethought, which is itself an iterative process. If the design cannot be altered or the mission is sufficiently critical, then perhaps a material needs to be developed to meet the requirements.

    Ratnesh lists many of the things that databases will not tell you, and alludes to the fact that there are more, and he is absolutely correct. When you have narrowed your selection down to a handful of materials you are then in a position to consult the SMEs about the peculiarities of their materials and processes to further narrow your selection.

    What do the SMEs have that the designer may not? Experience, which I suppose you could call a specialized database with limited user access, developed through trial and error. 



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    Paul Taylor
    Advanced Manufacturing Engineer – Metallurgy & Foundry Systems
    GIW Industries
    Grovetown GA
    paul.taylor@ksb.com
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  • 6.  RE: Materials Selection

    Posted 03-15-2023 10:21
    • First, put yourself "in the designer's shoes" -- find out what is expected and what is most important. In some situations a non-mechanical property (color, magnetic response, electrical conductivity, etc.) may be most important. 
    • Second, consider how invested the user is in one production process. (A multi-million dollar investment in metal stamping might dampen interest in nonmetals.) 
    • Third, consider use in off-design conditions (too hot, too much load, etc.). 
    • Finally, consider whether the system is expected to "fail gracefully" or whether sudden failure is acceptable.

    --
    John Grubb



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  • 7.  RE: Materials Selection

    Posted 03-14-2023 14:32

    Hi David,

    A good starting point would be to list out the key performance criteria the component would be expected to meet and then start looking at the materials/process choices. Databases would certainly help in the first iteration. If the primary criterion is strength related, the selection process is simpler. Without knowing more details of the component in question, it is not possible to recommend a path forward.

    You may work with a consulting company such as ours, www.rkdengg.com, to sort out the selection process.

    Thanks and good luck!



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    [Ratnesh] [Dwivedi]
    [President]
    [RKD ENGG, LLC]

    www.rkdengg.com
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  • 8.  RE: Materials Selection

    Posted 03-13-2023 17:30

    From a manufacturing standpoint, you tend to stay with the same supplier base when you have a new product.  The supplier may have more advanced materials than you normally use, that they work with. Even with new materials (more so on the electronics products) the product has to be an established material with established processes. If the material is too new there may not be established processes (stamping, machining, joining, or heat treating) to fabricate the component.

    The other consideration is: will the part be sourced locally, or moved to a lower cost country? Will the alloy / material be available in the alternate country, or you may need to convert drawings to different regional standards.



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    Patrick Mizik
    ASM Chapter Council Chair & District 11 Rep
    Principal Metallurgical Engineer
    Haldex SAF Holland Group
    pat.mizik@haldex.comHaldex SAF Holland GroupHaldex SAF Holland GroupHaldex SAF Holland GroupHaldex SAF Holland GroupHaldex SAF Holland Group
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  • 9.  RE: Materials Selection

    Posted 03-14-2023 02:32

    Patrick, I guess another similar question is how does one find the right supplier? First you have to know they have the right material for the current job, then hope they will also have the right material for future jobs since it's such a hassle to change suppliers every time a part is modified. Do you normally find the material first and find a supplier that can support it, or find a supplier and hope they can help you get the right material?



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    David Sapiro
    Senior Materials Engineer
    Seattle WA
    david@schonpiromaterials.com
    www.schonpiromaterials.com
    ------------------------------

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  • 10.  RE: Materials Selection

    Posted 03-14-2023 09:33

    In a larger manufacturing environment, the quality dept. will track the PPAP requirements, DFMEA submittals, Process control plans, etc. If a supplier cannot meet those requirements there are generally suppliers that can meet those requirements.  Does that supplier have consistent sourcing of materials suppliers, heat treaters, or surface finishers. If they switch material or process suppliers does it affect product quality fit, finish, or form?

    From the engineering dept.- is the supplier open to design changes for manufacturability or does the supplier provide cost savings ideas based on their expertise or combining operations? 

    From an operations standpoint, do they deliver parts on time, without shipping damage or corrosion. Will late shipments affect your manufacturing schedule and customer schedules? Will your company be monetarily penalized for delaying a customer's production line?

    Then from the sourcing and accounting depts... does the supplier nickel and dime them on minor charges or surcharges?  Do they have an adequate credit rating to procure raw materials?



    ------------------------------
    Patrick Mizik
    ASM Chapter Council Chair & District 11 Rep
    Principal Metallurgical Engineer
    Haldex SAF Holland Group
    pat.mizik@haldex.comHaldex SAF Holland Group
    ------------------------------

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  • 11.  RE: Materials Selection

    Posted 03-14-2023 11:25

    Following are links to selected chapters in the ASM Digital Library related to the materials selection process. The full text of the two articles from the Desk Edition volumes is available as a benefit to ASM members; member discounts are available for the other items. 

    J.R. Davis, Guide to Materials Selection, Engineered Materials Handbook Desk Edition, Edited By Michelle M. Gauthier, ASM International, 1995, p 106–154, https://doi.org/10.31399/asm.hb.emde.a0003005

    Factors in Materials Selection, Metals Handbook Desk Edition, 2nd ed., Edited By Joseph R. Davis, ASM International, 1998, p 141–149, https://doi.org/10.31399/asm.hb.mhde2.a0003089

    George E. Dieter, Overview of the Materials Selection Process, Materials Selection and Design, Vol 20, ASM Handbook, Edited By George E. Dieter, ASM International, 1997, p 243–254, https://doi.org/10.31399/asm.hb.v20.a0002450

    M.F. Ashby, Material Property Charts, Materials Selection and Design, Vol 20, ASM Handbook, Edited By George E. Dieter, ASM International, 1997, p 266–280, https://doi.org/10.31399/asm.hb.v20.a0002452

    M.F. Ashby, Performance Indices, Materials Selection and Design, Vol 20, ASM Handbook, Edited By George E. Dieter, ASM International, 1997, p 281–290, https://doi.org/10.31399/asm.hb.v20.a0002453

    George E. Dieter, Relationship between Materials Selection and Processing, Materials Selection and Design, Vol 20, ASM Handbook, Edited By George E. Dieter, ASM International, 1997, p 297–308, https://doi.org/10.31399/asm.hb.v20.a0002455

    Peter Elliott, Materials Selection for Corrosion Control, Corrosion: Fundamentals, Testing, and Protection, Vol 13A, ASM Handbook, Edited By Stephen D. Cramer, Bernard S. Covino, Jr., ASM International, 2003, p 909–928, https://doi.org/10.31399/asm.hb.v13a.a0003702

    Brett A. Miller, Materials Selection for Failure Prevention, Analysis and Prevention of Component and Equipment Failures, Vol 11A, ASM Handbook, Edited By Brett A. Miller, Roch J. Shipley, Ronald J. Parrington, Daniel P. Dennies, ASM International, 2021, p 3–19, https://doi.org/10.31399/asm.hb.v11A.a0006800

    The Materials Selection Process, Metallurgy for the Non-Metallurgist, 2nd ed., Edited By Arthur C. Reardon, ASM International, 2011, p 407–428, https://doi.org/10.31399/asm.tb.mnm2.t53060407

    Paul J. Gramann, Navigating the Plastic Material Selection Process, Characterization and Failure Analysis of Plastics, Vol 11B, ASM Handbook, Edited By Todd J. Menna, ASM International, 2022, p 428–436, https://doi.org/10.31399/asm.hb.v11B.a0006922



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    Scott Henry
    Senior Content Engineer
    ASM International
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