MecE 360: Engineering Design II
Section 3: Materials
Class Notifications
Jason Carey will be providing information about graduate
opportunities
B and A group meeting sign-up outside of 10-227
Quiz 1: early Feb
I posted: old A3 and soln online
Class notes purchased through MECE club for $20
Many extra examples, detailed notes
Teams are notified of projects
Relaxed design specifications as long as explained
5 pages of writing: figure out story, and write
Keys success : bearing, connections, fatigue, creativity
Objectives
Initial considerations
Materials, loading, failure
Presentation on designing materials
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Outline
Material considerations
Uncertainties in material properties (+/- 30%)
Basic engineering materials
Selecting the right material
Ashby charts
Manufacturing processes
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Material Considerations
(p.3-2)
1. Availability and cost
It is very possible that the perfect material exists
for you design - but at what cost.
Titanium: high specific strength (strength/density).
But costs $8.20/ kg vs. $1.50/kg for Al.
2. Strength
Critical for stress related failure (Section 5).
applied
y ,C ,T
n
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Material Considerations
3. Rigidity/stiffness
Designs are often limited by the amount of deflection
between mating components for alignment and proper
mating.
Deflection is dependent on elastic modulus (E) and
geometry.
4. Hardness and ductility
Is scratch resistance or large deformation important?
Contact problems: wear
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Material Considerations
5. Resistance to fatigue
Steel and aluminium have different fatigue behaviour.
6. Manufacturability and machinability
How easy is it to build?
3D printing: only certain materials
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Material Considerations
7. Resilience
The energy before yielding is important for combined
loading, temperature effects.
8. Friction coefficient
Different applications require different surfaces or
mediums for proper functions, e.g. bearings low, and
clutches high
9. Weight
Some designs are weight critical: consider polymers,
wood, foams, aluminium or titanium.
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Uncertainty
(p.3-3)
140
Number of test
120
100
80
60
40
20
0
40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61
Sy (kpsi)
Uncertainty and variability in material properties are
inherent due to microstructure variability
Assessed through experimental testing.
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Engineering Materials
Metals: Magnesium
Polymer: electrospun polyethylene oxideGarcia and Hernandez 2014
Ceramic: alumina
Carbon-reinforced-composite
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Metals
(p.3-6)
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Polymers
(p.3-7)
Different behaviour based on microstructure/chain linking
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Polymers
Properties change
significantly with
increasing temperature
Modulus drops
Should not used above
glass transition
temperature
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Composite Materials
(p.3-9)
In general, composites consist
of two or more materials
Fiber-reinforced polymers (FRP)
long fibers in resin matrix
fibers strength, brittle
resin toughness,
rigidity, protection of
fibers
Lamina is transverse isotropic material
Properties proportional to fiber volume fraction
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Composite Materials
Several laminae combined form a laminate
Laminates can be quasi-isotropic
Laminate layup can
be tailored to meet
specific strength and
stiffness requirements
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Ceramics
Only for compressive
loading
Poor in tension,
cracks propagate
catastrophically
Reinforced with steel,
or fibre reinforced
polymers
Good thermal and
electrical insulators
More later
(p.3-8)
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Comparison
Material
(p.3-10)
Advantages
Disadvantages
Steel
Strength, stiffness, ductility, strength and corrosion
resistance adjustable with alloying elements
Heavy
Aluminum
Lightweight, high ductility, corrosion resistant
Low strength and stiffness
Brass
Corrosion resistant, good wear properties
Heavy, cost
Titanium
Good strength over wide temperature range,
corrosion resistant, lightweight
Poor machinability, cost
Polymers
Lightweight, corrosion resistant, easy to form and
manufacture, versatile, impact resistance, shock
and vibration absorbance, low friction and wear,
recyclable (thermoplastics)
Low strength and stiffness, small
temperature changes cause
large change in properties, poor
recyclability (thermosets)
Lightweight, high specific strength and stiffness,
corrosion resistant, flexible design and versatility
Brittle, expensive, poorly
characterized (codes/standards),
quality strongly affected by
manufacturing, poor recyclability
FRP
Composites
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Material Selection
(p.3-16)
1. Decision matrix
Simple, basic design
Need specifications/requirements
Select material that best meets the specs
See previous sections for example
2. Ashby charts
Advanced methodology
Allows for optimization
Need information on function, objective, constraints
examples will be presented in Seminar #3
Ive never seen this in a 460 report, attempt to incorporate here
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Material Selection:
Ashby Charts
Used with permission: Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.
Material Selection:
Ashby Charts
Three basic elements are required for the selection charts:
Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.
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Material Selection:
Ashby Charts
Performance (p) of a component
based on the requirements of the design
Designs will have three requirements:
1. functional
2. geometric
3. materials property
These are associated to a function (equation)
(which are assumed be independent of each other)
Functional
Geometric Material
p f
, F ,
, G ,
, M
requirements parameters properties
p f1 F f 2 G f 3 M
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Comments
Example: All the materials
lying on a line of constant
E1/2/r perform equally well
as a light stiff beam.
Those above the line are
better, those below, worse.
A material with M = 8 in
these units gives a beam
which has one quarter the
weight of one with M = 2.
Example in seminar
Materials Selection in Mechanical Design, 2nd Edition, M.F. Ashby, Elsevier, 2011.
Designing Next Generation
Protection Materials
Jamie Hogan
Assistant Professor
Mechanical Engineering
University of Alberta
38
Take Away
Exposure to brittle materials
Failure depends on microstructure, stress-state and strain-rate
Talk about how to design microstructures to control failure
Example: fragmentation for body armor applications
300 um
PADB4C-Microstructure
50 um
PADB4C- Fragments
Materials in Defense Applications
bankspower.com
www.galls.com
Big question: Why is one system better than the other?
1.
Requires fundamental understanding of material failure (experiments and models)
2.
Manufacturing processes to produce tailored microstructures (processing)
Approaches to Materials Design
10 um
Twinning in Mg (Dixit)
Boron Carbide Microstructure
Microstructures and material properties (K1c, , E, ) + identification of failure mechanisms
Material Science: alter microstructure property performance (test, test, test)
Mechanics: microstructure/properties mechanisms (models) performance
Philosophy: see it (experiments), understand it (models), control it (processing)
Failure Mechanisms in Brittle Materials
Failure: Defects nucleate mechanisms, which lead to macro-cracks, and often to catastrophic failure
Defects: grain boundaries, secondary phases, initial cracks (we want to identify key defects)
Objective: Control failure mechanisms by designing the defect populations (microstructure design)
Impact Failure of Brittle Materials
Failure Processes (time and space):
1.
Fracture
2.
Granular flow
3.
Plasticity
4.
Phase transformations (amorphization)
Fig. Impact into PAD B4C at 930 m/s
500 microns
Manifest in fragmentation
Hypothesis: controlling fragmentation will
lead to improved performance
Fig. Ballistic fragments for PAD B4C at 930 m/s
Material: boron carbide
1. See it:
Microstructure Characterization
and Experimentation
Boron Carbide Material
Composition: B4C (or B12C3): rhombohedral (bucky balls)
High hardness (Mohs 9.5) and low density (2.5 g/cm3)
Silicon carbide (SiC): 3.2 g/cm3
Manufacturing: grow boron crystal, ball milled, hot-press
with carbon and aluminum nitride additives
Yields defects (serve as fracture sites).
Not all defects are bad
PADB4C- Microstructure
10 um
Boron Carbide Defect Microstructure*
Hot Pressing Direction
Globules (ellipsoids): graphitic disks
Spherical features: graphite/pores
Bright phases: aluminum nitride
Q: What processing defects initiate failure?
Hogan et al. JACS 2014
Strength and Failure
Dynamic Compressive Failure
Unconfined Configuration
2.5 mm
Bi-Axial Confined Configuration
2.5 mm
2 Mfps, exposure= 500 ns
5 Mfps, exposure= 110 ns
Strain rates: ~10-3 (MTS) and ~10+3 s-1 (Kolsky bar) and Stress-states: compression, confined, tension (BD)
Crack speeds set deformation time scales: 2,000 +/- 300 m/s (left) vs. 510 +/- 130 m/s (right)
Deformation mode changes with confinement: need to understand this
Hogan et al. JACS 2014
Strength: Confinement Effects
Hot Pressing Axis
Unconfined Configuration
Hot Pressing Axis
Confined Configuration
We can use strength measurements to guide us on package design
Hogan et al. Acta 2015
Rate-Dependent Strength
Kimberley et al. 2013 scaling relation for
strength as a function of strain rate*
Dynamic strength of brittle materials
is controlled by fracture
Governed by microstructure features
and properties
This example: can control strength by
controlling fracture through design of
defect populations
Fractography: Failure Mechanisms
2. Understand it:
Compressive Brittle
Fragmentation Model
2. Understand It: Theoretical and
Computational Modeling
Inputs From Experiments
Crack growth Kinetics
Flaw Orientation distribution
Flaw Size distribution
Initial Damage
Crack Nucleation
Brittle Failure Model
Self-Consistant
Scheme
Flaw Density
Damage Evolution
Irreversible
Damage Strain
Anisotropic Damage
Crack Growth
Crack Coalescence
Stiffness
Definition
Flow Behavior
Granular Flow
EOS
Micromechanics
Evolution as a
function of Damage
Flaw Density (#/m2)
and Spacing
Influence of Bulking
Visco-Plastic Flow
Porosity
Figure
Figure
11.
9.Orientation
Inclusion number/area
of inclusionsfraction
in relation
vs. to
the hot pressing
inclusion
axis
size
(AR
distribution.
is the aspect ratio).
Fig. Mind-map for brittle failure
Incorporate the physics in the model: properties and microstructure
2. Strength and Fragmentation
Micro-Mechanical Models
Flaw Size Dependence
1000 s-1
6 m
10 m
20 m
40 m
2
1.5
1.5
1
10
0.5
0.5
0
0
0.002
0.004
Strain
0.006
0
0.008
Normalized Size
Stress (GPa)
2.5
2.5
Tr(Damage)
10
10
10
10
10
3
Grady 2006
Glenn and Chudnovsky 1986
Zhou et al. 2006
Levy and Molinari 2010
Mod. Grady (vc c)
Spinel
PAD B4C
0
-1
PAD SiC-N
-2
10
Basalt
-4
10
-3
10
-2
10
-1
10
Stony meteorite
0
10
Normalized Strain Rate
We can use simple models to inform about materials design
10
3. Control it:
Materials Design
Ballistic Performance Curve
We designed microstructures for controlled strength and
fragmentation outcomes
Probability of Penetration
PS B4C
HP B4C
0.8
0.6
Pressureless sintered (PS)
0.4
0.2
0
0.7
Hot-pressed (PAD-B4C)
0.75
0.8
0.85
0.9
0.95
1.05
Normalized Velocity
Highlights power of simple model to inform design decisions
Remember: consider physics of problems (whats important
and what isnt)
5. Summary
Take Away
Exposure to brittle materials
Failure depends on microstructure, stress-state and strain-rate
Talk about how to design microstructures to control failure
Example: fragmentation for body armor applications
Length: 5 mm
Fig. Impact into PAD B4C at 1000 m/s
Compressive failure of boron carbide
Acknowledgements
Support of the Materials in Extreme Dynamic Environments
Collaborative Research Alliance through Cooperative Agreement
Number W911NF-12-2-0022.
Support from ARL (ITOL 2015-2443)
NSERC Engage
CFI for ultra-high-speed camera
Lukasz Farbaniec, Debjoy Mallick, Matt Shaeffer, Nitin
Daphalapurkar, Ravi Sastri, Jim McCauley, KT Ramesh
Undergraduate support: Will Wagers, Erez Krimsky
Bonus Work for ME 360
Assigned as 5%+ on quiz #1
Develop 1 ppt slide:
Choose an industrial application that interests you
Select a material within that application
Show its microstructure, material properties
Address why it is used in this application
Be creative
Due before Quiz 1- assignment box will be created
Next Topic
Unit # 2: Initial Considerations
Section 4: Loading and deflections
Static
Cyclic
Impact
Beam deflection
Section 5: Failure criteria
