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1 Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon A successful product – one that performs well, is good value for money and gives pleasure to the user – uses the best materials for the job, and fully exploits its potential and characteristics Materials selection is not about choosing a material, but a profile of properties that best meets the needs of the design Material and process are interdependent Materials and processes are grouped into families; each family has a characteristic profile, the “family likeness,” which is useful to know when selecting which family to use for a design Introduction to Materials and Processes Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

• A successful product – one that performs well, is good value for money and gives pleasure to the user – uses the best materials for the job, and fully exploits its potential and characteristics

• Materials selection is not about choosing a material, but a profile of properties that best meets the needs of the design

• Material and process are interdependent

• Materials and processes are grouped into families; each family has a characteristic profile, the “family likeness,” which is useful to know when selecting which family to use for a design

Introduction to Materials and Processes

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

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Figure 2.1

Families of Materials

Members of a family have common features:

• Similar properties

• Similar processing routes

• Similar applications

Hybrids are a combination of materials from other families

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Polymers (Macromolecules)Ceramics

Families of Materials

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

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Figure 2.2

Examples of Each Material Family

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Figure 2.3

These attributes in addition to processing characteristics, environmental impact and typical applications make-up thematerial’s property profile

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

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• Stiff – high E (Young’s modulus)

• Hard – High Y (Strength)

• Abrasion resistant

• Good high temperature strength

• Good corrosion resistance

• Brittle – low KIC

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Ceramics

• Hard

• Corrosion resistant

• Electrically insulating

• Transparent

• Brittle – low KIC

Glasses

• Light – low ρ

• Easily shaped

• High strength per unit weight (σ/ρ)

• Lack stiffness – low E (50X less than metals)

• Properties highly sensitive to temperature

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Polymers (Engineering Plastics)

• Lack stiffness – low E (500 – 5000X less than metals)

• Able to retain initial shape after being stretched

• Relatively strong and tough

Elastomers

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• Lightweight & Cost efficient

• Can be engineered

• Properties dependent on combination of materials

• Tough – high KIC

• Stiff – high E

• Ductile

• Wide range of strengths depending on composition and processing

• Thermally and electrically conductive

• Reactive – low corrosion resistance

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Metals / Alloys

Hybrids (Composites)

• Material

• Shape, dimensions, and precision

• Number to be made

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Choice of process is based on design requirements:

Process Families

Shaping -Primary

Shaping -Secondary Joining Surface

Treatment

Primary process creates shapes

Secondary process modifies shapes or properties

Classifying Processes

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Figure 2.4

Classes of Processes

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Primary ShapingHot Isostatic Pressing

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Secondary Processes

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Joining

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Surface Treatment

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Figure 2.7

Process selection involves matching attributes of a process to design requirements

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Process-property Interaction

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

• Soft, stretchy rubber becomes hard and brittle when vulcanized

• Annealing a metal increases its ductility• Glass becomes bullet-proof through a

specific heat treatment• Electroplating improves corrosion resistance

Effects processing can have on material properties:

• Gives an overview of physical, mechanical, and functional properties

• Reveal aspects of the physical origins of properties

• Tool for optimized selection of materialsMaterials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

• Plot of one property for all materialsBar Chart

• Plot of two properties for all materialsBubble Chart

Material Property Charts

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Figure 2.8

Bar chart comparing stiffness (modulus) between different material families

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Bubble chart comparing stiffness (modulus) and weight (density) of different material families

Figure 2.9

Figure 2.9

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Material and process records in CES contain two types of data:

Structured

• Numeric• Boolean (yes/no)• Discrete

(low/medium/high)

Unstructured

• Text• Images• Graphs• Schematics

Computer-aided Information Management

Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Figure 2.10

Part of a record for a material, ABS; it contains numeric data, text, and image-based information

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Materials: engineering, science, processing and design, 2nd edition Copyright (c)2010 Michael Ashby, Hugh Shercliff, David Cebon

Figure 2.10

Part of a record for a process, injection molding; the image shows how it works, and the numeric and Boolean data and text document its attributes