BK50A2700 Selection Criteria of Structural Materials

Lesson 102014

Material costs

Green technology and sustainability aspects in

material selectionLesson

102014

The goal of this lesson

Our goal is, that after this lesson, students are able to recognize the most important material related cost, environmental and sustainability aspects and are able to use specialized tools to objectively evaluate these aspects to support the systematic material selection process.

Material costs

Material certificates Possible complaints Orders

Green technologyClean technologyEco-technology

Raw and bulk materialMaterial properties of the product

Lifetime WearService and maintenance

Raw material Logistics

Administrative cost related to material business

Recycling, reuse and disposal costs

Costs of quality control

Material related costs during the usage period

Material related manufacturing and production costs

Material related design costs

Administrative costs related to material delivery and logistics

Design of cast productsDesign of ceramic productsDesign of products made of nanomaterials

Costs of castingCosts of moulds and tools in powder metallurgy of ceramic materialsNanocoating

Total material costs during the lifetime

DIFFERENT PROPORTIONS OF OVERALL MATERIAL COSTS

Comparison of pure raw material costs,[€/kg]Comparison based on relative material costsComparison of the costs of semi-products including the

costs of heat treatments and other finishing processes Comparison which includes also the material related

manufacturing costsCost calculations based on the scaling factors inside the

product family Utilization of calculated cost and performance ratios of the

productLife cycle cost analysis

DIFFERENT TOOLS TO ESTIMATE AND COMPARE MATERIAL COSTS

Three main rulesPure raw material costs can be used very seldom

in objective material selection for a product.Relative materials costs are reasonable only if the

optional materials really are suitable for the product and if the manufacturing related costs are included to the comparison.

It is possible to use the price of the known reference material to evaluate the price of another constructional material if reliable data is available from a long time period.

UTILIZATION OF SIZE DEPENDENT ESTIMATION CURVES BASED ON THE PRICE OF A KNOWN SIZE

Relative price

Diameter [mm]

Relative prices of steel rods related to their diameter

RELATIVE PRICE

TIME PERIOD

PRICE OF THE ALLOYING COMPONENTS

PRICE OF THE RAW MATERIAL

3.25

2.50

1.75

1.00

1v 2v 3v 4v 5v

The significance of the price due to the alloying (Ni, Cr) materials increases during the observation time period.

TYPICAL PRICE DEVELPOMENT OF STAINLESS STEELS

UTILIZATION OF TIME DEPENDENT ESTIMATION CURVES BASED ON THE PRICE OF THE ALLOYING MATERIALS

BLUE CURVE:STAINLESS STEEL

RED CURVE:NICKEL

THE COMPARISON OF NICKEL’S AND STAINLESS STEEL’S PRICE CURVES

TIME PERIOD

RELATIVE PRICE

NOTE!Usually it isreasonable andcost-effectiveto select the steelswith minimumpossible alloying!

0

50

100

150

200

250

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50 4.2

3.0

2.21.6

1.183

104130

196

160

2005 2007 2009 20132011 Year

Price €/kg65x

Price €/kg65x

Forecast of price development for multi-wall nanotubes

Forecast of price development for single-wall nanotubes

2005 2007 2009 20132011 Year

UTILIZATION OF TIME DEPENDENT ESTIMATION CURVES (LINES)

Relative price

Zinc coated plate

Cold rolled plate

Hot rolled plate

Period 1 Period 3

Time

Period 2

Periods 1 and 2 Z≈CR HR ≈1.2…1.4×CR

Period 3HR ≈ 1.2…1.3 × CRZ ≈ 1.2 × CR(Z ≈ 1.4…1.6 × HR)

UTILIZATION OF TIME DEPENDENT ESTIMATION CURVES (COEFFICIENTS OT MULTIPLYERS)

CORRECTION FACTOR

THE DIAMETER OF A STANDARDIZED ROD

UTILIZATION OF TIME DEPENDENT ESTIMATION CURVES (COREECTION FACTORS)

S235

S355

42CrM

o4

21NiC

rMo2

X 5 C

rNi

X 5 C

rNiM

o

Cu-OF

CuSn6

0

2

4

6

8

10

12

14

1 1.152.25 2.2

4.7

6.8 7.4

12

Relative price

Yeld strength is critical, not the price

The price depends on the heat treatment

Different properties against corrosion

The first one is for electrical engineering, the second one for constructions and mechanical assemblies.

PRICE COMPARISON CRITERIA FOR METALLIC RODS

NOTE!THE RELATIVE

PRICE COMPARISONDOES NOT WORK

HERE!

HDPE PPABS

PA6,6 PC

PTFE

PEEK PI0

20

40

60

80

100

120

1 1 2.2 4.4 3.915

48

110

Relative price

Relative pricePEEK /PA6.6 ≈ 9PI / PA6,6 ≈ 25Possible utilization in polymer gears.

PRICE COMPARISON OF POLYMER RODS

NOTE!THE RELATIVE PRICE COMPARISON

WORKS ONLY FOR THOSE MATERIALS WHICH ARE SUITABLE FOR MANUFACTURING GEARS!

PRICE COMPARISON OF CAST STEEL AND CAST IRONS

Cast steel GJS GJL0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2 1.85

1.3

1Relative price

NOTE!THE RELATIVE

PRICE COMPARISONWORKS ONLY

IF THESE METALSCAN BE USED FOR

THE SAME PRODUCT!

Some example of useful ratios:Cost/ increased strength unit , [€/MPa])Cost/ increased rigidity or flexibility, [€/mm]

E.g. is it more cost-effective to increase the rigidity of the metallic profile by chancing the material’s modulus of elasticity or by increasing the bending co-efficient?

Cost/ lifetime, [€/h] or [€/ year]) E.g. is it more cost-effective to change the material to

increase the wear resistance or should the contact area increased instead?

Cost/ power transmission capacity, [€/kW] E.g. is it more cost-effective to decrease power losses by

decreasing the density of the material of the rotating components or by changing the dimensions instead?

UTILIZATION OF CALCULATED COST AND PERFORMANCE RATIOS OF THE PRODUCT

STEEL RAIL

HOWEVER, IF THE SAME BENDING STIFFNESS IS REQUIRED, THE DIMENSIONS OF THE ALUMINIUM PROFILE SHOULD BE SO LARGE, THAT THE WEIGHT IS ONLY 50% SMALLER!

• ALUMINIUM RAIL• DENSITY IS 27% OF STEEL’S DENSITY

DIMENSIONS VS. STIFFNESS VS. WEIGHT

ADDITIONAL COSTS TO THE

RAW MATERIALS

MARKING

TRANSPORT

MATERIAL CERTIFICATES

HEAT TREATMENTS

SURFACE TREATMENTS/

PAINTING

BUNCHING

MEASUREMENTS

HANDLING OF DIFFICULT BULK SIZES (SMALL OR LARGE ONES)

CUTTING

8% 8%

11%

19%Additional

price portion (%) to the

initial material

priceS

tres

s re

lievi

ng

Ful

l ann

ealin

g

Nor

mal

izin

g

Que

nch

and

tem

per

RELATIVE PRICE PORTIONS OF SOME HEAT TREATMENTS

THINK, WHAT MIGHT BE THE ADDITIONAL COSTS TO THE PRICE OF THE RAW MATERIAL OF TYPICAL QUADRATE STEELS PROFILES?

COATING METHODS

Welded coatings and cladding

Laser-welding

SAW-submerged are welding

Zine

Hot dipping

Vacuum coating Chemical deposition

Electro-plating

Thermal spraying

Plasma arc spaying

Soldering Gluing

Other methods

Nickel

Electrolysis

PVD, CVD

Zinc

RECOGNITION OF THE CORRESBONDING MATERIAL PROPERTIES OF

THE COATING BASED ON THE COLLECTED REQUIREMENTS

PROFILE OF MATERIAL PROPERTIES

PROFILE OF REQUIREMENTS

SOME EXAMPLES:

WELDING PROCESSES ARE ORIGINALLY DEVELOPED FOR SOME

SPECIAL MATERIALS

DIFFERENT SINTERING PROCESSESS ARE DEVELOPED FOR DIFFERENT

CERAMICS

DIFFERENT CASTING PROCESSES ARE SUITABLE FOR DIFFERENT

MATERIALS AND DIFFERENS SIZES OD MANUFACTURING SERIES

MACHINABILITY DEPENDS A LOT ON THE MATERIAL

SOME MANUFACTURING PROCESSES NEED EIHER PRE- OR POST-

TREATMENTS DEPENDING ON THE MATERIAL (E.G. HEAT TREATMENTS)

HOW TO SOLVE THESE ISSUES? MATERIAL SELECTION OF THE

PRODUCT IS REASOANABLE TO CONSIDER TOGETHER WITH THE

SELECTION OF THE MOST (COST-) EFFECTIVE MANUFACTURING

PROCESS

MATERIAL RELATED MANUFACTURING COSTS

If the geometrical changes of the product follow the simplified change based of the dimensional change according to the scaling factor, cost-oriented engineering design can be based on the polynomial function as follows :

qH=(Af3×qL3) + (Bf2 × qL

2) + (Cf1 × qL) +Dwhere:

qH = the value descriging the relative change of the total product costs

qL= scaling factor of the new product in the product family

Af3 ,Bf2 , Cf1 = relative cost portions of the total product costs due to different changing reasons (note the different exponent values connected with each term)

D = relative portion of the constant product costs

COST CALCULATIONS BASED ON THE SCALING FACTORS INSIDE THE PRODUCT FAMILY

Example

Cost portion(example)

Term in the cost function

Exponent in the cost function

Machining Cf1 1

Finishing Bf2 2

Heat treatment Af3 3

Materials Af3 3

Constant costportions

D -

Let the scaling factor of the new product be qL=1.5.The equation gives :qH=(Af3 × qL

3) + (Bf2 × qL2) + (Cf1 ×

qL) +D qH=((0,25+0,30) × 1.53) + (0,20 × 1.52) + (0,15 × 1.5) +0.10 = 2.63So if the scaling factor increases to 1.t the overall

costs will be 2.63 times higher.

Cost portion(example)

Percentage portion of the costs during the

production of a product

[%]

Relative portion of the costs during the

production of a product

Exponent in the cots function

Machining 15 0,15 1

Finishing 20 0,20 2

Heat treatment 25 0,25 3

Materials 30 0,30 3

Constant costportions

10 0,10 -

Some practical issues…Think, how the total amount of products (to

be manufactured) might affect the material costs and is there the option to utilize product-family principles!

Notice the difference between the prices of the raw material and semi-products!

Green technology and sustainability aspects in

material selection

THE CORE OF SUSTAINABLE DEVELOPMENT

ENVIRONMENT HUMAN

ECONOMY

SUSTAINABLE DEVELOPMENT IN GENERAL

€€ €

€

SUCCESS CRITERIA OF A PRODUCT

DESIGN PROCESS

ENVIRONMENTAL ASPECTS

SAFETY ASPECTS OF THE PRODUCT

COST-EFFECTIVENESS OF

THE PRODUCT

FUNCTIONALITY OF THE

PRODUCT

QUALITY OF THE PRODUCT

SUCCESFUL PRODUCT DESIGN PROCESS

UTILIZATION OF THE SUSTAINABLE

DEVELOPMENT PRINCIPLES IN

MATERIAL SELECTIONSAVE ENERGY IN

DIFFERENT MATERIAL PROCESSING PHASES

SAVE TERRAIN AND GROUND IN RAW-

MATERIAL PROCESSES

SELECT SUCH MATERIALS WHICH ENABLE THE MINIMIZED ENERGY CONSUMPTION OF THE PRODUCT

SAVE WATER THROUGHOUT THE

WHOLE LIFECYCLE OF MATERIAL PROCESSING

REDUCE THE AMOUNT OF

USED MATERIALS

RECYCLE MATERIALS

SUSTAINABLE DEVELOPMENT IN MATERIAL SELECTION

REUSE MATERIALS

MAINTENANCE, SERFICE AND COST-

EFFECTIVENESS OF THE PRODUCT

LIFETIME OPTIMIZATIONOF THE PRODUCT

MINIMIZATION OF THE USE OF HARMFULL AND HAZARDOUS MATERIALS IN THE PRODUCT

RECYCLABILITY

ECO-EFFICIENCY OF MATERIALS

ENERGY-EFFICIENCY OF THE PRODUCT

CONNECTIONS BETWEEN PRODUCT

DESIGN AND MATERIAL

SELECTION

HOW TO COMBINE: “THE SUCCESFUL PRODUCT DESIGN PROCESS” AND

“THE PRINCIPLES OF SUSTAINABLE DEVELOPMENT IN MATERIAL SELECTION” ?

ENVIRONMENTAL EFFECTS

NOISE

DAMAGES OF THE ECOSYSTEMS

WATER CONSUMPTION

DAMAGES OF THE SCENERY AND LANDSCAPE

ENERGY CONSUMPTION

WATER POLUTION

AIR POLUTION

CARBON DIOXIDE (CO2-) EMISSIONS

CHEMICAL EMISSIONS AND EFFLUENTS

ENVIRONMENTAL EFFECTS

ECO-EFFICIENCY OF THE

MATERIAL

Minimize the amount of material(s) used in the construction

If possible, utilize waste material at least for energy production

Try to repair the product for its initial use and purpose

Utilize material(s) for producing new products

R4

THE BASIC APPROACH

LCA

LCC

TWO MAIN PROCESSES

Cumulative cost evaluation throughout the total lifetime of the

product

Environmental loading evaluation of the

product including the amounts of waste

material and emissions during the whole life

cycle

Maintenance costs

Operational costs

Disposal costs

Initial costs

Service costs

LCC

These cost portions are related to the material selection!

LIFE CYCLE COSTS

LCAEnvironmental

loading including the amounts of waste material and emissions

during the whole life cycle

DISPOSAL

RECYCLING

USE, SERVICE AND MAINTENANCE OF THE

PRODUCT

TRANSPORT, DELIVERY, STORAGE AND

PACKAGING OF THE PRODUCT

PRODUCTION AND MANUFACTURING OF THE PRODUCT

REUSE

ORE PROCESSING

RAW MATERIAL PROCESSES

LIFE CYCLE ASSESMENT

QUANTIFIED ECO-EFFICIENCY

CHARACTERISTICS BASED ON MIPS-CALCULATIONSFACTOR 4

EVALUATION OF ENVIRONMENTAL

LOADING

MIT-INTENSITY

MI-FACTOR

FACTOR 10

LIFE CYCLE ASPECTSINTENSITY FACTORS

LIFECYCLE

ASSESMENT

SOME NUMERICAL CHARACTERISTICS

Factor 4 and Factor 10Refers to ecological sustainability:Factor 4 –principle aims to improve the

efficiency of using the resources from nature to be four times higher compared to the current situation.

Factor 10 –aims to decrease the total use of resources from nature to the half on the current level until year 2040.

MIPS - coefficientEco-efficiency can be measured and

expressed with the MIPS-coefficientMIPS = Material Input Per Service Unit MIPS is calculated by dividing the total

consumption of nature resources (MI-factor) with the achieved output function unit of the product (S) (e.g. the driven distance with a car)

MIPS = MI / S.

Material intensity (MIT)Material intensity (MIT) is the ratio, which

utilizes MI-factor by describing how much nature resources are needed to produce e.g. one weight unit of material.

MIT-intensity is among the best values to support systematic material selection process if green values and sustainability are in key-role.

Examples of calculated MIT-values

Produced metal

Consumption of fossil fuels and minerals

[tn/tn]

Consumption of water

[tn/tn]

Consumption of air

[tn/tn]

Cold formed aluminium

35 1000 10

Cold formed steel 9 75 0.5

Stainless steel 1(18%Cr, 9% Ni)

14 205 2.8

Stainless steel 2 (17%Cr, 12% Ni)

18 240 3.4

ECOLABEL

The EU ECOLABEL helps to identify products and services which have a reduced environmental impact throughout their life cycle.

ECO-MANAGEMENT AND AUDIT SCHEME

EMAS is a management instrument developed by the European Commission for companies and organizations to evaluate, report and improve their environmental performance.

NUMBER OF DIFFERENT MATERIALS USED IN IT-PRODUCTS

Some practical examples

1980-luku 1990-luku 2000-luku0

10

20

30

40

50

60

70

1115

60

Number of different materials used in IT-applications

Kierrätetystä materiaalista tehdyn uuden metallin osuus

39 %

32 %

74 %

42 %

20 %

0 % 20 % 40 % 60 % 80 %

Alumiini

Kupari

Lyijy

Teräs

SinkkiSINC

STEEL

LEAD

COPPER

ALUMINIUM

PERCENTAGE OF RECYCLED MATERIALS IN NEW METALS’ PRODUCTION

Energian säästö kierrätyksen avulla

95 %

85 %

60 %

68 %

60 %

0 % 20 % 40 % 60 % 80 % 100 %

Alumiini

Kupari

Lyijy

Teräs

SinkkiSINC

STEEL

LEAD

COPPER

ALUMINIUM

ENERGY SAVING IN PRODUCTION DUE TO RECYCLING

VW Golf made from over 40% recycled materials

Recycling of polymers 1 PET (polyethylene terephthalate)

Most recycled polymer. 2 HDPE (high-density polyethylene)

Easy to recycle. 3 PVC (polyvinyl chloride)

Difficult to recycle. 4 LDPE (low-density polyethylene)

Very difficult to recycle. 5 PP (polypropylene)

Difficult to recycle. 6 PS (polystyrene or polystyrene foam)

Difficult to recycle. 7 Other Plastics 

Difficult to recycle or technology for reclying is missing

Lifecycle costs

Eco-efficiency

Sustainability

GT-guidelines

Energy efficiency

Recycling Reuse Recovery Disposal

LCA TRM EMAS WEEE RoHS ELV Ecodesign ISO 14000

LCC

Metals

Ceramics

POLYMERS

Composites

Nanomaterials

ADAPTIVE MATERIALS

Improve the recycling ratio

Wear resistance

BiopolymersPET ja HDPE

Bio-composites

Decrease the weight of constructions

Phase-change materials

Cleaning of pollutants

Sy

ste

ma

tic

ma

teri

al

se

lec

tio

n p

roc

es

s

GREEN TECHNOLOGY