topic 1 1 materials selection criteria and standards

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UEMK1103 - Introduction to Chemical Process and Electrical System - Rev Jan 2015

Materials Selection Criteria and

Standards

Topic 1: Selection of Engineering Materials and Equipments


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Material Selection is Important!

Besides than SOFTWARE ENGINEER, the designers ofany products must involve in material selection.


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Your Decision!

So many materials! Too much information!

How do we decide?

How do we begin to choose?


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Types of Materials

Metals

Alloys Ceramics

Polymers


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METALS

a solid material that is typically hard, shiny, malleable, fusible, and

ductile, with good electrical and thermal conductivity.


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ALLOYS

An alloy is a mixture of metals or a mixture of a metal and another

element.


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Metals

Ferrous Non Ferrous

Pure

Ferrous

Metals

Ferrous

Alloys

Pure NonFerrous

Metals

NonFerrous

Alloys

Copper Alum.

Zinc Tin

Brass Bronze Solder

Lead Silver

Gold Mercury

Mercury is the only non

ferrous metal that is liquid at

room temperature.

Copper

+

Zinc

Copper

+

Tin

Lead

+

Tin

Alloying.

IronSteel

High

Speed

Steel

High Speed Steel Cutting Tools


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Ferrous Metals / AlloysFerrous metal is referring to iron (Fe). Ferrous alloys are consist mostly ofiron and small amounts of other elements. These materials are prone to

rusting if exposed to moisture. Ferrous metals / alloys can also bepicked

up by a magnet. The rusting and magnetic properties in ferrous metals

are both down due to the iron. Typical examples include mild steel, cast

iron and steel.

Rusting.

Magnetism.


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Example: Stainless Steels Type SS316 16% chromium, 10% nickel, and 2% molybdenum

Type SS304 18% chromium, 8% nickel, no molybdenum.

SS316L

SS304L

L Low carbon content Maximum 0.03% carbon (regular max 0.08%) Avoid corrosion problem caused by welding Used in pharmaceutical and food industry.


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Example: Cast Iron Is a very strong metal when it is in compression and is also very brittle. It consists of 93% iron and 4% carbon plus other elements.

Used as car brake discs, car cylinders, manhole covers etc.


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Example: Mild Steel Mild steel will rust quickly if it is in frequent contact with water. Ductile and malleable.

Used as nuts and bolts, building girders, car bodies, gates etc


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Non-ferrous Metals / AlloysNon-ferrous metals / alloys are metals /alloys that do not have any iron inthem at all. This means that non-ferrous metals are not attracted to amagnet and they also do not rust in the same way when exposed tomoisture. Typical Non-ferrous metals include copper, aluminium, tin andzinc.


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Bauxite mining in Kuantan, Pahang

(Source: Bernama / Astro Awani, Jan 12, 2016)

(Source: Sinarharian, Jan 6, 2016)


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Message

Its important to recycle the aluminium cans.


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Example: Copper It is a very good conductor of heat and electricity. red / brown in colour

Used for plumbing, electric components, cookware and roof coverings

Heat ConductorElectricity Conductor


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Example: Solder an alloy of Lead and Tin fusible metal alloy used to join together metal work pieces and having a

lower melting point than the work pieces (200C).


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Types of Materials - Ceramics

Made of nonmetallic (clay) and firing at a high temperature.


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Types of Materials - Polymers

A polymer is a large molecule, or macromolecule, composed of many

repeated subunits.

You will learn more inPolymer Science and

Technology


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Example: Polyvinyl Chloride (PVC)

Production of PVC

Applications: Piping & fittings, cables

Light, chemical resistant, durable (for cables), rust resistant,

cheap. Cant sustain under high temperature, non biodegradable


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PVC fittings

PVC cables


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Material Properties

Chemical Properties

Physical Properties Mechanical Properties

Dimensional Properties


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CHEMICAL PROPERTIES

Compositions

Crystal structure

A crystal structure composes of a unit cell, a set of atoms arranged in

a particular way; which is periodically repeated in three dimensions ona lattice.

Corrosion resistance

The ability of a substance (especially a metal) to withstand damagecaused by oxidization or other chemical reactions.

Reactivity

The chemical reactions of two or more substances that interact witheach other.


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PHYSICAL PROPERTIES

Melting point

Thermal conductivity

The property of a material to conduct heat

Electrical conductivity/resistivity

Material's ability to conduct an electric current/opposes the flow ofelectric current

Grain size

Also known as particle size, refers to the diameter of individual grains ofsediment.

Porosity

Also known as void fraction, a measure of the void (empty) spaces in amaterial.

Color


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MECHANICAL PROPERTIES

Tensile properties

Indicate the response of a material when tension/force is beingapplied.

Ductility

The ability of a material to deform under tensile stress

Compressive properties

The capacity of a material or structure to withstand loads tending toreduce size

Fracture toughness The ability of a material containing a crack to resist fracture


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MECHANICAL PROPERTIES

Hardness

The resistant of solid matter to various kinds of permanent shapechange

Creep resistance

The ability to resist any kind of distortion when under a load over anextended period of time.

Fatigue

The weakening of a material caused by repeatedly applied loads

Reinforcement

The process of strengthening or increasing the mechanical propertiesof a material.


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DIMENSIONAL PROPERTIES

Available shapes

Available sizes

Surface textures

Manufacturing tolerances (thickness, width, length, flatness)

You will learn more inMaterial Science


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Materials Selection

What does it do?

How does it do it?Where does it do it?

Who uses it?

What should it cost?


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Case Study Soft Drink Container

Provide leak free environment for storing liquid.

Comply with food standards & protect liquid from healthhazards.

For fizzy drinks, withstand pressure. Brand image & identity

Easy to open

Easy to store & transport

Cheap for high volumes


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Case Study Soft Drink Container

Possible materials: Aluminium

Glass

Plastic Paper


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Key factors applied to material

selection

Operating conditions.

Design life time.

Good market availability and documented fabrication andservice performance.

The number of different material types shall be minimizedconsidering costs, interchangeability and availability of relevantspare parts.

Philosophy applied for maintenance and degree of system

redundancy. Environmental issues related to corrosion inhibition and other

chemical treatments.


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Engineering Codes and Standards

Code: A document which gives guidelines for design,construction and installation, which are converted intolaw.

Standard: A document which gives sizes/ rating/joining methods of components.

Each country has its own Codes and Standards.Normally American National standards are mostwidely used all over the world and compliance withthose requirements are accepted globally.


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Major Organizations of Standards

Countries Organization

U.S.A. ASME The American Society ofMechanical Engineers

ASTM The American Society forTesting and Materials

ANSI The American NationalStandards Institute

United Kingdom BSI British Standards Institute

Germany DIN Deutsches Institute Normung

France AFNOR Association FrancoiseEurope CEN Europe Community of

Standardization

Japan JIS Japanese Industrial Standards

topic 1 1 materials selection criteria and standards

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