What are common methods to ensure material safety and reliability?

Endorsing to the expert comment earlier and adding some views, mechanical design is totally different as compared to the Materials design. Design of compounds / compositions/formulation, design of Alloys and design of composites of any materials are based on internal structures ( crystalline , amorphous or mix ) obtained by chemical reactions or physical changes ; for specific functions and applications. Nonetheless, internal structures are micro , nano and lower than nano levels are designed in different orientations, textures, and containing defects to enhance required properties as per the characteristics of different elements of periodic table.

The above is correct from a Mechanical perspective. However, an important part that is often missed, is the resistance to corrosion. Especially if the component will be exposed to a corrosive environment during its life. Design for reliability, from a Materials and Corrosion perspective, involves considering the expected operating conditions of the component (greenfield projects) or the existing operating conditions (brownfield projects). In both cases, material selection is key to guarantee the reliability of the component. Considering safety as the most important factor. Although material selection is key for performance and reliability, factors such as cost and criticality of the component should be considered.

Common methods for materials safety and reliability include: 1. Choosing materials that meets the required specifications and standards for the intended applications by considering factors such as strength, durability, corrosion and thermal stability 2. Good quality control practices during the manufacturing process 3. Storing materials in appropriate conditions to avoid degradation 4. Evaluating materials for their performance under various conditions 5. Conducting life cycle analysis of the material.

Design for reliability (DfR) is a process that involves planning for reliability from the earliest stages of system design. DfR is a crucial aspect of system design, ensuring that systems can consistently meet their performance and safety requirements throughout their operational life cycle. Finite element analysis (FEA) plays a pivotal role in DfR by enabling engineers to assess the reliability of system designs under various loading conditions and environmental factors.

First the safety and reliability criterias for the parts should be thoroughly determined. These criterias may include from mechanical, thermal, or electrical performance to optical properties, fire and chemical resistance or performance in contact with food or chemicals. After that various material testing and characterization methods including standard or in-house developed tests can be used to ensure the performance of selected material. In this regard, besides the material properties, design of the part itself can play an important role.

Ensuring material safety and reliability is crucial for the successful development and deployment of products and systems. Material testing and characterization play a critical role in this process by providing valuable insights into the physical, mechanical, chemical, and thermal properties of materials. By conducting comprehensive testing and analysis, engineers can assess the suitability of materials for specific applications, identify potential defects or anomalies, and predict material performance under various conditions.

We cannot ensure materials safety by testing, we can estimate the probability of failure; this is specifically important to distinguish when materials failure is stochastic in nature such as fatigue. It is noted that by some estimates fatigue constitutes 90% of all metallic materials failure. Thermal properties are sub group of physical properties, so there is no need to be mentioned separately. Nano mechanical testing has been stabilised as a useful tool especially in materials research. So instead of micro one could state that the scale of characterisation starts from nano.

One method by which we can characterize the materials are microstructure analysis. Examining the structure of materials at microscopic levels to understand properties such as grain size, phase composition, and defects. Methods include: Scanning electron microscopy (SEM): Provides high-resolution images and elemental analysis of surfaces. Transmission electron microscopy (TEM): Analyzes materials at the atomic scale. These testing and characterization methods are crucial for understanding material properties, ensuring quality control during manufacturing, predicting performance in real-world conditions, and facilitating continuous improvement in material development and application across various industries, including defense.

I am working on polymers used as biomedical application so testing and characterization has to consider the impact of applying environments. Eg: a routine mechanical test in ambient environment may quite different from the result under physiological conditions. Another point is the test range. I have seen lots of data reported the ultimate strength at the stain level far beyond the physiological working range. Comparing to use those data to assess the properties (which is quite common in the academia), I prefer exploring the mechanical behavior within the bounds of physiological levels, allowing for a judicious and reasonable expansion of this scope.

Final application of a product is totally different from laboratory scale, where tests and the product itself is developed. One of the critical factors is the upscale. At this point, as much quality control values where extracted you have better set of statistical parameters to be considered and analyzed. Also, is very important to monitoring the product during its use along all the life and at the same time compare with the environment condition where it was used. Today, we can have data bases to store parameters and algorithms using artificial intelligence to process them to help in a prediction in several situations.

Choosing the appropriate testing methods based on the material type, application requirements, and desired property is as crucial. Consider factors such as sample size, loading conditions, environmental factors, and measurement precision. Adhere to standardized testing procedures and protocols to ensure consistent and reliable results. Utilize certified testing equipment and maintain proper calibration records.

Yup, make sure the material meet the latest certification, like JIS standard, ASTM standard. Always check if there is a latest version. Once you failed to follow the standard, it is hard to rebuild the reputation. It is easier to lose a trust and to regain it.

To ensure material safety and reliability, rigorously follow certification and regulation. Compliance with standards set by national or international bodies, industry associations, or third-party agencies is vital. This varies based on material type, application, and location. Such adherence guarantees material quality, safety, and sustainability, while safeguarding against legal and ethical pitfalls. It's a critical step for responsible material management, encompassing both use and disposal, and forms a cornerstone of ethical and compliant business practices.

Material characterization techniques are crucial for material innovation and improvement as we can gain insights into material properties, structure, and behavior. Such techniques (e.g., optical, electron, or atomic force microscopy, X-ray diffraction, scanning electron microscopy, differential scanning calorimetry, thermogravimetric analysis, dielectric spectroscopy, mechanical testing, non-destructive testing etc.) enable a thorough understanding of material characteristics. A combination of these characterization techniques can provide a holistic view and approach in the development of novel and innovative materials with enhanced performance, reliability, and safety.

I know innovation is a term sounds very attractive but as the scientist and researcher whose target is creating an innovative material/product, it's quite challenging and time consuming. I am kinda in favor of keeping small iterations for a prototype. The unmet need from the market or society definitely is the ultimate goal, however, a strategy to allow you to keep pushing with small goals could accumulate a big victory, or at least giving you enough time to adjust/justify your research strategy. Innovation often requires aiming high, iterating with small steps, and staying vigilant to adapt to changing landscapes. Setting ambitious goals, agile iterations, and continuous environmental awareness pave the path toward progress.

Choose the correct materials for a particular application is not trivial. One of the firsts steps is known its chemical, mechanical, and electrical compatibility with the purpose or processes where it will be used for. At the same time, the material chosen must be economically profitable, eco-friendly and if possible, reusable, or recyclable. Thinking in a large-scale process, you must guarantee that the feedstock has a reliable quality. So, it is not just the selection material is important, but the good quality from suppliers.

To tackle challenges in material selection, focus on: 1. Continuous Learning: Stay updated with emerging materials and technologies. 2. Sustainability: Prioritize eco-friendly materials with lower environmental impacts. 3. Technology Integration: Use AI and data analytics for predictive insights and optimization. 4. Collaboration: Engage with industry experts and suppliers for innovative solutions. 5. Testing and Certification: Ensure safety and reliability through rigorous testing and adhering to standards. 6. Customer Focus: Align material choices with user needs and market trends. 7. Risk Management: Anticipate and mitigate risks related to availability, costs, and geopolitical factors.

Reliability prediction and modelling Using mathematical models and simulations to predict the lifespan, reliability, and performance of materials under various operating conditions.

Taking into account the material selection for a particular application, one of the great examples are the silicon (Si) solar cells and gallium arsenide (GaAs) solar cells. GaAs has better electrical properties than Si, but is not used in a commercial applications because the fabrication process is much more expensive than silicon. By the other hands, it is very used in space applications as satellites power generation, where the cost of the final product is so high and the minimal failure system can damage and interrupt the missions.

In my experience, none of the above conditions work in isolation. The journey from hypothesis to proof of concept and commercialization is similar to any other product, especially one with biological impact. Therefore, the role of a multidisciplinary team is crucial. One new material cannot be used by chemists alone but it needs physicists for further characterization, biologists, and medical professionals for better profiling, engineers for designs, economists for marketing, lawyers for IP, parents, and many more experts to make the new material ready for safe and constructive implementation. All must be planned well for a formulation to be viable.