You need to choose materials for your mechanical components. How do you ensure you pick the best ones?

Factors to consider for selecting Material : mechanical properties (strength, stiffness, and toughness), thermal properties, chemical resistance, electrical conductivity, weight, cost, availability, and manufacturing feasibility also environmental factors (temperature, humidity, and corrosive elements). Its very important to conduct Research and Analysis. It involves consulting material databases, textbooks, journals, and industry standards.

While selecting the material, first determine in which environment it will be used. For example in a hollowcore extruder machine there are parts which come in direct contact with the concrete, which needs high wear resistance properties else the parts will fail within hours. And for the main frame of the machine, cast iron is used to absorb the vibration caused by the compaction of the machine. And shafts and other moving parts are mostly made with the alloys of steel. So it all depends on where the machine will be used.

While selecting the material of components first we need to identify the function and application of the product or component. Also we should known about the operating environment/condition Based on that we can choose the material by considering their properties and characteristics. And also considering durability of the component while selecting the material. Cost of the material is also important in this.

Antes de escolher os materiais, é essencial definir os requisitos funcionais e ambientais para seus componentes. Considere as forças, torques, pressões, vibrações, temperaturas de operação, umidade, exposição a produtos químicos e fluidos. Perguntas sobre a durabilidade desejada e a necessidade de manutenção frequente ajudarão a refinar as propriedades necessárias, como resistência, rigidez, tenacidade, dureza, ductilidade, condutividade térmica, expansão térmica, resistência à corrosão e resistência à fadiga. Essa análise cuidadosa é fundamental para a escolha adequada dos materiais para atender às demandas específicas do seu projeto.

Aside from just defining the requirements of your components, it is essential that the limits of your requirements must be defined also. By defining what is acceptable/unacceptable in the requirement, the designer will have a firm understanding on the level of adjustment he/she must do in terms of choosing the material and can initially limit the cost of the design. In choosing the material, this depends on the functional and environmental requirements. Always rely on the material/product datasheet in material selection as this contains significant information regarding the material you need.

It is absolutely critical that the appropriate material is chosen for the specific application There are many factors to be considered eg. Corrosion resistance, physical properties, abrasion resistance, fatigue, temperature of the application etc, etc. Should one not carefully pay attention to these and other factors, costly consequences would be faced.

Após definir suas necessidades, compare diferentes materiais que atendam aos seus critérios. Utilize fontes como bancos de dados, manuais, catálogos e ferramentas online para obter dados e especificações relevantes. Gráficos de seleção de material, que plotam propriedades uma contra a outra para diferentes classes de materiais, como metais, polímeros, cerâmicas e compósitos, são úteis. Esses gráficos auxiliam na identificação de compensações e compromissos entre diferentes propriedades, facilitando a escolha do material mais adequado para o seu projeto.

In my experience, comparing different materials can be challenging, as there are thousands of options available, each with its own advantages and disadvantages. One thing I’ve found helpful is to use a Material Selection Chart, also known as an Ashby Chart, which is a graphical representation of the properties of different materials. It helps to make the selection process easier by systematically comparing materials based on various attributes, such as strength, stiffness, density, cost, etc.

Comparing materials is an important task. In my experience, I have used CES in various cases, which is a database that helps to generate graphs that are useful for projects. Those graphs could be useful to visually see the different properties of the materials (even some trending topics as the possibility to recicle).

For highly corrosive service conditions found in oil and gas production, NACE MR0175/ISO 15156 provides recommendations for selection of steel and corrosion resistant alloys (CRAs).

Além disso, considere o custo e a disponibilidade dos materiais, garantindo que estejam dentro do seu orçamento e prontamente disponíveis. Avalie também os custos de processamento, como usinagem, soldagem, fundição, moldagem ou revestimento, envolvidos na fabricação dos componentes. Alguns materiais podem ter custos iniciais mais elevados, mas oferecer menor custo de manutenção ou substituição, enquanto outros podem ser mais acessíveis inicialmente, mas exigem reparos frequentes. É crucial ponderar os prós e contras de cada opção para encontrar o equilíbrio ideal entre custo e desempenho para o seu projeto.

What form of material do you need? Bar, plate, sheet, tube? This will dictate the specifications. Make sure that you don't use materials that are easy to machine like resulfurized steels or stainless steels IF you have high pressure applications or high cycle fatigue applications....Not 1144, for instance, but use 1045 - for your 500,000 cycle application.

Depending on the requirements listed out in point-1, say the suitable materials listed are >1 The cost and availability factors might vary for each type. Some materials are expensive and easily available or less expensive and more time procuring, could be any case. Some materials with appropriate surface treatment may give similar strength and purpose as expensive materials and this assessment can be cost effective. In some cases sourcing the material and manufacturing at your site might be at a higher cost, and in some cases, manufacturing at the supplier location can be economical or vice versa.

The financial and geographical choice is always very important before selection of the material. If the material is not available for the quantity as required & not from nearby manufacturers then it's impact on the product price as well which is not good for the future of the product. So it's important to select such material which will also come into manufacturer budget.

Por último, é fundamental realizar testes e avaliações dos materiais antes de finalizar o projeto e iniciar a produção. Métodos como testes de laboratório, simulações, protótipos ou testes de campo podem ser empregados para avaliar o desempenho em condições realistas, comparando com expectativas e padrões. O feedback de clientes, usuários ou especialistas também pode ser valioso para aprimorar o design e a seleção de materiais. O teste e a avaliação ajudam a validar suposições, identificar possíveis problemas e otimizar soluções. Escolher materiais para componentes mecânicos é desafiador, mas seguindo esses passos, você pode garantir uma seleção eficaz para seu projeto de engenharia.

By testing and identifying the proper material's good enough for the Environmental conditions suitable for the component. Various methods of Equipments can also guided for testing and identifying the needs for useable materials.

As we discussed in the first step, according to the main function the material has to pass through some cordially tests at the maximum calculated condition to confirm this is the one which we are looking for. If a mechanical functional device is going to use material then check UTS and all other parameters which are mainly affecting our material during in work Condition.

4. Test and evaluate your materials: Conduct tests to validate material properties and performance under relevant conditions. 5. Additionally, factor in considerations such as environmental impact, manufacturability, and compatibility with other components for comprehensive material selection. #MechanicalEngineering #MaterialSelection

Heat treatment, big factor. Be aware of effects tgis will have on the part geometry- movement, distortion, etc. Or you may need special racking/fixturing. Color may change. Can you make it by machining after heat treatment? Then you don't need to worry about distortion or growth/shrink of the part- but tooling cost is higher. ... Consider washing of parts (say before welding to insure a good weld) and RP needed to prevent rust or discoloration.

Conclusion: it is best practice to identify the cost of materials and long lead items during early stages of the project to plan efficiently. In the end, It all comes to the cost of the project and its impact on the project delivery.

Assess requirement and desired outcome - 1. For what manufacturing process is the material required 2. Where is the component going to sit. Is it airborne, automotive, water application etc. 3. Based on the application, choose the right grade of the material ex- AL6061 is good for aerospace application but AL2024 is not (this is most important step) 4. Get the material sample and check if all the parameters such as carbon percentage, strength & durability is as per application. 5. Now check the availability and future requirements. Assess the logistics PoV and go ahead for ordering. My weightage to these parameters are 20%, 25%, 25%, 20% & 10% accordingly. If the score is above 90%, go ahead.

In my view, there are some other aspects to consider when selecting a material, such as sustainability, recyclability, environmental impact, social impact, ethical issues, etc. These aspects are becoming more relevant and important in the modern world, as they affect the reputation and responsibility of the engineer and the company. For instance, when I was working on a project to develop a barcode reader device, I had to consider the sustainability and recyclability of the material, as well as the energy efficiency and carbon footprint of the product. I chose a material that was renewable, and low-emission, and I also designed the product to be easy to disassemble and recycle.

I always look in terms of its Application first i.e., what is the function it has to perform, under what environmental conditions it will be used. What are its environmental implications during scrap or disposal. Longevity (Durability) and the availability of material. Cost and maintenance. Safety in usage of material. Various physical and chemical properties of the material. Is it a critical component, etc ,