Study on Material Selection for Particular Design
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This document discusses material selection for engineering designs and describes tensile testing conducted on aluminum alloy specimens. It begins by explaining the importance of selecting the appropriate material based on the intended application and life of the product. Tensile testing is then introduced as a common mechanical test to determine material properties like yield strength and modulus of elasticity. The document goes on to describe tensile tests performed on aluminum alloy 6061-T6 and 2024-T3 specimens using a digital testing system equipped with strain sensors. The results show the yield point, modulus of elasticity, and ultimate tensile strength differed between the two aluminum alloys. This information helps engineers select the best material based on the design criteria and requirements.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 708
STUDY ON MATERIAL SELECTION FOR PARTICULAR DESIGN
Chaithanya B. V1, Siva Subba Rao Patange2, Sowmia Devi M2, Panbarasu K2, Joyti B1
1GSSS Institute of Engineering & Technology for Women, Mysuru-570016.
2CSIR-National Aerospace Laboratories, Bengaluru-560017, India.
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract- This paper demonstrates the importance of
Material selection in engineering design is all aspects. When
selecting a material for a specific application based on
properties appropriate testing must be performed to ensure
that the material will remain suitable for its intended
application throughout the intended life of the product.
Tensile testing is a way of determining how something will
react when it is pulled apart, when a force is applied to it in
tension. Tensile testing is one of the simplest and most widely
used mechanical tests. By measuring the force required to
elongate a specimen to breaking point, material properties
can be determined that will allow designers and quality
managers to predict how materials and products will behave
in their intended applications.
Keywords: Digitally controlled universal testing system,
Strain gauge, tensile testing, Al alloy 6061-T6, Al alloy
2024-T3.
1. INTRODUCTION
Material selection in engineering design is very
important in all aspects. There are numerous engineering
design criteria and facts have to be considered when
selecting a particular material for a certain design. Material
selection is one of the main functions of effective design and
it determines the reliability of the design in terms of
industrial and economical aspects. If the product does not
meet appropriate material combination a great design may
fail to be profitable product. So, it is important to know the
best materials for particular design. How to get an idea
about the best materials for a design? In this aspect
engineers use numerous facts of materials to make the
reasonable decision. They are mainly concentrating on the
properties of the material which are identified for that
specific design.
Advancement of materialscienceandthetechniques
for processing material have been madefromthesecondhalf
of 20th century. As a result, a wide range of material is now
available for any imaginable applications. The development
of modern transport, particularly the airplane is associated
with a huge increase in varieties of materials andmakingfull
use of their properties. For example, in development of
modern transports entirely alloy material and new
composite materials are used, because exhibitingproperties
could not be achieved by ordinary metals. The principles
governing the behavior of materialsare grounded in science
and are understandable. The properties of a given material
are determined by its structure and it changes according to
environmental conditions. When selecting a material for a
specific application, sufficient and appropriate testing must
be performed to ensure that the material will remain
suitable for itsintended applicationthroughouttheintended
life of the product [1].
2. TYPES OF MATERIAL AND ITS PROPERTIES
Generally, materials are classified into groups. One
could classify them according to structure,properties,use.In
metals the valence electrons are detached from atoms, and
spread in an 'electron sea' that "glues" the ions together.
Metals are usually strong, conduct electricity and heat
dissipation and are opaque to light (shiny if polished).
Examples: Aluminum, steel, brass, gold. In Semiconductors,
the electrons are shared between atoms. They are opaqueto
visible light but transparent to the infrared. Examples:Si,Ge,
GaAs. Ceramic atoms behave either positive or negative
ions, and they are bound by Coulomb forces between them.
They are usually combinations of metals or semiconductors
with oxygen, nitrogen or carbon. Examples: glass, porcelain,
many minerals. Polymers are bounded by covalent forces
and also by weak van der Waals forces, based on H, C and
other non-metallic elements. They decompose at moderate
temperatures (100–400C), and are lightweight. Other
properties vary greatly. Examples: plastics (nylon, Teflon,
polyester) and rubber. Some categories are not based on
bonding. Particular microstructure
identifies composites, made ofdifferentmaterialstointimate
the contact for achieving specific properties. Example:
fiberglass, concrete, wood. Biomaterials can be any type of
material that is biocompatible and used for instance, to
replace human body parts [2].
Advanced Materials used in"High-Tec"applications,
usually designed for maximum performance, and normally
expensive. Examples are titanium alloys for supersonic air
planes, magnetic alloysfor computer disks, special ceramics
for the heat shield of the space shuttle, etc. There are many.
Use of nuclear energy requires solving problem with
residues, or advances in nuclear waste processing.
Hypersonic flight requires materials that are light, strong
and resist high temperatures. Optical communications
require optical fibersthat absorb light negligibly. Structures
require strong materialslikemetals and resistcorrosionlike
plastics [2].
When selecting a material for agivenapplicationthe
material properties must satisfy the function and the
operating conditions of the component or the structure](https://image.slidesharecdn.com/irjet-v4i12136-180112083014/85/Study-on-Material-Selection-for-Particular-Design-1-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 709
being designed. Properties are the way; the material
responds to the environment. For example, the mechanical,
electrical and magnetic properties are the responses to
mechanical, electrical and magnetic forces, respectively.
Other important properties are thermal (transmission of
heat, heat capacity), optical (absorption, transmission and
scattering of light), and the chemical stability incontactwith
the environment (like corrosion resistance). Processing of
materials is the application of heat (heat treatment),
mechanical forces, etc. to affect their microstructure and
their properties. The properties, which directlyinfluencethe
choice of material, are mechanical properties e.g. stiffness,
strength, ductility, hardness, toughness, etc. Physical
properties: e.g. density, electrical conductivity, thermal
conductivity, etc. Chemical properties e.g. corrosion
resistance in various environments. Manufacturing
properties e.g. formability, machinability, easeofjoining,etc.
The functional requirements of a product are directly
determined by the mechanical, physical,chemicalproperties.
For the product to be technically manufacturable, the
material must have the right manufacturing properties. For
example, a forged component requires a material with
sufficient flow ability without cracking during forging, a cast
component requires a material that flows readily in the
molten state and fills the mold and on solidification doesnot
produce undesirable pores and cracks. So, many testing are
done to find the capability of material for the product
manufacturing and while selecting a material for a specific
application. Example tensile testing,compressiontestingand
fatigue testing are done for aircraft structure.
3. TENSILE TESTING ON DIFFERENT
ALUMINUM ALLOY
Tensile testing is one of the simplest and most widely
used mechanical tests. By measuring the force it is required
to elongate a specimen at breaking point, so the material
properties can be determined that will allow designers and
quality managers to predict how materialsandproductswill
behave in their intended applications. Tensile testing is
generally done using digital universal testingsystem.Tensile
testing is done on aluminum alloy 6061-T6 and aluminum
alloy 2024-T3 specimen. Strain gauge sensor is bounded on
the specimen. Foil strain gauge based on wheatstone bridge
configuration is selected. Because strain measurement
typically requires the detection of very small mechanical
deformations, and small resistance changes, the resultant
magnitude of most strains measurements in stress analysis
application. The wheatstone bridge is comprised of four
resistive arms arranged in the configuration of a diamond.
An excitation voltage is applied across bridge input, and a
resultant output voltage can be measured across the other
two vertices [3].
Fig -1: Tensile testing block diagram
As shown in the figure1 specimen is connected to
digitally controlled universal testing system. When static
load is applied to the specimen it experiences the pull-off
force. After some time of elongation, the specimen takes
place and plastic deformation occurs. The data of stress and
load with respect to time will be recorded and displayed by
digitally controlled universal testing system. Plotting stress
v/s strain graph gives the point of distraction, yield point/
strength, young’s modulus, ductile strength [4].
4. RESULT AND DISCUSSION
Chart -1: graph of stress v/s strain for aluminum alloy
6061-T6
Chart -2: Modulus of elasticity for aluminum alloy
6061-T6
Static
load
Digitally
controlled
universal testing
system Data
recorder
and
display
Strain gauge
sensor
bounded on
specimen](https://image.slidesharecdn.com/irjet-v4i12136-180112083014/85/Study-on-Material-Selection-for-Particular-Design-2-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 710
Chart -3: graph of stress v/s strain for aluminum alloy
2024-T3
Chart -4: Modulus of elasticity for aluminum alloy
2024-T3
The result shows in the Chart -1 and Chart -3 in the
graph of stress v/s strain for each specimen shows the yield
point were the deformation of specimen starts under static
load. Point of distraction is 158 Mpa, Modulus ofelasticity is
76 Gpa and ultimate tensile strength is 160 Mpa for
specimen aluminum alloy 6061-T6. Point of distraction is
146 Mpa, Modulus of elasticity is 72 Gpa and ultimatetensile
strength is 320 Mpa for aluminum alloy 2021-T3 [5].
5. CONCLUSION
This paper is concluded with tensile testing on two
different aluminum alloy material which shows the point of
destruction, modulus of elasticity and ultimate tensile
strength. In this tensile test aluminum alloy 6061-T6 is
having more point of destruction and modulusofelasticityat
early stage of testing compared to aluminum alloy 2024-T3,
also there is different ultimate tensile strength. So,
aluminum alloy is used based on requirement of their
strength for different applications like Aerospace Industry,
Automotive Industry, Beverage Industry and Construction
Industry.
ACKNOWLEDGEMENT
The authors would like to thank the Director, Mr.
Jitendra J Jadhav CSIR-National Aerospace Laboratories for
his persistence to carry out the work and Dr. SatishChandra,
Head Structural TechnologiesDivision (STTD) for providing
all the facilities for completing this work and Dr. S. Raja
Group Head of STTD for supporting and inspiring to
complete the work. My Special thanks to Mr.Raghavendra,
Structural Technologies Division (STTD), CSIR-National
Aerospace Laboratories, for their help.
REFERENCE
[1] Pyles, R. A. Aging Aircraft USAF Workload and
Material Consumption Life Cycle Patterns. Rand,
USA, 2003.
[2] JAC Chapman, Elexsys, “Comparative look at strain
gauge and piezoelectric sensors”, E+C SPOT ON •
November 2013.
[3] “Introduction to Tensile Testing”, 2004 ASM
International. All Rights Reserved. Tensile Testing,
Second Edition.
[4] “Standard Test Methods for Tension Testing of
Metallic Materials”. American Association State
Highway and Transportation Officials Standard
AASHTO No.: T68 An American National Standard
[5] Halil İbrahim Kurt, Ramazan Samur, “Study on
Microstructure, Tensile Test and Hardness 304
Stainless Steel Jointed by TIG Welding”, Gaziantep
Vocational High School, Gaziantep University,
Gaziantep-Turkey ,Technical Education Faculty,
Marmara University, Göztepe-İstanbul-Turkey.](https://image.slidesharecdn.com/irjet-v4i12136-180112083014/85/Study-on-Material-Selection-for-Particular-Design-3-320.jpg)
Study on Material Selection for Particular Design
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 708 STUDY ON MATERIAL SELECTION FOR PARTICULAR DESIGN Chaithanya B. V1, Siva Subba Rao Patange2, Sowmia Devi M2, Panbarasu K2, Joyti B1 1GSSS Institute of Engineering & Technology for Women, Mysuru-570016. 2CSIR-National Aerospace Laboratories, Bengaluru-560017, India. ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract- This paper demonstrates the importance of Material selection in engineering design is all aspects. When selecting a material for a specific application based on properties appropriate testing must be performed to ensure that the material will remain suitable for its intended application throughout the intended life of the product. Tensile testing is a way of determining how something will react when it is pulled apart, when a force is applied to it in tension. Tensile testing is one of the simplest and most widely used mechanical tests. By measuring the force required to elongate a specimen to breaking point, material properties can be determined that will allow designers and quality managers to predict how materials and products will behave in their intended applications. Keywords: Digitally controlled universal testing system, Strain gauge, tensile testing, Al alloy 6061-T6, Al alloy 2024-T3. 1. INTRODUCTION Material selection in engineering design is very important in all aspects. There are numerous engineering design criteria and facts have to be considered when selecting a particular material for a certain design. Material selection is one of the main functions of effective design and it determines the reliability of the design in terms of industrial and economical aspects. If the product does not meet appropriate material combination a great design may fail to be profitable product. So, it is important to know the best materials for particular design. How to get an idea about the best materials for a design? In this aspect engineers use numerous facts of materials to make the reasonable decision. They are mainly concentrating on the properties of the material which are identified for that specific design. Advancement of materialscienceandthetechniques for processing material have been madefromthesecondhalf of 20th century. As a result, a wide range of material is now available for any imaginable applications. The development of modern transport, particularly the airplane is associated with a huge increase in varieties of materials andmakingfull use of their properties. For example, in development of modern transports entirely alloy material and new composite materials are used, because exhibitingproperties could not be achieved by ordinary metals. The principles governing the behavior of materialsare grounded in science and are understandable. The properties of a given material are determined by its structure and it changes according to environmental conditions. When selecting a material for a specific application, sufficient and appropriate testing must be performed to ensure that the material will remain suitable for itsintended applicationthroughouttheintended life of the product [1]. 2. TYPES OF MATERIAL AND ITS PROPERTIES Generally, materials are classified into groups. One could classify them according to structure,properties,use.In metals the valence electrons are detached from atoms, and spread in an 'electron sea' that "glues" the ions together. Metals are usually strong, conduct electricity and heat dissipation and are opaque to light (shiny if polished). Examples: Aluminum, steel, brass, gold. In Semiconductors, the electrons are shared between atoms. They are opaqueto visible light but transparent to the infrared. Examples:Si,Ge, GaAs. Ceramic atoms behave either positive or negative ions, and they are bound by Coulomb forces between them. They are usually combinations of metals or semiconductors with oxygen, nitrogen or carbon. Examples: glass, porcelain, many minerals. Polymers are bounded by covalent forces and also by weak van der Waals forces, based on H, C and other non-metallic elements. They decompose at moderate temperatures (100–400C), and are lightweight. Other properties vary greatly. Examples: plastics (nylon, Teflon, polyester) and rubber. Some categories are not based on bonding. Particular microstructure identifies composites, made ofdifferentmaterialstointimate the contact for achieving specific properties. Example: fiberglass, concrete, wood. Biomaterials can be any type of material that is biocompatible and used for instance, to replace human body parts [2]. Advanced Materials used in"High-Tec"applications, usually designed for maximum performance, and normally expensive. Examples are titanium alloys for supersonic air planes, magnetic alloysfor computer disks, special ceramics for the heat shield of the space shuttle, etc. There are many. Use of nuclear energy requires solving problem with residues, or advances in nuclear waste processing. Hypersonic flight requires materials that are light, strong and resist high temperatures. Optical communications require optical fibersthat absorb light negligibly. Structures require strong materialslikemetals and resistcorrosionlike plastics [2]. When selecting a material for agivenapplicationthe material properties must satisfy the function and the operating conditions of the component or the structure
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 709 being designed. Properties are the way; the material responds to the environment. For example, the mechanical, electrical and magnetic properties are the responses to mechanical, electrical and magnetic forces, respectively. Other important properties are thermal (transmission of heat, heat capacity), optical (absorption, transmission and scattering of light), and the chemical stability incontactwith the environment (like corrosion resistance). Processing of materials is the application of heat (heat treatment), mechanical forces, etc. to affect their microstructure and their properties. The properties, which directlyinfluencethe choice of material, are mechanical properties e.g. stiffness, strength, ductility, hardness, toughness, etc. Physical properties: e.g. density, electrical conductivity, thermal conductivity, etc. Chemical properties e.g. corrosion resistance in various environments. Manufacturing properties e.g. formability, machinability, easeofjoining,etc. The functional requirements of a product are directly determined by the mechanical, physical,chemicalproperties. For the product to be technically manufacturable, the material must have the right manufacturing properties. For example, a forged component requires a material with sufficient flow ability without cracking during forging, a cast component requires a material that flows readily in the molten state and fills the mold and on solidification doesnot produce undesirable pores and cracks. So, many testing are done to find the capability of material for the product manufacturing and while selecting a material for a specific application. Example tensile testing,compressiontestingand fatigue testing are done for aircraft structure. 3. TENSILE TESTING ON DIFFERENT ALUMINUM ALLOY Tensile testing is one of the simplest and most widely used mechanical tests. By measuring the force it is required to elongate a specimen at breaking point, so the material properties can be determined that will allow designers and quality managers to predict how materialsandproductswill behave in their intended applications. Tensile testing is generally done using digital universal testingsystem.Tensile testing is done on aluminum alloy 6061-T6 and aluminum alloy 2024-T3 specimen. Strain gauge sensor is bounded on the specimen. Foil strain gauge based on wheatstone bridge configuration is selected. Because strain measurement typically requires the detection of very small mechanical deformations, and small resistance changes, the resultant magnitude of most strains measurements in stress analysis application. The wheatstone bridge is comprised of four resistive arms arranged in the configuration of a diamond. An excitation voltage is applied across bridge input, and a resultant output voltage can be measured across the other two vertices [3]. Fig -1: Tensile testing block diagram As shown in the figure1 specimen is connected to digitally controlled universal testing system. When static load is applied to the specimen it experiences the pull-off force. After some time of elongation, the specimen takes place and plastic deformation occurs. The data of stress and load with respect to time will be recorded and displayed by digitally controlled universal testing system. Plotting stress v/s strain graph gives the point of distraction, yield point/ strength, young’s modulus, ductile strength [4]. 4. RESULT AND DISCUSSION Chart -1: graph of stress v/s strain for aluminum alloy 6061-T6 Chart -2: Modulus of elasticity for aluminum alloy 6061-T6 Static load Digitally controlled universal testing system Data recorder and display Strain gauge sensor bounded on specimen
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 710 Chart -3: graph of stress v/s strain for aluminum alloy 2024-T3 Chart -4: Modulus of elasticity for aluminum alloy 2024-T3 The result shows in the Chart -1 and Chart -3 in the graph of stress v/s strain for each specimen shows the yield point were the deformation of specimen starts under static load. Point of distraction is 158 Mpa, Modulus ofelasticity is 76 Gpa and ultimate tensile strength is 160 Mpa for specimen aluminum alloy 6061-T6. Point of distraction is 146 Mpa, Modulus of elasticity is 72 Gpa and ultimatetensile strength is 320 Mpa for aluminum alloy 2021-T3 [5]. 5. CONCLUSION This paper is concluded with tensile testing on two different aluminum alloy material which shows the point of destruction, modulus of elasticity and ultimate tensile strength. In this tensile test aluminum alloy 6061-T6 is having more point of destruction and modulusofelasticityat early stage of testing compared to aluminum alloy 2024-T3, also there is different ultimate tensile strength. So, aluminum alloy is used based on requirement of their strength for different applications like Aerospace Industry, Automotive Industry, Beverage Industry and Construction Industry. ACKNOWLEDGEMENT The authors would like to thank the Director, Mr. Jitendra J Jadhav CSIR-National Aerospace Laboratories for his persistence to carry out the work and Dr. SatishChandra, Head Structural TechnologiesDivision (STTD) for providing all the facilities for completing this work and Dr. S. Raja Group Head of STTD for supporting and inspiring to complete the work. My Special thanks to Mr.Raghavendra, Structural Technologies Division (STTD), CSIR-National Aerospace Laboratories, for their help. REFERENCE [1] Pyles, R. A. Aging Aircraft USAF Workload and Material Consumption Life Cycle Patterns. Rand, USA, 2003. [2] JAC Chapman, Elexsys, “Comparative look at strain gauge and piezoelectric sensors”, E+C SPOT ON • November 2013. [3] “Introduction to Tensile Testing”, 2004 ASM International. All Rights Reserved. Tensile Testing, Second Edition. [4] “Standard Test Methods for Tension Testing of Metallic Materials”. American Association State Highway and Transportation Officials Standard AASHTO No.: T68 An American National Standard [5] Halil İbrahim Kurt, Ramazan Samur, “Study on Microstructure, Tensile Test and Hardness 304 Stainless Steel Jointed by TIG Welding”, Gaziantep Vocational High School, Gaziantep University, Gaziantep-Turkey ,Technical Education Faculty, Marmara University, Göztepe-İstanbul-Turkey.