Materials Selection and Applications in Mechanical Engineering

630 Pages·2006·36.14 MB·English

by  Dr. A. Raman

MATERIALS SELECTION AND APPLICATIONS IN
MECHANICAL ENGINEERING
Aravamudhan Raman
Chevron Professor
Department of Mechanical Engineering
Louisiana State University
Baton Rouge, LA 70803
Industrial Press, Inc.
Library of Congress Cataloging-in-Publication Data
Raman, A. (Aravamudhan)
Materials selection and applications in mechanical engineering / Aravamudhan
Raman.
p. cm.
Includes index.
ISBN 0-831 1-3287-6
1. Mechanical engineering. 2. Materials. I. Title.
TJ151.R25 2006
62 1.3--dc .22
2006049038
Industrial Press, Inc.
989 Avenue of the Americas
New York. NY 10018
First Printing, 2007
Sponsoring Editor: John Carleo
Cover Design: Janet Romano
Copyright 0 2007 by Industrial Press Inc., New York. Printed in the United States of America.
All rights reserved. This book, or any parts thereof, may not be
reproduced, stored in a retrieval system, or transmitted in any form without the
permission of the publisher.
1 2 3 4 5 6 7 8 9 10
Nomenclature and Abbreviations
AAA -Aluminum Association of HAZ - Heat Affected Zone (in welds)
America HC -Hydrogen Cmcking
ABS - Acrylonitrile -Butadiene - HCF - High Cycle Fatigue
Styrene (Rubber) HCP - Hexagonal Close Packed
AC - Air-Cooled; Alternating Current HDPE - High Density PE
ACC - Automatic Can Crusher HE - Heat Exchanger;
ACE -AutomaticChalkboard Eraser also - Hydrogen Embrittlement
AE -Acoustic Emission HIP -Hot Isostatic Pressing
AISI - American Iron and Steel HP -Horse Power
Institute HRSIT -High Temperature Reusable
ASM - American Society for Metals SurfaceInsulation Tiles
ASTM - American Society for Testing HT - High Temperature
and Materials ICE -Internal Combustion Engine
B -Bainite IGC - InterGranular Corrosion
BCC -Body centered Cubic Imp. Str. -Impact Strength,
BHN - Brinell Hardness Number (mechanical enexgy to cause
BTA - Benzothiazole fracture under impact )
Cermet - Ceramic -Metal composite IN - International Nickel
-
CFRP - Carbon Fiber Reinforced kA - Archard constant in ftiction
Plastic dated wear (Archard Wear
CMC -CeramicMatrixComposite rate)
CP - CathodicP rotection KF- fatiguestrength reduction factor
CTC - Coefticiento f Thermal KIC- Critical stress intensity factor
Conductivity in mode1 fracure, Stress
CTE - Coefficient of Thermal intensity Fmcture Toughness
Expansion ksi -kilo (1000) psi
DQN - DiazonaphthoQuinone KT- stress concentration factor
DS -Directional Solidification LCF - Low CycleFatigue
E -Young’s modulus of elasticity LDPE - Low Density PE
EMM - Electmchernical Long. - Longitudinal
Micro -Machining LPG - Liquid Petroleum Gas
F - ‘Fast’ in SI plot paths M - Martensite
FC - Furnace -Cooled MAA - MethAcrylic Acid
FCC - Facecentered Cubic ME -Mechanical Engineering
FR - Fatigue Ratio in fatigue ME1 - Material Engineering Index
FRCI - Fibrous Refractory Composite MEMS -Micro -ElectroMechanical
Insulation System
- FractureToughness MMC -Metal Matrix Comp osite
GB - Grain boundary MPC - Materials Property Chart
GFRP - Glass Fiber Reinforced MPE -Material Performance
Plastic Efficiency, given in MPI
GTE - Gas Turbine Engine MPI - Material PerformanceIndex
HAWT -Horizontal Axis Win d MSE - Materials Science and
Turbine Engineering
xxiv
-d,- - Coefficient of Friction under SFE - Stacking Fault Energy
dynamic and static conditions SHC -Stress Hydrogen Crac king
N - Newton, unit of force SHE - Standard Hydrogen Electrode
NDT -Non Destructive Test SI -Satisfadion Index
Nicraly -a Ni alloy with Cr,AI, and Y -,,YS,Y.St. -Yield Strength
(used for coatings on turbine - Yield strength in compression
-p
blades) TS S - Tensile Strength, UTS
-t, ut
P- Pearlite SMA- ShapeMemory Alloy
Pa -Pascal, unit of stress SMC -Similar Material Composite;
PAN - Poly Aqlo Nitrile (or) Sheet Molding Compound
PBS - Poly -Butene Sulfone SS, stst -stainless steel
PE - PolyEthylene STA -Solution Treating and Aging
PEB -Post Exposure Bake T, Temp. - Temperature
YO Eln. - YO Elongation; linear strain TBC - Thermal Barrier Coating
x 100, i.e., YO strain to h&re TDN, TD -Ni -Thoria Dispersed
PET - PolyE thylene Terephthalate, a Nickel
Polyester TEM - Transmission Electron
PH - precipitatio n Hardenable Microscope
PI - Performance Index T4,T6,etc - Temper Designations for
PMMA - PolyMethyl Meih Acrylate Aluminum alloys
PMC -PolymerMatrix Composite Ti-6-4, Ti-6A1-4V -Titanium alloy
ppt - precipitate containing 6 wt%Al and 4 wtY0 V
PR - Property Ratio TM -Tempered Martensite
Prop -Property TP - Thermoplastic
psi - pound force per square inch Trans - Transverse
PSZ -Partially Stabilized Zirconia TS -Thermoset
PTCFE - PolyTetra Chloro Fluoro - UCT - Upper Critical Temperature
Ethylene UTS VS), S ut - Ultimate Tensile
PTFE -Poly Tetra Fluoro Ethylene Strength
Veflon) UV - Ultra Violet
PVC - PolyVinylChloride VAWT -Vertical Axis Wind Turbine
q -notch sensitivity factor W,Wt - Weightageor Weight
R - Stress ratio in fatigue WEDWG - WireElectrodeDischaqge
RoM - Rule of Mixture MachiningGrinding
RPM -Revolutions Per Minute WT -Wind Turbine
RT -Room Tempemture WQ -Water -Quenched
S - ' Slow' in SI plot paths XRD - X-Ray DifFraction
SA -Super Alloy; YSZ -Yttria (Y 203) Stabilized
also - StrengtheningA gent Zirconia
SAE - Society ofAutomotive
Engineem
SCC -Stress Corrosion Cracking
SCE - Standard Calomel Electrode
SCuE - Standard CopperElectrode
SEM - Scanning Eledmn
Microscope
xxv
Preface
Materials are basic to man’s needs and it is well established that materials and
energy are two of the most important entities that move the universe around. There is no
economy without engineering, and there is no engineering without materials and energy.
Mechanical engineering (ME) dedicates itself to building machines and
equipment. In this pursuit, it involves itself in specifying the principles and functionality
of machines and equipment. Through new designs, new machines are constantly being
synthesized and brought to usage.
The efficiency of machines and their useful lives depend upon how successfully
the design principles have been deployed in their synthesis and how elegantly the
machines have been produced. As the adage goes “without materials, there won’t be any
machine,” it therefore derives that “without proper materials and their skillful application,
there won’t be any successful and efficient machines.’‘ For efficient and fruitful
mechanical engineering or, indeed, for any engineering, it follows that the best and
optimum possible materials be sought, processed properly and applied. This necessitates
that the mechanical engineers be thoroughly conversant and skillful in selecting,
processing, and applying the right kind of materials in the systems they develop and use.
Best machines have been designed and built by engineers and scientists before,
and this has been accomplished based on past experience of materials’ functionality.
However, numerous problems that arose during applications could be traced to materials’
deficiency. Better materials and/or synthesis procedures were adopted to overcome those
problems. Although most of these problems are well realized, the engineers are still
forced to learn about them through practical experience. The engineering curricula
offered in schools, I believe, are not offering adequate venues (courses) to bring all the
materials-related information to design, manufacture, and maintenance of equipment.
Most engineering curricula include at the basic level only one fundamental course
in the fairly vast and exhaustive field of Materials Science and Engineering (MSE),
introducing only the basic concepts of MSE. The time allotted in the curricula does not
permit adequate coverage of materials engineering topics in the selected programs such
as ME, albeit this kind of coverage also is badly needed for the successful basic training
of students in the engineering disciplines. With this in mind, many programs around the
world have deployed a second course on Engineering Materials, particularly emphasizing
the principles of Materials Selection and Application, oriented to engineering. Yet, a
large number of other programs are to follow the suit.
What should be covered in such a second course is very clear, but how much can
be covered adequately is debatable. It is obvious that this should be a course that would
follow-up on the first one and be oriented toward design, manufacture, and maintenance
in the specific discipline.
The second course should verily be of the Materials engineering type and should
discuss fully the properties and behavior of materials related to the branch of engineering
concerned. The various prime materials that are in use in the specific branch of
engineering should be thoroughly introduced; common problems and deficiencies of
these materials should be outlined and discussed. It is also very essential to learn how to
...
111
work with these materials and prepare them for optimum use in the various components
of the engineering system. Finally, integrating all of the background information
available on the various materials, one should be able to select and apply the best possible
materials that would suit the requirements posed by design and application.
All of the above issues are addressed in the current book that I have developed
over a fairly long period of time. Taking on the idea that there should be separate books
for different engineering disciplines in similar lines, I have developed the current version
mainly for the ME discipline, although this same book can be used with some
modifications in a few other engineering branches as well, particularly in the
Manufacturing, Chemical, Nuclear and Agricultural Engineering fields. The book is easy
to read and many of the chapters can be assigned for self study.
This book is divided into seven Parts. It starts out in Part A with the equipment
and machines, commonly developed and handled by mechanical engineers, and defines
the principles and a simple method of materials selection for mechanical systems. In Part
B, the important properties of materials are defined, including the properties that relate to
practical problems, such as corrosion, friction, and fracture. Part C introduces the various
materials that are commonly used in ME, whereas Part D describes the special processing
procedures and problems commonly encountered during operation of mechanical
systems, the NDT methods used to identify the problems, and various procedures used to
alleviate them.
Part E dwells on materials commonly used in selected mechanical components
and systems, whereas Part F has many sample Material Selection problems and projects
that illustrate the optimum ways of material selection and application in selected
prevalent, as well as new and evolving systems. Ample examples of projects undertaken
by ME undergraduate students, standing alone or working in groups, are included in Part
F. Selected exercises and problems are given at relevant places for students to work out
as homework and projects. Finally, Part G is an Appendix that gives a compilation of
engineering formulae useful for mechanical engineering, tables carrying units of
properties and their conversion from one system to the other, and a listing of important
ASTM Standards useful for Materials Selection in ME.
I have found students vastly enthusiastic in carrying out project activities.
Therefore, the course gives ample room to assign and weigh the project activities
appropriately. Introductory homework assignments help to prepare them to tune their
materials selection and analysis skills appropriately.
A word of caution is in order. The data and information provided in this book are
from very many different sources and represent possible values of properties attainable.
They should not be construed as absolutely realizable. Data sources and material
manufacturers and testers should be consulted wherever needed to obtain the best
possible data on materials.
An enormous amount of work and analysis has gone into the development of the
topics for the projects and I am very fortunate and thankful to have had a large number of
outstanding projects done by students in my classes. I have skimmed through some of
their fine work and included them in appropriate places. My sincere thanks to Nicholas
Dauzat, David Freeman, Berkeleigh Bailey, Guille DeVega, et al., for taking the
Materials Selection course seriously, carrying out excellent project studies, and letting me
show the world how good their work is. Graduate assistants MI. Rakesh Behera and
iv
Lucian Zigoneanu provided valuable support in developing sample projects write-up, and
several figures and Tables. To Chevron Oil Company, I offer my deepest appreciation for
supporting me with financial assistance in the form of a titled professorship and to the
Department of Mechanical Engineering at LSU for enabling me to develop the Materials
Selection course and this book for it. My thanks are likewise extended to Professor
Wanjun Wang for letting me use some of the fine pictures he has taken on several MEMS
products he has recently developed. To my other colleagues and early mentors who have
helped me in so many different ways, I offer my sincere appreciation and thanks.
To three great souls, late Professor Konrad Schubert, who showed me what hard
scientific pursuit can bring forth, late Professor Werner Koester, Director of Max-Planck
Institute for Metal Research, Stuttgart, Germany, who embraced me and gave tremendous
support to be independent, and Professor Tendolkar of I.I.T., Bombay (Mumbai), India, I
am eternally indebted.
Industrial Press is a staunch supporter of books on machines and Mechanical
Engineering and I am fortunate to have this book published by this unit. Robert
Weinstein has patiently gone through the entire work and edited it elegantly. John Carleo,
the Editorial Director of IP has been a tremendous motivator. To these gentlemen and to
others in IP who are responsible in bringing out this book to the public I offer my sincere
thanks.
Finally, I dedicate this book to the fond memory of my late mother who is
teaching me silently and showing me directions for achievements of all kinds.
Aravamudhan Raman
LSU, Baton Rouge, LA USA
June 2006
V
Contents (in Brief)
Preface ...
111
Contents vii
Nomenclature and Abbreviations ix
Part A: Materials Selection Principles and Application to
Mechanical Engineering 1
Ch. 1. Materials Selection for Mechanical Engineering 3
Ch. 2. The Material Engineering Index (MEI) 13
Ch. 3. Analysis of Materials Performance Efficiency 19
Ch. 4. Specific Example - MPI Analysis for optimum Material
Selection for a Steam Turbine Rotor 34
Bibliography for Part A 44
Part B: Properties of Interest in Mechanical Components and
Systems 45
a) Mechanical Properties:
Ch. 5. Mechanical Properties of Importance in Mechanical 47
Engineering - Tensile and Compressive Properties
Ch. 6. Material Properties - Mechanical - 61
Fracture Characteristics and Fracture Toughness
Ch. 7. Material Properties - Mechanical - Fatigue 75
Ch. 8. Material Properties - Mechanical - Creep 85
Ch. 9. Material Properties- Mechanical - Friction and Wear 97
Ch. 10. Variation of Mechanical Properties and Residual Stresses 107
b) Physical Properties
Ch. 11 . Physical Properties of Interest to Mechanical Engineering - 114
Thermal Properties of Materials
Ch. 12. Physical Properties of Interest to Mechanical Engineering - 122
Electrical Properties
c) Chemical Properties
Ch. 13. Material Properties - Chemical - Surface Properties - 133
Corrosion
Bibliography for Part B 157
Part C: Materials used in Mechanical Components and Systems 159
Ch. 14. Mechanical Engineering Materials - Metallic -Ferrous Alloys - 161
Steels, Stainless Steels, and Cast irons
Ch. 15. Mechanical Engineering Materials - Metals - Non-ferrous 174
Aluminum, Titanium and Copper Alloys
Ch. 16 . Mechanical Engineering Materials- Metallic- Non-Ferrous 184
Alloys - Nickel-, and Cobalt-base Superalloys
Ch. 17. Other Metallic Materials Used in Mechanical Engineering 192
Ch. 18. Engineering Ceramics and Polymers 196
Ch. 19. Engineering Materials - Composites 205
Bibliography for Part C 214
vi
Part D: Materials Engineering 215
a) Processing Techniques
Ch. 20. Mechanical Processing and Thermal Treatments 217
Ch. 21. Materials Processing - Surface Treatments and Case Hardening 227
Ch. 22. Micromanufacturing - Micromachining, Lithography, MEMS 233
b) Materials Handling
Ch. 23. Problems with Materials during Use - Manifestation, Detection 248
and Correction
Ch. 24. Materials Maintenance - Non-Destructive Testing of Mechanical 256
Components
Bibliography for Part D 269
Part E: Materials in Use in Mechanical Components and Systems 271
Ch. 25. Materials Commonly Used for Single Mechanical Engineering 273
Components
Ch. 26. Examples of Selection of Materials for Single Components 279
Ch. 27. Materials Selection for Components in Simple Mechanical 288
Systems. 1. Materials Selection for Components of a Windmill 288
2. Lightweight Competitive Mountain Bike 305
Ch. 28. Materials Analysis in Multi-component Mechanical Systems - 326
Materials in Use for Components in Engines of Various Kinds
Ch. 29. Materials in Use in Multi-component Mechanical Systems - 360
Pumps
Ch. 30. Materials Selection for Selected Thermal Systems 379
Bibliography for Part E 395
Part F: Selected Materials Selection Projects 40 1
Ch. 3 1. Examples for Materials Selection for Single Components 403
Ch. 32. Material Selection for Components in Multi-component 412
Mechanical Systems: Selected Projects
Ch. 33. Analysis of Materials Selection for New Mechanical Designs 438
and Systems
Automatic Chalkboard Eraser (ACE) 43 8
Automatic Can Crusher (ACC) 449
Ch. 34. Simple Materials Selection Projects 46 1
Mechanical Solar Clothes Dryer 46 1
Bibliography for Part F 482
-
Part G: Appendix Useful Tables and Data 485
Important Engineering Formulae 487
Units and Conversion of Units 492
Selected ASTM Standards Useful for Materials Selection 497
Subject Index 5 03
vii
Part A
Materials Selection Principles and Application
to Mechanical Engineering
Chapter 1. Materials Selection for Mechanical Engineering
Chapter 2. The Material Engineering Index (MEI)
Chapter 3. Analysis of Materials Performance Efficiency
Chapter 4. Specific Example
MPI Analysis for Optimum Material Selection
for a Steam Turbine Rotor - Justification of a
Special Steel in a Steam Turbine Rotor
Bibliography for Part A