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Rolls-Royce University Technology Centre in Materials

EGA320 - High Performance
Materials and Selection

Dr Karen Perkins


Rolls-Royce/Swansea UTC in Materials
Institute of Structural Materials
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Rolls-Royce University Technology Centre in Materials
Useful information
Lecturer:
Karen Perkins
Materials Research Centre, Room 965A
k.m.perkins@swansea.ac.uk

When and Where?
Semester 2 of 2012/2013 session
Wednesday 9am Vivian 404
Thursday 1pm Vivian 404

Assessment:
80% examination
20% continuous assessment 1
Material Selection in Aerospace - 3000 word essay (topic t.b.c.)





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Rolls-Royce University Technology Centre in Materials
Useful Information
Recommended Texts:
Introduction to Aerospace Materials by Mouritz

Materials Engineering: An Introduction by W.D. Callister

Manufacturing Technology for Aerospace Structural Materials by
F.C. Campbell Jr

Materials Selection in Mechanical Design by M.F. Ashby

Other Resources:
lecture slides will be provided in the form of printed handouts
sanitized lecture slides will be provided via blackboard (research related
images and data removed)
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Rolls-Royce University Technology Centre in Materials
Syllabus

This module introduces material properties, and high performance metallic and non-
metallic materials as used in the aerospace industry. In a number of case studies,
you will learn the systemic selection of materials based on requirements as derived
from design specifications.

At the end of the module you should:

Have a thorough understanding of relevant materials properties

Types of high performance materials

Materials Selection

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Rolls-Royce University Technology Centre in Materials
Properties of Materials Part 1
Learning Objectives
stress and strain
elastic and plastic deformation, role of dislocations
modulus, stiffness, proof strength, tensile strength, ductility
Mechanical assessment
Stress / strain and design
toughness / fracture toughness
Definition
Mechanical assessment
Fracture toughness and design
Creep
Definition
Mechanical assessment
Creep and design
Fatigue
Low cycle fatigue, high cycles fatigue, crack propagation threshold and Paris,
Mechanical assessment
Fatigue and design
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Material Properties Part 2
Learning Objectives
Other properties to consider:

Density
Electrical
Thermal
Magnetic
Optical
Corrosion
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Rolls-Royce University Technology Centre in Materials
High Performance Materials
Learning Objectives
Titanium Alloys
The metal and its alloy
Melting, working and heat treatment
Microstructure and mechanical properties
Titanium aluminides
Nickel Alloys
Microstructure and heat treatment
Relationship of microstructure and mechanical properties
Steels
The metal and its alloy
Heat treatment, microstructure and relationship to mechanical properties
Ultra strength /high performance steels
Aluminium
The metal and its alloy
Heat treatment, microstructure and relationship to mechanical properties
Composites
Types of composites
Designing with composites


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Rolls-Royce University Technology Centre in Materials
Materials Selection
Learning Objectives
An introduction to materials selection
Methodology
Translation
screening/Rejection
Ranking,
Research
Specific Constraints
Material Performance Indices
What are material performance indices
Example 1a: Blades
Example 2a: Pressure Vessels
Material property charts
Material Choices for Case Studies
Example 1b: Blades
Example 2b: Pressure Vessels
Material Selection and the Gas turbine
Material Selection Case Studies



Case Study 1 Turbine Disc
Nickel alloys
Guest Lecture Dr Mark Hardy
Rolls Royce plc

Case Study 2 Mainline Shaft
Steels
Guest Lecture Dr Paul Hill
Rolls Royce plc

Case Study 3 Landing Gear
Steels
Guest Lecture Dr Steven Preston
Airbus

Case Study 4 Fuselage
Composites
Guest Lecture T.B.C
Airbus




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Rolls-Royce University Technology Centre in Materials
INTRODUCTION
Materials Selection
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Rolls-Royce University Technology Centre in Materials
Materials selection - Introduction
Weight reduction in aerospace
systems has always been a major
factor
From the designers perspective the
primary function of a structure is to
transmit forces through space with
the minimum possible weight and
cost
The job of the designer is to balance
the variety of functional requirements
with constraints so as to arrive at the
optimum choice of structural concept
and material selection for a given
weight and/or cost.
Wide range of choices available
make this task extremely demanding


Depending on the engineers
background, their answer to the
question may also be quite different
Need a robust and systematic
methodology for connecting material
and application
Material selection Manufacturability
Structural concepts
cost performance
durability
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Rolls-Royce University Technology Centre in Materials
Materials selection - Introduction
Design is a non-linear process as it can involve multiple iterations
Consequences of structural and material choices made at the preliminary
concept or embodiment stage may not become apparent until much later
Iteration is an essential part of the design process as is material selection which
enters each stage of the design process

50% of the life cycle cost is locked in
by the end of the preliminary design
phase
85% by the end of the embodiment
phase
Almost 100% by production
However, only 10% of the life cycle
cost has been expended
To reduce life cycle cost we need to
connect material selection and
application as early as possible
Larson and Pranke, 1999
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Rolls-Royce University Technology Centre in Materials
Materials selection - Introduction
Material information is central to all aspects of engineering products
Nature of data needed in early stages differs in its level of precision and breadth
from that needed later on
How can the vast range of data be presented to give the designer the greatest
freedom in considering alternatives?
Approximate property values -
broadest possible range of materials
Problem - not precision and detail, its
is breadth and speed of access
Concept Stage
Identification of a market
need concepts are
developed to fill that need
All options are open: a polymer may be the
best choice for one concept, a metal for
another, even though the function is the
same
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Rolls-Royce University Technology Centre in Materials
Materials selection - Introduction
Risk now is losing sight of the bigger spread of materials which we must return if
the details do not work out
Easy to get trapped into a single line of thinking other combinations may offer a
better solution to the problem

Embodiment stage
Most promising concepts
developed
Data for a subset of materials with
higher level of precision and detail
single class or sub class of materials
found in specialized handbooks and
software
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Rolls-Royce University Technology Centre in Materials
Materials selection - Introduction
Final stage of detailed design requires a still higher level of precision and detail
Information only required for few materials and is best found in the data
sheets issued by the material producers
A given material will have a range of properties derived from different
manufacturing by different producers
Supplier must be identified and the properties of their product used in design
calculations
If the component is a critical one, then additional tests to measure critical
properties maybe necessary using a sample of the material that will be used to
make the product

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Rolls-Royce University Technology Centre in Materials
Materials selection - Introduction
There is an inherent interaction between function, material, shape and process
Function dictates choice of material and shape
Material and process cannot be separated from the choice of shape
Process also interacts with shape and also changes material properties

Specification of shape restricts choice of material and process specification of
process limits materials you can use and the shapes they can take
function
material
process shape
More sophisticated the design,
the greater the iterations and tighter
the specifications