Why we need different material?

The main reason for the choice of material is the financial constraints
one has to see, besides technical factors for instance, strength, shear
strength, tensile strength. During the last decades many new materials and
material types have been developed. At present era, there is about 1 lac
engineering materials that exist. Upon research, many existing materials
have successfully improved their properties. This material selection is a
part of several design criteria. For example, previously cast iron in cylinder
heads, where as now cast aluminum alloys are also used so that the better
material properties formed as a result of combination of two different
materials which help the product to have long life.

Design process:

It is vital to consider every possible alternative during the design

process as design decisions will determine the feasibility and cost of the
manufacturing processes and the final product. It is difficult process to
determine feasible combinations of material and manufacturing processes
during concept design since the requirements and product characteristics
are not known completely before hand.

Methods of material selection:

First best material method is used in industrially developing

countries (like Pakistan) where designing is rarely done while industries
emphasize merely upon production. Another method which is used
Common material method. It is assumed that the component which is to
be designed will work same in different products.
The above mentioned methods are non- systematic design
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processes are not preferable due to the wastage of both time and money.
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This is why efficient designers prefer systematic designing process.

Systematic designing process:

Material selection can be made during any stage of the life cycle of a
product but usually it is done when the component is first designed or when
it is redesigned. The reason is simply that the introduction of a new material
in general requires the modification of the component geometry. If failures
of the part take place it may be necessary to change the material. Many
times even small geometrical changes make a new material the optimum
one.
The Ashby approach is design-led. It starts by asking 'What is the
function of the component in the design?', 'What objectives need to be
optimized?', and 'What constraints must be satisfied?'
For instance, a car body panel (function) needs to be as light as
possible (objective) for a specified stiffness and cost (constraint). Other
constraints on the design might be acceptable resistance to mechanical
impact and to contact with various environments.
The advantage of this approach is that it is systematic and unbiased
in its focus on product objectives and it leads to optimization or innovation
of the product. We will be using this approach in our case study.

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Factors that affect design process:

There are no hard and fast rules that how many factors should be
considered as key factors. It depends from case to case.
For example: If you are designing an industrial robotic arm you will be
bound to account for the max shear and normal stresses, the density of the
material that is to be considered for use and correspondingly the total
4

weight of the arm, the tensile strength as well the factors for the working of
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internal components involved such as the motors used to move the arm
,their maximum and minimum angular frequencies, maximum and minimum
voltages that can be applied to motor, the sensors and controllers etc.
Aesthetic appearance of the product is also a factor which helps to
gain more value of the product in market.

Case study:
(For CNG cylinder of car)

We now consider case study of material selection for a CNG cylinder,

we shall keep the dimensions constant for each material which we shall
consider. We shall select material for frame only.

Assumptions:

We assume that this case study is for a thin walled cylinder and there
is no torsion or shear stresses.

The procedure of our methodology:

1) Compare Aluminum alloys among themselves and picking the most

suitable material in Al alloys
2) Compare Steel and carbon alloys among themselves and picking the
most suitable material in Fe and C alloys
3) Compare above two dominant representatives, the most suitable will
be chosen.

The factors that we will be taking in account will be:

1) Weight or density
2) Yield strength
3) Tensile strength
4) Specific heat
5) Thermal expansion
6) Thermal conductivity

Comparison Among Steels:

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Iron/ steel Density(Kg/m^ Tensile Yield Specific thermal Thermal

3) strength(Mp strength(Mp heat expansion*10 conductivit
a) a) ^-6(20 C) y

SAE 4027 7872 515 325 477 12.6 44.6

SAE 4340 7872 745 472 477 12.6 44.6
SAE 8620 7872 536 357 477 12.2 46.6
SAE 1010 7872 325 305 448 12.2 51.9
SAE 1045 7872 625 310 486 11.7 50.9
SAE 1070 7872 640 495 490 12.1 51.2
ASTM A536 6640 496 345 506 11.6 32.3
ASTM 40 7200 276 827 490 9 53.3

Comparison of properties of different steels using graphs:

Weight or density:
Density
8000
7800
7600
7400
7200
7000 Density
6800
6600
6400
6200
6000

0 27 3 40 6 20 0 10 0 45 0 70 36 40
E4 E4 E8 E1 E1 E1 A5 TM
SA SA SA SA SA SA TM AS
AS

Weight considerations are important because too much weight will

affect the performance of the car as we are dealing with case study of a
CNG cylinder for a car. As dimensions are kept constant initially,so keeping
that in view, it is clear from the above chart that ASTM A536 and ASTM 40
may be sensible choices while considering the density as the major factor.

Yield strength:
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 Yield strentgh
900
800
700
600
500
400 Yield strentgh
300
200
100
0

0 27 3 40 6 20 0 10 0 45 0 70 36 40
E4 E4 E8 E1 E1 E1 A5 TM
SA SA SA SA SA SA TM AS
AS

Yield strength is an important criterion for the mechanical stability of a

material. ASTM 40 has the greatest yield strength of 827 MPa while other
steels will mostly deform at about 300-400 MPa and SAE 1070 at 495 MPa,
Note that it is the minimum value and it is for the case of compressive
stresses.

Tensile strength:

Tensile strength
800
700
600
500
400
Tensile strength
300
7

200
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100
0
7 0 0 0 5 0 6 0
4 0 2 4 3 4 8 6 2 1 0 1 1 0 4 1 0 7 A 53 M 4
E E E E E E ST
SA SA SA SA SA SA STM A
A

Tensile strength determines to what extent a material is ductile. The

graph shows that ASTM 40 has the least resistance to normal stresses and
it is the most ductile among all. So, it should not be selected for the
situations where normal stresses are very large.

Specific heat:

Thermal properties related with the material for a CNG cylinder are
also crucial.

Specific heat determines how much heat the material would absorb.
Specific heat is directly proportional with its tendency to absorb heat. We
shall be interested in choosing that material with lowest specific heat. The
lowest is SAE1010 and the highest is ASTM A536. ASTM 40 and SAE
1070 are sharing the second spot for the comparison. So, if one wishes to
keep in view specific heat as the main factor, he would naturally go for
SAE1010.

specific heat
520

500

480

460 specific heat

440

420

400
2 7 4 0 2 0 1 0 4 5 7 0 ... 40
40 43 86 10 10 10 TM TM
SA
E
SA
E
SA
E
SA
E
SA
E
SA
E AS AS

Thermal expansion:
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 Thermal expansion
14

12

10

Thermal expansion
6

0 27 3 40 6 20 0 10 0 45 0 70 36 40
E4 E4 E8 E1 E1 E1 A5 TM
SA SA SA SA SA SA TM AS
AS

If the temperature inside the cylinder varies largely, significant

thermal expansion may occur which is known as thermal stress.
The graph shows that ASTM 40 has the maximum resistant to thermal
stresses as its co-efficient of thermal expansion is the lowest

Thermal conductivity:
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 Thermal conductivity
60
50
40
30
Thermal conductivity
20
10
0

0 27 3 40 6 20 0 10 0 45 0 70 36 40
E4 E4 E8 E1 E1 E1 A5 TM
SA SA SA SA SA SA TM AS
AS

The thermal conductivity of a material is a quantitative measure of its

ability to conduct heat. The cylinder under the application of high pressure
(as the CNG name specifies Compressed Natural Gas), if temperature
difference between surrounding and cylinder is high then the heat transfer
will take place which cannot be ignored. Keeping temperature difference
constant, the most efficient material will be the one having the least thermal
conductivity. That material would allow the minimum heat transfer to take
place which will avoid surplus expansion due to high temperature and
hence pressure of the gas.
ASTM 40 has the largest value for thermal conductivity among the all
which is its main disadvantage while ASTM A536 has the lowest.

Comparison of Al-Alloys:

Aluminum is a light weight metal but have low strength that is why it is
used in combination with other materials.
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Below is the tabular data of some of Al-alloys:

Name of Density(Kg/m^ Tensile Yield Specific thermal Thermal

Alloy 3) strength(Mp strength(Mp heat expansion*10 conductivit
a) a) ^-6(20 C) y

Al-Mg 5050 2690 221 55 900 23.8 193

Al-Zn 7005 2780 195 80 875 23.6 166
Al-Mn 3003 2730 110 41 893 23.2 193
Al-Cu 2011 2830 379 296 880 22.9 151
Al-Cu 2014 2800 186 97 880 23 193
Al-Cu 2017 2790 179 69 880 23.6 193

Density:

density
2840
2820
2800
2780
2760
density
2740
2720
2700
2680
05 03 11 14 17
70 30 20 20 20
n n u u u
-Z -M -C -C -C
Al A l Al Al Al

Al-Cu 2011 has the largest value for density making it unsuitable for
weight considerations. Al-Mn3003 has the least density

Yeild Strength:

The graph shows that Al-Cu (especially Al-Cu 2011) has a better and
greater tendency to bear normal stresses than any of the other alloys of
Aluminum.
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 yield strength
350
300
250
200
150 yield strength
100
50
0
50 05 03 11 14 17
g5
0 70 30 20 20 20
n n u u u
l-M -Z -M -C -C -C
A Al A l Al Al Al

Tensile strength:

Tensile strength
400
350
300
250
200
Tensile strength
150
100
50
0
50 05 03 11 14 17
g5
0 70 30 20 20 20
n n u u u
M -Z -M -C -C -C
A l- Al Al Al Al Al
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Al-Cu 2011 has the greatest tensile strength and Al-Mn 3003 has the
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least value.

Specific heat:

All Al-Cu alloys have same value for specific heat but yet Al-Zn 7005
has the least specific heat, making it a bit competent.
 specific heat
905
900
895
890
885
880 specific heat
875
870
865
860
0 05 03 11 14 17
05 70 30 20 20 20
g5 n n u u u
-l M -Z -M -C -C -C
A Al Al Al Al Al

Thermal Expansion:

Thermal expansion
24
23.8
23.6
23.4
23.2
Thermal expansion
23
22.8
22.6
22.4
50 05 03 11 14 17
g5
0 70 30 20 20 20
n n u u u
M -Z -M -C -C -C
A l- Al Al Al Al Al
13

Al-Cu 2011 has the least value for the thermal expansion and this
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thing indicates that it is the most resistant to thermal stresses.

Thermal conductivity:

AL-Cu 2011 has the least conductivity among the all while Al-Mg5050
,Al-MN 3003 and ,Al-Cu 2014 and Al-Cu 2017 have same value that 193.
 thermal conductivity
250

200

150

100 thermal conductivity

50

0
50 05 03 11 14 17
g5
0 70 30 20 20 20
n n u u u
l-M -Z -M -C -C -C
A Al A l Al Al Al

Semi-final decision:

From the above mentioned detailed comparison carried out, we

conclude that among the Al alloys Al-Cu 2011 is the most appropriate and
among the steels ASTM A536 and ASTM 40 are suitable.
Density of Al-Cu 2011 is greatest among Al alloys which constraints
it. ASTM 40 has the greatest thermal conductivity among the steels, while
ASTM A536 has the greatest specific heat value. Now we need to compare
these three.

Density
8000
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7000
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6000
5000
DEnsity
4000
3000
2000
1000
0
Al-Cu 2011 ASTM 40 ASTM A536
 Tensile strength
600

500

400
Tensile strength
300

200

100

0
Al-Cu 2011 ASTM 40 ASTM A536

Specific heat
1000
900
800
700
600 Specific heat
500
400
300
200
100
0
Al-Cu 2011 ASTM 40 ASTM A536
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 Yield strength
900
800
700
600
500 Yield strength

400
300
200
100
0
Al-Cu 2011 ASTM 40 ASTM A536

Thermal conductivity
160
140
120
100
Thermal conductivity
80
60
40
20
0
Al-Cu 2011 ASTM 40 ASTM A536
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Tabular results of graphs:

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Al-Cu 2011 ASTM 40 ASTM A536

density low highest medium
Tensile Strength medium low highest
Specific heat highest low medium
Yield strength low highest medium
Thermal conductivity highest medium low
 So, Al-Cu 2011 is ruled out straight away in the semi-final
comparison. We are left with ASTM 40 and ASTM A536 which are tough
competitors. We shall find out that which one of these two is more
appropriate.

Final decision:
Property ASTM 40 ASTM A536

Corrosion Low Low

resistance
Weldibility Low Low
Machinability Good Good
Castability High Good
Wear resistance Low Low

ASTM A536 is more suitable for the CNG cylinder. Although, it has
relatively a lower castability than ASTM 40 and also it has higher yield
strength, specific heat and co-efficient of thermal expansion.
Despite all these facts and properties it is lighter, has a higher tensile
strength which is very important because we are going to assume that this
case study was for a thin walled cylinder and there are no torsion or shear
stresses.
Difference in the values of co-efficient of thermal expansion and
specific heat is very small, so it does not matter much. Rather the thermal
conductivities do matter and that is significantly low for ASTM A536.
Castability of ASTM 40 is high but that of ASTM A536is good rather than
low.

Result:
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So we chose ASTM A536 for the application in CNG cylinder of car.

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