Final Production / 4.1 /
Properties of Materials
Final Production / 4.1 /
Properties of Materials
Materials are selected for manufacturing products based primarily on their properties. The rapid pace of scientific discovery and new technologies has had a major impact on material science, giving designers many more materials from which to choose for their products. These new materials have given scope for “smart” new products or enhanced classic designs. Choosing the right material is a complex and difficult task with physical, aesthetic, mechanical and appropriate properties to consider. Environmental, moral and ethical issues surrounding the choice of materials for use in any product, service or system also need to be considered.
Physical properties are inherent characteristics of a material that can be observed or measured without applying external forces. These properties describe the material itself, regardless of how it will behave under stress. Physical properties commonly considered in design are weight, mass, volume, density, electrical resistivity, thermal conductivity, thermal expansion and hardness.
Mass: The amount of matter an object contains, constant regardless of location (measured in kilograms, kg).
Weight: The force exerted on an object due to gravity (depends on location, measured in Newtons, N). Think of weight as the heaviness you feel.
Volume: The amount of space an object occupies (measured in cubic meters, m³).
Density: How much mass is packed into a unit volume (mass per unit volume, kg/m³). High density means more mass in a smaller space. Opposite: Friability.
Electrical resistivity: How strongly a material opposes electric current (measured in ohm-meters, Ω⋅m). High resistivity means a material is a good insulator. Low resistivity means a material is a good conductor.
Thermal conductivity: How well a material conducts heat (measured in watts per meter-kelvin, W/(m⋅K)). High conductivity means heat flows easily.
Thermal expansion: How much a material's dimensions change with temperature (usually a unitless ratio). Higher expansion means it grows more when heated.
Hardness: A material's resistance to permanent indentation (various scales like Rockwell, Vickers or Mohs). Harder materials scratch softer ones more easily. Opposite: softness.
Weight and Mass are often confused and used interchangeably. Mass is the amount of matter contained in a space. Mass is measured in kg. The mass of an object is constant, regardless of where it is measured. A 2kg object on Earth will have the same mass of 2kg on Mars.
Mechanical properties tell you how a material responds to external forces. They describe the material's behaviour under stress or strain. Mechanical properties commonly considered in design are tensile strength, compressive strength, stiffness, toughness, hardness, ductility, elasticity, plasticity and Young’s modulus. Think of it this way: physical properties are like a material's identity card, while mechanical properties are like its report card on how it performs under pressure.
Strength: More specifically tensile strength, compressive strength, shear strength, yield strength or breaking strength. Strength is a general term describing the ability of a material to withstand stress without breaking.
Tensile strength: The maximum stress a material can withstand before pulling apart. High tensile strength is crucial for suspension cables in bridges and elevators, which need to bear weight without snapping.
Compressive strength: The maximum stress a material can withstand before crushing. Concrete has excellent compressive strength, making it ideal for building foundations that support massive structures.
Stiffness: Resistance to elastic deformation under load. It describes how much a material bends before breaking. I-beams used in buildings are designed with high stiffness to minimize bending under heavy loads placed on floors.
Ductility: The ability to deform plastically under tension without breaking (drawability as opposed to brittleness. Imagine stretching a wire. Copper wires are ductile, allowing them to be drawn into thin wires for electrical applications.
Toughness: The ability of a material to absorb energy before fracturing (impact resistance or fracture resistance as opposed to brittleness). It combines both strength and ductility. Steel is a tough material because it can withstand a significant impact without breaking, making it suitable for car frames.
Elasticity: Ability of a material to return to its original shape after deformation (resilience or springiness as opposed to plasticity). Think of a rubber band snapping back. Springs rely on elasticity to store and release energy, using their ability to return to their original shape. Pole-vaulting poles need to flex when a force is applied to it in order to propel the athlete over the bar.
Plasticity: The ability of a material to deform permanently under stress, without breaking (yielding as opposed to elasticity). Imagine bending clay to a new shape. Aluminum is a good example of a plastic material. It can be bent and moulded into different shapes without breaking.
Malleability: Ability of a material to be hammered or pressed into thin sheets without breaking (pliability as opposed to brittleness ).
Fatigue Strength or endurance limit: Maximum stress a material can withstand for a specific number of loading cycles without failure.
Creep: Tendency of a material to deform slowly under a constant load over time.
Abrasion resistance: Ability of a material to resist wear and tear from friction.
Young's Modulus: A measure of stiffness that relates stress to strain in the elastic region. A higher Young's Modulus indicates a stiffer material. Piano wires require a high Young's Modulus to maintain their tight tension and vibrate at precise frequencies when struck, producing clear musical notes.
Young's Modulus is a measure of the stiffness of an elastic material. It is the ratio of stress to strain of a material as force is applied along its length.
A low Young's modulus value means a solid is elastic.
A high Young's modulus value means a solid is inelastic or stiff.
Each material has its own unique modulus.
As a designer or an engineer, it is necessary to understand what the graph represents, and how it would influence the choice of materials. As a designer, the goal is to find the ideal material for a design.
Material A represents a material that can withstand a great amount of force but then fails suddenly. It is brittle, and would likely break into many small pieces. Glass or ceramics would be a good example. There is no elastic zone.
Material B represents a material that is strong, but not ductile. Steel wires are very strong but break suddenly. There is a small elastic zone.
Material C represents a material that is ductile and could be extruded to create wires or cables. Gold and silver are good examples.
Material D represents a very plastic material. It has almost no elastic zone, and a very large plastic zone. Clingwrap would be an example.
Stress and Strain are usually plotted on a graph that shows the relationship between the amount of force applied (Stress) and how much the materials change in length (or deform in a different way).
Think of the graph of telling a journey. As more force (often tension) is applied to the material sample, it will undergo a series of changes. It will move through different zones, each affecting its performance characteristics, until it reaches a fracture point (it breaks).
The linear first part of the graph indicates the elastic region. If the material was stretched and then the force was released, it would return to its original shape.
The Yield Point is the point at which the material will no longer return to its original shape. It has now entered the plastic region.
The Ultimate (Tensile) Strength (UTS) is the point at which the material can maintain a maximum load. After this point, the material is moving towards its fracture or failure point. Necking occurs between the ultimate strength and fracture.
Material selection charts compare two material properties. The materials are plotted on the chart and displayed in groups. Material selection charts help designers choose suitable materials for their designs.
Aesthetic properties of materials aren't as clearly defined as physical or mechanical properties. They deal with how a material appeals to our senses, and perception can be subjective. However, some common characteristics contribute to a material's aesthetic appeal:
Visual (appearance): This includes properties like colour, gloss, transparency, and pattern. These properties can be influenced by factors like:
Surface finish: Polishing, sanding, or etching can alter a material's visual and tactile qualities.
Light interaction: How a material reflects, absorbs, or transmits light can affect its perceived colour and texture.
Tactile (texture): How a material feels to the touch, such as smooth, rough, soft, hard, cool, or warm.
Auditory: Some materials have unique sounds associated with them, like the crackle of wood burning or the clink of glass.
While taste and smell are technically senses involved with materials, they're often associated with consumption rather than inherent material properties.
Mixing materials with different aesthetic properties can create interesting contrasts or complements.
Smart materials, also called intelligent or responsive materials, are a group of engineered materials that can significantly change one or more of their properties in a controlled and reversible way. This change happens in response to external stimuli, such as:
Physical: Stress, moisture, temperature
Electrical: Electric fields, voltage
Magnetic: Magnetic fields
Chemical: Chemical compounds, pH
Light
These changes allow smart materials to act as sensors, actuators, or even mimic biological muscles. Smart materials can open up new and innovative possibilities for product designs. Here are some cool properties of some smart materials:
Piezoelectricity: Generates electricity when mechanically stressed (pressure, vibration). Piezoelectric crystals are used in pressure sensors, like those in car airbags, which detect a collision and trigger airbag deployment.
Shape Memory: Returns to a pre-defined shape upon heating or exposure to another stimulus. Shape memory alloy (SMA) eyeglass frames can be adjusted to fit perfectly and then "remember" that shape when heated by body temperature.
Photochromicity: Changes color reversibly in response to light. Photochromic lenses in eyeglasses darken in sunlight, acting like sunglasses, and lighten indoors for better vision.
Magneto-rheostatic fluids: Fluid whose viscosity changes dramatically in a magnetic field. Magneto-rheostatic dampers are used in high-performance car suspensions, adjusting fluid viscosity to control shock absorption based on driving conditions.
Electro-rheostatic fluids: Fluid whose viscosity changes dramatically when an electric field is applied. The change can be almost instantaneous. The change can change from a thick fluid to a solid almost instantaneously. The rapidly changing viscosity of ER fluids has potential applications in haptic devices, which provide users with tactile feedback. By controlling the electric field and thus the stiffness of the ER fluid, these devices could simulate different textures or sensations during interaction with virtual objects.
Thermoelectricity: Converts heat into electricity or vice versa.Thermoelectric generators can be used in remote areas to convert waste heat from car engines or power plants into electricity