CHAPTER 1 Introduction 1
1.1 Introduction and Synopsis 2
1.2 Materials in Design 2
1.3 The Evolution of Engineering Materials 4
1.4 The Evolution of Materials in Products 8
1.5 Summary and Conclusions 12
1.6 Further Reading 12
CHAPTER 2 The Design Process 15
2.1 Introduction and Synopsis 16
2.2 The Design Process 16
2.3 Types of Design 20
2.4 Design Tools and Materials Data 21
2.5 Function， Material， Shape， and Process 23
2.6 Case Study： Devices to Open Corked Bottles 24
2.7 Summary and Conclusions 27
2.8 Further Reading 27
CHAPTER 3 Engineering Materials and Their Properties 31
3.1 Introduction and Synopsis 32
3.2 The Families of Engineering Materials 32
3.3 Materials Information for Design 35
3.4 Material Properties and Their Units 38
3.5 Summary and Conclusions 54
3.6 Further Reading 55
CHAPTER 4 Material Property Charts 57
4.1 Introduction and Synopsis 58
4.2 Exploring Material Properties 59
4.3 The Material Property Charts 64
4.4 Summary and Conclusions 93
4.5 Further Reading 95
CHAPTER 5 Materials Selection—The Basics 97
5.1 Introduction and Synopsis 98
5.2 The Selection Strategy 99
5.3 Material Indices 106
5.4 The Selection Procedure 115
5.5 Computer-aided Selection 120
5.6 The Structural Index 122
5.7 Summary and Conclusions 123
5.8 Further Reading 123
CHAPTER 6 Case Studies： Materials Selection 125
6.1 Introduction and Synopsis 126
6.2 Materials for Oars 127
6.3 Mirrors for Large Telescopes 130
6.4 Materials for Table Legs 134
6.5 Cost： Structural Materials for Buildings 138
6.6 Materials for Flywheels 142
6.7 Materials for Springs 146
6.8 Elastic Hinges and Couplings 151
6.9 Materials for Seals 154
6.10 Deflection-limited Design with Brittle Polymers 155
6.11 Safe Pressure Vessels 160
6.12 Stiff， High-damping Materials for Shaker Tables 165
6.13 Insulation for Short-term Isothermal Containers 169
6.14 Energy-efficient Kiln Walls 172
6.15 Materials for Passive Solar Heating 175
6.16 Materials to Minimize Thermal Distortion in Precision Devices 178
6.17 Materials for Heat Exchangers 181
6.18 Heat Sinks for Hot Microchips 186
6.19 Materials for Radomes 189
6.20 Summary and Conclusions 194
6.21 Further Reading 194
CHAPTER 7 Multiple Constraints and Conflicting Objectives 197
7.1 Introduction and Synopsis 198
7.2 Selection with Multiple Constraints 199
7.3 Conflicting Objectives 203
7.4 Summary and Conclusions 211
7.5 Further Reading 211
7.6 Appendix： Weight Factors and Fuzzy Methods 212
CHAPTER 8 Case Studies： Multiple Constraints and Conflicting Objectives 217
8.1 Introduction and Synopsis 218
8.2 Multiple Constraints： Light Pressure Vessels 218
8.3 Multiple Constraints： Con-rods for High-performance Engines 222
8.4 Multiple Constraints： Windings for High-field Magnets 226
8.5 Conflicting Objectives： Table Legs Again 232
8.6 Conflicting Objectives： Wafer-thin Casings for Must-have Electronics 233
8.7 Conflicting Objectives： Materials for a Disk-brake Caliper 237
8.8 Summary and Conclusions 241
CHAPTER 9 Selection of Material and Shape 243
9.1 Introduction and Synopsis 244
9.2 Shape Factors 246
9.3 Limits to Shape Efficiency 257
9.4 Exploring Material-shape Combinations 260
9.5 Material Indices That Include Shape 265
9.6 Graphical Coselecting Using Indices 269
9.7 Architectured Materials： Microscopic Shape 270
9.8 Summary and Conclusions 274
9.9 Further Reading 276
CHAPTER 10 Case Studies： Material and Shape 277
10.1 Introduction and Synopsis 278
10.2 Spars for Human-powered Planes 279
10.3 Forks for a Racing Bicycle 282
10.4 Floor Joists： Wood， Bamboo， or Steel？ 284
10.5 Table Legs Yet Again： Thin or Light？ 287
10.6 Increasing the Stiffness of Steel Sheet 289
10.7 Shapes that Flex： Leaf and Strand Structures 291
10.8 Ultra-efficient Springs 293
10.9 Summary and Conclusions 296
CHAPTER 11 Designing Hybrid Materials 299
11.1 Introduction and Synopsis 300
11.2 Holes in Material-property Space 303
11.3 The Method： “A + B + Configuration + Scale” 305
11.4 Composites 307
11.5 Sandwich Structures 316
11.6 Cellular Structures： Foams and Lattices 328
11.7 Segmented Structures 336
11.8 Summary and Conclusions 338
11.9 Further Reading 339
CHAPTER 12 Case Studies： Hybrids 341
12.1 Introduction and Synopsis 342
12.2 Designing Metal Matrix Composites 342
12.3 Flexible Conductors and Percolation 344
12.4 Extreme Combinations of Thermal and Electrical Conduction 347
12.5 Refrigerator Walls 349
12.6 Materials for Microwave-transparent Enclosures 352
12.7 Connectors That Don’t Relax Their Grip 354
12.8 Exploiting Anisotropy： Heat-spreading Surfaces 356
12.9 The Mechanical Efficiency of Natural Materials 358
12.10 Further Reading： Natural Materials 365
CHAPTER 13 Processes and Process Selection 367
13.1 Introduction and Synopsis 368
13.2 Classifying Processes 369
13.3 The Processes： Shaping， Joining， Finishing 372
13.4 Processing for Properties 388
13.5 Systematic Process Selection 392
13.6 Ranking： Process Cost 406
13.7 Computer-aided Process Selection 411
13.8 Summary and Conclusions 413
13.9 Further Reading 413
CHAPTER 14 Case Studies： Process Selection 415
14.1 Introduction and Synopsis 416
14.2 Casting an Aluminum Con-rod 416
14.3 Forming a Fan 419
14.4 Spark Plug Insulators 429
14.5 A Manifold Jacket 431
14.6 Joining a Steel Radiator 433
14.7 Surface-hardening a Ball-bearing Race 435
14.8 Summary and Conclusions 436
CHAPTER 15 Materials and the Environment 437
15.1 Introduction and Synopsis 438
15.2 The Material Life-cycle 438
15.3 Material and Energy-consuming Systems 440
15.4 The Eco-attributes of Materials 442
15.5 Eco-selection 447
15.6 Case Studies： Drink Containers and Crash Barriers 453
15.7 Summary and Conclusions 457
15.8 Further Reading 458
CHAPTER 16 Materials and Industrial Design 461
16.1 Introduction and Synopsis 462
16.2 The Requirements Pyramid 463
16.3 Product Character 464
16.4 Using Materials and Processes to Create Product Personality 467
16.5 Summary and Conclusions 476
16.6 Further Reading 476
CHAPTER 17 Forces for Change 479
17.1 Introduction and Synopsis 480
17.2 Market Pull and Science Push 480
17.3 Growing Population and Wealth and Market Saturation 487
17.4 Product Liability and Service Provision 487
17.5 Miniaturization and Multifunctionality 489
17.6 Concern for the Environment and for the Individual 490
17.7 Summary and Conclusions 492
17.8 Further Reading 492
APPENDIX A Data for Engineering Materials 495
Table A.1 Names and Applications： Metals and Alloys；Polymers and Foams； and Composites，Ceramics， Glasses， and Natural Materials 497
Table A.2 Melting Temperature， Tm， and Glass Temperature， Tg 500
Table A.3 Density， ρ 502
Table A.4 Young’s Modulus， E 504
Table A.5 Yield Strength， σy， and Tensile Strength， σts 506
Table A.6 Fracture Toughness （plane strain）， KIc 508
Table A.7 Thermal Conductivity， λ， and Thermal Expansion， α 510
Table A.8 Heat Capacity， Cp 512
Table A.9 Resistivity and Dielectric Constant 514
Table A.10 Embodied Energy and CO2 Footprint 516
Table A.11 Approximate Material Prices， Cm 518
Ways of Checking and Estimating DatA 520
Further Reading 523
APPENDIX B Useful Solutions for Standard Problems 525
Introduction and Synopsis 527
B.1 Constitutive Equations for Mechanical Response 528
B.2 Moments of Sections 530
B.3 Elastic Bending of Beams 532
B.4 Failure of Beams and Panels 534
B.5 Buckling of Columns， Plates， and Shells 536
B.6 Torsion of Shafts 538
B.7 Static and Spinning Disks 540
B.8 Contact Stresses 542
B.9 Estimates for Stress Concentrations 544
B.10 Sharp Cracks 546
B.11 Pressure Vessels 548
B.12 Vibrating Beams， Tubes， and Disks 550
B.13 Creep and Creep FracturE. 552
B.14 Flow of Heat and Matter 554
B.15 Solutions for Diffusion Equations 556
B.16 Further Reading 558
APPENDIX C Material Indices 559
C.1 Introduction and Synopsis 560
C.2 Uses of Material Indices 560
APPENDIX D Data Sources for Documentation 565
D.1 Introduction 566
D.2 Information Sources for Materials 566
D.3 Information for Manufacturing Processes 589
D.4 Databases and Expert Systems as SoftwarE 590
D.5 Additional Useful Internet Sites 592
APPENDIX E Exercises 595
E.1 Introduction to Exercises 595
E.2 Material Evolution in Products （Chapter 1） 596
E.3 Devising Concepts （Chapter 2） 597
E.4 Using Material Properties （Chapter 3） 597
E.5 Using Material Property Charts （Chapter 4） 599
E.6 Translation： Constraints and Objectives （Chapters 5 and 6） 602
E.7 Deriving and Using Material Indices （Chapters 5 and 6） 605
E.8 Multiple Constraints and Objectives （Chapters 7 and 8） 613
E.9 Selecting Material and Shape （Chapters 9 and 10） 622
E.10 Hybrid Materials （Chapters 11 and 12） 629
E.11 Selecting Processes （Chapters 13 and 14） 633
E.12 Materials and the Environment （Chapter 15） 638
INDEX 641