How do you choose a Material ?

Material EvolutionSince 1960, Polymers have displaced metals….

Growth of composite industry.

Material ConductivityW/m-C

Densitykg/m3

Specific HeatJ/kg-C

Aluminum, 2024, Temper-T351 143.0 2.8E+3 795.0

Beryllium, Pure 175.0 1.85E+3 1.885E+3

Brass, Yellow, 65%Cu-35%Zn 119.0 8.8E+3 380.0

Copper, Alloy, 11000 388.0 8.933E+3 385.0

Copper, Aluminum bronze, 95%Cu-5%Al 83.0 8.666E+3 410.0

Copper, Pure 386.0 8.954E+3 380.0

Copper, Red brass, 85%Cu-9%Sn-6%Zn 61.0 8.714E+3 385.0

Gold, Pure 318.0 18.9E+3 130.0

Iron, Pure 71.8 7.897E+3 452.0

Nickel, Ni-Cr, 90%Ni-10%Cr 17.0 8.666E+3 444.0

Nickel, Pure 99.0 8.906E+3 445.9

Silver, Pure 418.0 10.51E+3 230.0

Steel, Carbon, 1.0%C 43.0 7.801E+3 473.0

Tin, Pure 64.0 7.304E+3 226.5

Titanium 15.6 4.51E+3 544.0

Tungsten 180.0 19.35E+3 134.4

Zinc, Pure 112.2 7.144E+3 384.3

Metal vs PlasticAdvantages of Plastic Fabrication • Ease of forming: • Reduced finishing: • Faster production: • Lighter weight: • Chemical resistance:

Disadvantages of Plastic Fabrication• Limited wear resistance: • Structural weaknesses:. ----------------------------------------------------------------------------------Advantages of Metal Fabrication • Heat resistance: • Improved strength: • Versatility: • Cost-effectiveness:. Disadvantages of Metal Fabrication

• Secondary operations: • Design limitations: • High start-up fees:

SLA machinehttp://www.youtube.com/watch?v=nwQ5HA8sE-k3D Printing - supporthttp://www.youtube.com/watch?v=PDLOmoQj4H0&NR=1&feature=fvwpBasic shape of the Injection machine:http://www.youtube.com/watch?v=l1jNrmpx-Rw&NR=1http://www.youtube.com/watch?v=cANvFsvY0Awhttp://www.youtube.com/watch?v=wScUAoCciGo A & B cavity, ejectorsRib design: play at the endhttp://www.youtube.com/watch?v=a46_fnCXQb8Sheetmetal forming play at the endhttp://www.youtube.com/watch?v=GxysBla3NyIDie castinghttp://www.youtube.com/watch?v=W6VgCaRozq8Ultrasonic machinehttp://www.youtube.com/watch?v=KTe8FBNAREAHow to solder – lead-free-RoHS, Cold-solderhttp://www.youtube.com/watch?v=I_NU2ruzyc4Electroplating of the plastic-hard, salt testings – environmentalhttp://www.youtube.com/watch?v=I_u_nh_78lEPanasonic SMT- speed – vision systemhttp://www.youtube.com/watch?v=4_MofAvgJC8SMT reflow soldering- speed uphttp://www.youtube.com/watch?v=5AUpN5kfiLc&NR=1

Material

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Typical Applications WeaknessesHIPS (styrene) 0.44-0.52 1.04 306,000 330,000 5.0x10-5 Fair Variable Good Case parts (SAN for windows) Chemical resistance, HDT, mechanical propsABS 0.50-0.58 1.04 330,000 380,000 Fair Variable Good Case parts, mech parts Chemical resistance, mechanical propsABS 20% GF 0.69-0.74 1.22 870,000 850,000 2.0x10-5 Poor Variable Good Mech parts Chemical resistance, mechanical propsAcetal (POM) 0.62-0.66 1.41 375,000 Good Excellent Good (small parts) Gears/small parts, friction & wear, chemical High shrink, dimensional stability for medium/large parts, wear on selfPolycarbonate 1.19-1.54 1.2 340,000 340,000 3.7x10-5 Fair Variable Excellent Chemical resistancePolycarbonate 20% GF 1.14-1.30 1.34 1,000,000 850,000 1.5x10-5 Poor Variable Excellent High precision parts Chemical resistanceNoryl 2.18-2.28 1.06 360,000 3.3x10-5 Fair Variable Good Mech parts Processing, tool erosion, single sourceNoryl 20% GF 1.25-1.35 1.2 942,000 800,000 2.0x10-5 Poor Variable Good Mech parts Processing, surface appearance, tool wear and erosion, single sourcePET 15% GF 1.12-1.37 1.47 850,000 1.2x10-5 Fair/Good Excellent Good Mech parts, chemical, friction/wear Processing, tool erosionPolypropylene 20% GF 0.99-1.09 1.14 470,000 Fair/Good Excellent Fair Mech parts, chemical, friction/wear Processing, dimensional stability for medium/large partsPolypropylene 40% GF 0.85-0.95 1.22 1,000,000 Fair/Good Excellent Fair Mech parts, chemical, friction/wear Processing, dimensional stability for medium/large parts