Challenges in materials and process selection

Recent developments are outlined of materials and process selection methods leading towards industrial applications. The systematic implementation of selection for multiple criteria and multiple design elements is presented as a natural extension of Ashby's method. The importance of a “pre-defined questionnaire” approach in process selection is illustrated for casting, joining and surface treatments. The use of materials selection methods for materials and multi-materials development is described for the case of glass, composite materials and sandwich structures, and the application of various optimization techniques adapted to each problem is given. In conclusion, possible new developments toward a better integration of materials and process selection in the whole design procedure are proposed.     

An aggregation technique for optimal decision-making in materials selection

Materials selection is an onerous but very important activity in the design process. An inappropriate choice of material(s) can adversely affect the productivity and profitability and hence reputation of a manufacturing organization. The complexity of materials selection makes multi-criteria analysis an invaluable tool in the engineering design process. However, the application of various multi-criteria decision making (MCDM) methods can yield different results, especially when alternatives lead to similar performance. Therefore, an aggregation technique is proposed in this paper for optimal decision-making. In this approach, ranking orders obtained by various MCDM methods are used as the input of the suggested procedure and the outputs are aggregation rankings, which help designers and engineers to reach a consensus on materials selection for a specific application. An illustrative example is given to demonstrate the application of this procedure and its effectiveness in obtaining optimal materials selection.     

Introducing a novel method for materials selection in mechanical design using Z-transformation in statistics for normalization of material properties

Optimum materials selection is a very important task in design process of every product. There are various materials selection methods like Ashby’s method or digital logic methods such as DL and MDL. In the present research work the Z-transformation method is proposed for scaling the material properties to overcome the shortcoming of MDL method. The results show that despite the simple scaling function used, the ranking procedure is as powerful as MDL method and even it is superior to MDL when it ranks the less important materials existing among a list of candidate materials.     

A target-based normalization technique for materials selection

Ranking and selection of the optimal material is an important stage in the engineering design process. However, most of the methods proposed for ranking in materials selection have tended to focus on cost and benefit criteria, with target values receiving much less attention in spite of their importance in many practical decision-making problems such as selecting materials to best match the properties of human tissue in biomedical engineering applications. In response to this perceived gap, the development of a new normalization technique is considered in this paper that provides an extension of the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method and objective weighting in materials selection. There are four example cases included to validate the accuracy of outcomes from the proposed model. It is believed that the proposed decision-making model is suitable for linking to material databases and has the potential to enhance the efficiency of computer-aided materials selection systems.     

Arrays of indefinitely long uniform nanowires and nanotubes

Nanowires are arguably the most studied nanomaterial model to make functional devices and arrays. Although there is remarkable maturity in the chemical synthesis of complex nanowire structures, their integration and interfacing to macro systems with high yields and repeatability still require elaborate aligning, positioning and interfacing and post-synthesis techniques. Top-down fabrication methods for nanowire production, such as lithography and electrospinning, have not enjoyed comparable growth. Here we report a new thermal size-reduction process to produce well-ordered, globally oriented, indefinitely long nanowire and nanotube arrays with different materials. The new technique involves iterative co-drawing of hermetically sealed multimaterials in compatible polymer matrices similar to fibre drawing. Globally oriented, endlessly parallel, axially and radially uniform semiconducting and piezoelectric nanowire and nanotube arrays hundreds of metres long, with nanowire diameters less than 15 nm, are obtained. The resulting nanostructures are sealed inside a flexible substrate, facilitating the handling of and electrical contacting to the nanowires. Inexpensive, high-throughput, multimaterial nanowire arrays pave the way for applications including nanowire-based large-area flexible sensor platforms, phase-changememory, nanostructure-enhanced photovoltaics, semiconductor nanophotonics, dielectric metamaterials,linear and nonlinear photonics and nanowire-enabled high-performance composites.     

Materials and Process Selection from Teaching to Research and Back: the Rhone Alpes Experience

The development of systematic methods for materials and process selection is a relatively new field. The variety of materials and processes available to the engineer, as well as the complexity of the set of requirements encountered in industrial situations, are the driving forces behind the development of software aiming at the guidance of the designer. Born as pedagogical tools, such software, tailored for a given class of materials or of applications, has now in certain cases reached a degree of specialization that is mature and applicable to the industrial design process.     

Hybrid Data-Driven and Mechanistic Modeling Approaches for Multiscale Material and Process Design

The world’s increasing population requires the process industry to produce food, fuels, chemicals, and consumer products in a more efficient and sustainable way. Functional process materials lie at the heart of this challenge. Traditionally, new advanced materials are found empirically or through trial-and-error approaches. As theoretical methods and associated tools are being continuously improved and computer power has reached a high level, it is now efficient and popular to use computational methods to guide material selection and design. Due to the strong interaction between material selection and the operation of the process in which the material is used, it is essential to perform material and process design simultaneously. Despite this significant connection, the solution of the integrated material and process design problem is not easy because multiple models at different scales are usually required. Hybrid modeling provides a promising option to tackle such complex design problems. In hybrid modeling, the material properties, which are computationally expensive to obtain, are described by data-driven models, while the well-known process-related principles are represented by mechanistic models. This article highlights the significance of hybrid modeling in multiscale material and process design. The generic design methodology is first introduced. Six important application areas are then selected: four from the chemical engineering field and two from the energy systems engineering domain. For each selected area, state-of-the-art work using hybrid modeling for multiscale material and process design is discussed. Concluding remarks are provided at the end, and current limitations and future opportunities are pointed out.     

Selection of porous materials in marine system design: The case of heat exchanger aboard ships

Porous materials are processed in various areas of material science and manufacturing. Furthermore, the varieties of porous materials ensure great advantages to designers. This paper proposes a decision aid mechanism based on fuzzy axiomatic design (FAD) to select adequate form of porous materials in marine systems design. It enables elimination and choice of suitable material alternatives in respect to two sets of attributes: generic material selection attributes (GMSA) and specific material selection attributes (SMSA). Furthermore, the paper specifically addressed use of porous materials in plate type heat exchanger design to demonstrate the proposed model. It is expected that the paper ensures a novel procedure for marine engineers and naval architectures in conceptual design process of marine systems.     

Patterned Arrays of Functional Lateral Heterostructures via Sequential Template‐Directed Printing

The precise integration of microscale dots and lines with controllable interfacing connections is highly important for the fabrication of functional devices. To date, the solution‐processible methods are used to fabricate the heterogeneous micropatterns for different materials. However, for increasingly miniaturized and multifunctional devices, it is extremely challenging to engineer the uncertain kinetics of a solution on the microstructures surfaces, resulting in uncontrollable interface connections and poor device performance. Here, a sequential template‐directed printing process is demonstrated for the fabrication of arrayed microdots connected by microwires through the regulation of the Rayleigh–Taylor instability of material solution or suspension. Flexibility in the control of fluidic behaviors can realize precise interface connection between the micropatterns, including the microwires traversing, overlapping or connecting the microdots. Moreover, various morphologies such as circular, rhombic, or star‐shaped microdots as well as straight, broken or curved microwires can be achieved. The lateral heterostructure printed with two different quantum dots displays bright dichromatic photoluminescence. The ammonia gas sensor printed by polyaniline and silver nanoparticles exhibits a rapid response time. This strategy can construct heterostructures in a facile manner by eliminating the uncertainty of the multimaterials interface connection, which will be promising for the development of novel lateral functional devices.     

Material selection for the tool holder working under hard milling conditions using different multi criteria decision making methods

Nowadays machining of materials in their hardened state, also called hard machining, is a challenge in production of tools and molds. It has some advantages such as lower process time and lower manufacturing cost when compared to conventional machining. In machining of hard workpiece materials, however, very high stresses act on the tool holder through the cutting tool. These stresses necessitate the tool holder to have some specific properties. Especially in hard milling, the tool holder should have high stiffness and should be able to dissipate the energy generated during interrupted cutting. Material cost of the tool holder is also important since lower costs provide a competitive advantage for manufacturers. The material selection for the tool holder should be conducted considering aforementioned requirements. To tackle the difficulty of the material selection with specific properties from a large number of alternatives, multi-criteria decision-making (MCDM) methods have been used. In this paper a decision model including extended PROMETHEE II (EXPROM2) (preference ranking organization method for enrichment evaluation), TOPSIS (technique for order performance by similarity to ideal solution) and VIKOR (VIšekriterijumsko KOmpromisno Rangiranje) methods were used for the selection of the best material for the tool holder used in hard milling. The criteria weighting was performed by compromised weighting method composed of AHP (analytic hierarchy process) and Entropy methods. The candidate materials were ranked by using these methods and the results obtained by each method were compared. It was confirmed that MCDM methods can be used for the solution of real time material selection problems. Tungsten carbide–cobalt and Fe–5Cr–Mo–V aircraft steel were found as the best materials for the tool holder production. The obtained results are found to be rather satisfactory and can be used in design stage of hard machining operations.     

Materials optimization ∼ The key to product profitability

This paper describes the relationship of materials selection to the design and manufacture of an engineering component. A systematic approach to materials selection, and commonly used methods of assessing candidate materials are described, with particular reference to a specific example, a magnetic-coupled drive pump. Particular importance is attached to the availability of comparative information on the performance and properties of the engineering materials under consideration. The influence of total cost on the selection of the optimum material is discussed.     

Filtration in materials selection and multi-materials design

Materials selection methods by free searching consist in four steps: translation, filtration, classification and documentation. The second step, limiting the field of solutions, must be analysed accurately when the constraints are related with free design parameters. This paper describes methods to deal with this filtration step in the cases of materials selection and multi-materials design. The classical filtration in single materials selection is extended to cases with several free geometric parameters. Then, a filtration approach for multi-materials design with undefined number of components and free geometric parameters is proposed. Finally, a case study concerning the design of a pipe material for offshore oil extraction is presented. The application of this work allows a preliminary elimination of unsuitable materials in the definition of multi-materials components, so it will be useful to avoid long numerical studies.     

Shape, sizing optimization and material selection based on mixed variables and genetic algorithm

In this work, we explore simultaneous designs of materials selection and structural optimization. As the material selection turns out to be a discrete process that finds the optimal distribution of materials over the design domain, it cannot be performed with common gradient-based optimization methods. In this paper, material selection is considered together with the shape and sizing optimization in a framework of multiobjective optimization of tracking the Pareto curve. The idea of mixed variables is often introduced in the case of mono-objective optimization. However, in the case of multi-objective optimization, we still face some hard key points related to the convexity and the continuity of the Pareto domain, which underline the originality of this work. In addition to the above aspect, there is a lack in the literature concerning the industrial applications that consider the mixed parameters. Continuous variables refer to structural parameters such as thickness, diameter and spring elastic constants while material ID is defined as binary design variable for each material. Both mechanical and thermal loads are considered in this work with the aim of minimizing the maximum stress and structural weight simultaneously. The efficiency of the design procedure is demonstrated through various numerical examples.     

Microtopography‐Guided Radial Gradient Circle Array Film with Nanoscale Resolution

Distribution of multimaterials at arbitrary positions with nanoscale resolution and over a large area substrate is essential to future advances in functional graded materials. Such stringent requirements are highly beyond the reach of current techniques, although newly developed 3D printing technologies are addressed. Here, a radial gradient circle array film with the distribution accuracy up to ≈18 nm is fabricated by using microtopographic substrate. A mathematical model is developed to guide the distribution of position, size, shape, and type of materials on an arbitrary section for the given morphology of substrate. The periodic electrical and mechanical properties of the radial gradient circle film are identified, which can be beneficial for further functionalization and applications, such as gradient refractive index lenses, microcoils, and microantennas.     

Concurrent engineering approach in the development of composite products: A review

Concurrent Engineering (CE) is regarded as a systematic design approach which integrates concurrent design of product with the related processes which is able to accomplish product that can be produced at lower cost, shorter time and with higher quality and this achievement was termed as cost, time and quality (CTQ) improvement. Since its establishment, CE philosophy was well implemented in product development with traditional materials such as metals but up to date, the work on CE in composite product development is still limited. Hence, a review on the implementation of Concurrent Engineering (CE) approach in the development of composite products is presented in this paper which includes review of various studies of CE techniques in composite product development. In addition, the relationship between CE and Pugh total design method is discussed in the context of composite design. Moreover, publications related to materials selection, life cycle analysis and sustainability issues of composite materials are also reviewed whereby a section is devoted to highlight previous work on materials selection using Analytical Hierarchy Process method. It was observed that materials selection of composite materials is a very important activity as far as CE in composite product development. The use of various techniques and computer aided materials selection tools such as Analytical Hierarchy Process has helped designers to select the most optimum composite materials for engineering components. Furthermore, based on current trends in composites product development, the role of CE is expected to be more crucial to assist composites designers in achieving the design requirements from various stakeholders effectively and efficiently considering the expanding range of composite materials availability as well as realizing new potential for biocomposites applications through introduction of innovative alternative problem solving methods as part of the CE family.     

Materials selection using complex proportional assessment and evaluation of mixed data methods

Material selection is a very fast growing multi-criteria decision-making (MCDM) problem involving a large number of factors influencing the selection process. Proper choice of material is a critical issue for the success and competitiveness of the manufacturing organizations in the global market. Selection of the most appropriate material for a particular engineering application is a time consuming and expensive process where several candidate materials available in the market are taken into consideration as the tentative alternatives. Although a large number of mathematical approaches is now available to evaluate, select and rank the alternative materials for a given engineering application, this paper explores the applicability and capability of two almost new MCDM methods, i.e. complex proportional assessment (COPRAS) and evaluation of mixed data (EVAMIX) methods for materials selection. These two methods are used to rank the alternative materials, for which several requirements are considered simultaneously. Two illustrative examples are cited which prove that these two MCDM methods can be effectively applied to solve the real time material selection problems. In each example, a list of all the possible choices from the best to the worst suitable materials is obtained which almost match with the rankings as derived by the past researchers.     

Multiphase topology optimization with a single variable using the phase-field design method

In this study, a multimaterial topology optimization method using a single variable is proposed by combining the solid isotropic material with penalization method and the reaction-diffusion equation. Unlike ordinary multimaterial optimization, which requires several variables depending on the number of material types, this method intends to represent various materials as one variable. The proposed method combines two special functions in the sensitivity analysis of the objective function to converge the design variable into prespecified density values defined for each of the multimaterials. The composition constraint based on a normal distribution function is also introduced to estimate the distribution of each target density value in a single variable. It enables density exchange between multiple materials by increasing or decreasing the amount of a specific material. The proposed method is applied to structural and electromagnetic problems to verify its effectiveness, and its usefulness is also confirmed from the viewpoint of cost and computation time.     

Selection of materials using compromise ranking and outranking methods

Selection of proper materials for different components is one of the most challenging tasks in the design and development of products for diverse engineering applications. Materials play a crucial and important role during the entire design and manufacturing process. Wrong selection of material often leads to huge cost involvement and ultimately drives towards premature component or product failure. So the designers need to identify and select proper materials with specific functionalities in order to obtain the desired output with minimum cost involvement and specific applicability. This paper attempts to solve the materials selection problem using two most potential multi-criteria decision-making (MCDM) approaches and compares their relative performance for a given material selection application. The first MCDM approach is ‘Vlse Kriterijumska Optimizacija Kompromisno Resenje’ (VIKOR), a compromise ranking method and the other one is ‘ELimination and Et Choice Translating REality’ (ELECTRE), an outranking method. These two methods are used to rank the alternative materials, for which several requirements are considered simultaneously. Two examples are cited in order to demonstrate and validate the effectiveness and flexibility of these two MCDM approaches. In each example, a list of all the possible choices from the best to the worst suitable materials is obtained taking into account different material selection criteria. The rankings of the selected materials almost corroborate with those as obtained by the past researchers.     

三维全五向编织复合材料的特性及制备

三维编织复合材料是一种先进复合材料,在航空航天等尖端领域的应用越来越广泛。本文分析了传统三维编织复合材料的优势、用途及存在的缺陷和不足,并提出了改进该材料性能的可能途径,即发展一种新的三维全五向编织复合材料。针对三维全五向编织复合材料这种新型的编织形式,提出了几种可能的工艺实现途径,指出用四步法编织是对材料性能影响最小,最可能实现工业化生产的途径。最后,以三维全五向编织法兰为例,对其在制备过程中的材料选择、模具设计及固化工艺进行了详细的讨论。     

A tool for meaning driven materials selection

There are several tools used in materials selection processes by designers. However, they are mostly engineering based tools, which are dominated by numerical (or technical) material data that is mostly of use in embodiment or detailed design phases of new product development. On the other hand, product designers consider certain aspects such as product personality, user-interaction, meanings, emotions in their material decisions. In this regard, existing tools and methods do not fully support designers in their materials selection processes. This paper describes the development of a new materials selection tool holding the idea of [meaning driven materials selection]. In addition, the paper consists of a study conducted to create data for a dummy application.