Materials Enabled Designs

The Materials Engineering Perspective to Product Design and Manufacturing


  • Michael Pfeifer, President, Industrial Metallurgists, LLC Northbrook, IL, USA

There are books aplenty on materials selection criteria for engineering design. Most cover the physical and mechanical properties of specific materials, but few offer much in the way of total product design criteria. This innovative new text/reference will give the “Big picture” view of how materials should be selected—not only for a desired function but also for their ultimate performance, durability, maintenance, replacement costs, and so on. Even such factors as how a material behaves when packaged, shipped, and stored will be taken into consideration. For without that knowledge, a design engineer is often in the dark as to how a particular material used in particular product or process is going to behave over time, how costly it will be, and, ultimately, how successful it will be at doing what is supposed to do. This book delivers that knowledge.
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* Materials Engineers, Mechanical Engineers, Product Designers and Packagers; Graduate Students in Materials Engineering, Industrial Engineering and Mechanical Engineering


Book information

  • Published: April 2009
  • ISBN: 978-0-7506-8287-9

Table of Contents



Chapter 1 The Materials Engineering Perspective

1.1 Introduction

1.2 The Materials Engineering Perspective

1.3 What is Materials Engineering?

1.4 Products and Their Materials

1.5 Product Success and the Materials Engineering Perspective

1.6 Types of Product Development Projects

1.7 Companies Applying the Materials Engineering Perspective

1.8 Costs to Gain Materials Engineering Knowledge

1.9 Costs of Bad Materials Engineering Decisions

1.10 The Remainder of the Book


Chapter 2 Design Requirements

2.1 Introduction

2.2 Developing Design Requirements

2.3 Product Design Requirements

2.4 Subassembly Design Requirements

2.5 Product Element Design Requirements


Chapter 3 Selecting Materials

3.1 Introduction

3.2 Materials Selection Process

3.3 Identifying Potential Materials

3.4 Evaluating the Materials

3.5 Selecting the Materials

Chapter 4 Material Properties and Materials Science

4.1 Introduction

4.2 Material Properties and Material Features

4.3 Categories of Materials

4.4 Metals

4.5 Ceramics

4.6 Polymers

4.7 Composites

4.8 Surfaces

4.9 Interfaces

4.10 Defects

4.11 Materials Information Resources


Chapter 5 Manufacturing Process Considerations

5.1 Introduction

5.2 Component Fabrication Processes

5.3 Overview of Joining Processes

5.4 Overview of In-Process Structures

5.5 Process Inputs and Outputs

5.6 Process Variation and Capability


Chapter 6 Degradation and Reliability of Materials

6.1 Introduction

6.2 Modes of Material Degradation and Failure

6.3 Characterizing the Degradation and Reliability of Materials

6.4 Accelerated Stress Testing

6.5 Advantages and Disadvantages of Product Verification and Materials Reliability Testing

6.6 Testing Protocols

6.7 Testing Problems


Chapter 7 Product Planning and Control Documents

7.1 Introduction

7.2 Product Planning

7.3 Control Documents

7.4 Control Document Information


Chapter 8 Product Concept Development

8.1 Introduction

8.2 Perform Detailed Market Analysis

8.3 Write Detailed Product Specification

8.4 Product Concept Generation, Evaluation, and Selection


Chapter 9 Materials Engineering Considerations for System-Level Design

9.1 Introduction

9.2 Design Subassemblies and Product Elements

9.3 Design Product Elements

9.4 Develop Sourcing Strategy

9.5 Select Type II and Type III Suppliers

9.6 Supplier Proposal Process


Chapter 10 Detail Design and Testing

10.1 Introduction

10.2 Select Custom Subassemblies and Components Suppliers

10.3 Select Off-the-Shelf Subassemblies and Components

10.4 Select Materials

10.5 Manufacturing Process Development

10.6 Complete Subassembly and Component Specifications

10.7 Product Verification Testing

10.8 Root Cause Analysis


Chapter 11 Production

11.1 Introduction

11.2 Improve Manufacturing Yield

11.3 Cost Reduction

Chapter 12 Materials Engineering Strategies for the Product Realization Process

12.1 Introduction

12.2 Start with Materials That Offer a High Probability of Success

12.3 Do not Consider Every Material, Component, and Subassembly in the World as Options for a Product

12.4 Work Out All Custom Component or Subassembly Details before Using a Low-Cost Supplier

12.5 Develop Design Guidelines

12.6 Budget for Materials Engineering Support

12.7 Consolidate Materials within and Across Platforms