1. Constituents goals recognize the abundance of options multiple parameter search protocol for selecting candidates mapping strategy merit index few examples

2. Issue millions of candidates how to select best materials how to conceptually formulate a composite contention – a few materials sit at the outside edges of properties, and they make frequent first choices for particulate composites 2

3. Cost is a Major Consideration 3 scatter plot of use-price for some elements

4. Strength – Cost Scatter 4

5. Hardness – Density Scatter 5

6. Silicon Carbide 6

7. Leading Choices for Cost plastics, about $2/kg steels, about $0.7/kg concrete, about $0.12/kg compare to diamond –$1,250/kg industrial grade –$20,000/kg gemstone 7

8. A Few Leading Choices high density, tungsten high stiffness, tungsten carbide high hardness, diamond high strength, tool steel high toughness, maraging steel high wear resistance, polycrystalline diamond high corrosion resistance, nickel alloys high temperature oxidation resistance, oxide ceramics high electrical conductivity, copper high thermal conductivity, diamond 8

9. Continued high thermal expansion coefficient, styrene soft magnetic response, iron antimicrobial, silver low flammability, aluminum hydroxide low thermal expansion coefficient, silicate glass low stiffness, polyurethane foam low thermal conductivity, calcium silicate foam low density, balsa wood low corrosion resistance, magnesium low oxidation resistance, titanium 9

10. Our Approach down selection hierarchical process start with large base computer search best fit to criteria identify novel compositions model to predict properties 10

11. Ceramic Examples 11

12. Elastic Modulus 12

13. Fracture Toughness 13

14. Thermal Conductivity 14

15. Thermal Expansion Coefficient 15

16. Tensile Strength 16

17. Search Protocol 17

18. Many Key Actors synergy for an application combine two phases of different attributes high hardness + corrosion resistance leads to diamond + nickel composite 18

19. Ashby Mapping Idea rely on many materials and properties plot values over wide range of options look for best match to criteria formally embedded in Cambridge Engineering Selector by Granta Design 19

20. Example Scatter Elastic and Density 20 plot shows SiC is high stiffness and low density

21. All Materials 21

22. Explore Options 22

23. Diamond Particles 23 bonded abrasive

24. Oxidation Resistance Comparison 24

25. Example Thermal Management active heat dissipation – fluid flow loop passive heat dissipation – heat spreader to air 25

26. Selection Protocol high thermal conductivity –Al, AlN, BeO, Be, brass, Ca, Cu, diamond, Au, W, Mo, … no toxicity or hazards –removes BeO, Be, Ca corrosion and oxidation resistant minimum fracture toughness cost per unit volume below $1/cc –Al, brass, Cu, graphite, SiC remain nonmagnetic 26

27. Thermal Management Options 27

28. Now the Final Analysis low thermal expansion coefficient –graphite and SiC best note graphite is anisotropic easily fabricated –not graphite and SiC, brass evaporation thus composite arises –Al, Cu + graphite, SiC relax cost and W-Cu, Al-AlN are viable some solutions – W-Cu, Mo-Cu, Al-SiC, Cu-graphite remove cost – Cu-diamond is winner 28

29. Heat Sink Material 29 W-10Cu

30. Wire Drawing Die hard, low cost, resist thermal softening (frictional heating), long life selection leads to WC-Co as low cost solution longer life leads to Ti(C,N)-WC-Co solution 30

31. Example Dies 31

32. Composite Microstructure 32

33. Self-Winding Watch Weights high density nontoxic easy fabrication, precise weight no defects low cost solution Mo-Ni-Cu composites compact and sinter to full density 33

34. Frangible Bullets low cost sufficient strength for shooting easy fracture at target nontoxic easy to fabricate - billions Cu-Sn (react to form brittle intermetallic) 34

35. Brittle Microstructure 35

36. Radiation Putty 36

37. Hard Magnets – Stereo Speakers 37

38. Other Examples in Book concrete saw segments –diamond-cobalt electric bicycle motor segments –iron-cellulose hot steel sheet oxide descaling –glass-alumina 38

39. Chromatography Filter 39

40. Processing Also Option 40

41. Example Size Ranges 41

42. Wall Thickness Range 42

43. Tolerances 43

44. Complexity – Production Quantity 44

45. Porosity - Elastic Modulus Decrease 45

46. Alumina Strength - Porosity 46

47. Thermal Conductivity Alumina 47

48. Data Sources books, on-line companies trade associations (Society of Plastics Engineers) professional societies (ASM International) standards (ASTM) handbooks (Smithell’s Metals Reference) databases (Granta Design CES) government compilations (NIST) papers – www.scholar.google.comwww.scholar.google.com 48