Metal design.
Stiff. Strong.
Engineering basics.
Metal design fundamentals — material selection, stress analysis, fatigue, fastener engineering, weld design. Engineering basics for metallic structures.
Key principles.
Match to load
Aluminum cheap & light. Steel cheap & strong. Stainless corrosion-resistant. Titanium light + strong.
Avoid
Sharp corners concentrate stress 3-5×. Generous fillets reduce concentration.
Cyclic loading
Fatigue limit ~50% UTS. Surface finish, residual stress affect.
Match material
Match fastener strength, corrosion compatibility to base metal.
Strength reduction
Heat-affected zone weakened. Plan critical features away from welds.
Specify per function
Bearings smooth. Fatigue surfaces polished. Cosmetic per aesthetics.
FAQ
Strength to weight optimization?
Aluminum specific strength similar to steel. Titanium higher. Composites highest.
Stiffness or strength?
Different. Modulus = stiffness (deflection). Strength = failure load.
Stress concentration factors?
Sharp corner ~3×. Generous fillet ~1.5×. Hole ~3×. Threaded hole ~2-3×.
Corrosion compatibility?
Galvanic series — pair compatible metals. Insulate dissimilar metals to prevent galvanic corrosion.
Heat treatment effects?
Through-hardening dramatic strength increases. Specify exact heat treat condition for design strength.
Joining methods?
Welding strongest. Mechanical fasteners removable. Adhesives for dissimilar materials.
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