I think I've located the confusion here:
"You claim that high-alloy high-tensile steels beat all other metals for strength to weight ratio. I don't see how this can be true if titanium is 50% lighter and just as strong."
Titanium is about as strong as
mild steel. Low-alloy high-tensile steels are much stronger, as much as three times as strong as mild steel per square inch, at about the same weight.
There seems to be a pretty basic confusion about how to go about engineering for optimum weight, too -- maybe a misunderstanding of the word "optimum"?
Optimizing weight means making weight as low as possible without impairing function. In order to do that you must choose the best materials for the job and then choose dimensions based on the characteristics of those materials and the stresses and strains involved in the application -- that is the only way to optimize; any other approach to engineering will not produce the optimum weight.
It often happens that an engineer saddled with a legacy design that was not originally designed for optimum weight can improve the turkey a little by taking out an overdesigned steel part and replacing it with an alloy part of the same dimensions, which will often have adequate strength simply because weight was not considered in the original design and the steel part was made much heavier than it needed to be. That's not optimizing; that's making an overweight turkey a little less overweight.
"If you cannot make changes to the part - which is usually the case - What are some of these other ways of optimizing weight?"
Just to hammer it into the ground (spare the rod and spoil the dead horse
) -- if you're not allowed to make changes to any of the parts other than changing the alloys, you cannot hope to optimize weight; the best you can hope to do is make the turkey less overweight than it was.
-Cougar Allen :{)
[This message has been edited by Cougar Allen (edited 28 September 1999).]