Priv.-Doz. Dr.-Ing.

Ulrich Krupp
Institut fr Werkstofftechnik
Fachbereich 11: Maschinentechnik
Universitt Siegen

Materials Science and Engineering Test Examination

Attention: the answers are not complete!!
1. Which are the most important criteria for the engineering materials selection process?
(5pt)
application - loading conditions
materials available
price
joining
manufactoring
recycling

2. Draw a schematic representation of the Bohr atomic model for aluminum (Z=13) and
write down its quantum number notation.
(3pt)
Al: 1s
2
2s
2
2p
6
3s
2
3p
1





3. Explain Pauli's exclusion principle and the physical meaning of the quantum numbers.
(6pt)
each electron state can hold no more than two electrons of opposite spin
electrons have discrete energy levels: energy quantisation

4. Which kinds of bonding are present in the case of graphite? Draw schematically the
graphite structure and explain which material properties are a consequence of this
structure.
(6pt)
covalent bonding in hexagon layers
van der Waals between the layers


5. Calculate the atomic packing factor (APF) for the fcc lattice.
(6pt)
APF=atom volume within unit cell (4 x 4/3r)/volume of the unit cell (a)
a=2r x 2
0.5




APF=0.74

6. Draw the hcp unit cell. How many atoms does it contain? What is the corresponding
stacking sequence?
(4pt)
n=6, stacking sequence ABAB...

7. Calculate the theoretical density of fcc Ni (A=58.7g/mole, atomic radius: 0.1246nm).
(6pt)
density=atomic weight per 1 mole unit cells/mole unit cell volume
( )
/ 866 . 8884
10 023 . 6 2 10 1246 . 0 2
/ 7 . 58 4
23
3
9
m kg
m
mole g
N V
nA
A c
=


= =



8. Draw schematically a bcc unit cell and show a slip plane. Give the Miller indices for
the slip plane and slip direction.
(5pt)
slip directions: <111>slip planes {100}

9. Explain the properties of a grain boundary. How can you reduce the grain size of a
metallic alloy?
(6pt)
discontinuity of the crystalline lattice alignment - separates grains, - arrangement of vacancies,
dislocations, may act as obstacles for plastic deformation

cold rolling (strain working) and recrystallization heat treatment
'
a/2
r
10. Draw the stress-strain diagram of an Al alloy with the yield strength
Y
=210MPa, the
ultimative tensile strength of UTS=250MPa and a stress level of =160MPa at
fracture (%EL=40%). How can you determine the diagram and the corresponding
data? What is the main difference between elastic and plastic deformation?
(8pt)
diagram
determination of the diagram: tensile test - recording force and displacement,
stress: force/original cross-sectional area,
strain: original length+displacement/original length,
%EL: strain at fracture in %

11. The Al material given above shall be used for a tube-shaped retainer. The inner
diameter has to be 10mm. For the application a safety factor of N=2.5 is given. The
static load is P=12000N. Calculate the outer diameter of the retainer.
(4pt)
maximum allowed stress:
w
=210MPa/2.5=84.5MPa
loading: =12000N/(r
a
2
-25mm) => mm mm
MPa
N
r
a
38 . 8 25
5 . 84
12000
2
= +

(=radius)

What kind of data would you have to consider if the loading conditions were cyclic?
Draw a schematic Whler (S/N) diagram for Al alloys.
(4pt)
cyclic data from fatigue tests according
Whler diagram

12. By using the electron band scheme - explain the difference between semiconducting
and non-conducting materials.
(6pt)
width of the energy gap between full valence band and empty conduction band, E
gap
>2eV insulator,
<2eV semiconductor

13. What is a Bohr magneton? In which way does it describe the origin of the magnetic
properties of materials?
(4pt)
fundamental magnetic moment - spin magnetic moment: +/-
B
, orbital magnetic moment: magnetic
quantum number x
B


14. Draw a B vs. H hysteresis and explain the characteristic shape by means of "domains":
(6pt)

gradual change of domain shape and size by movement of domain boundaries - 1. randomly oriented, 2.
macroscopic specimen becomes a single domain,
reversal of the applied magnetic field: change in direction of the domain magnetic moments, residual
alignment at H=0

15. Sketch and explain how a semiconductor laser works.
(6pt)

excited electrons combine with holes - photon emissions, reflection and stimulation of further
recombination events - process control by current in forward-biased GaAs layered diode.

16. Draw the metastable Fe-C phase diagram and label the phase areas, the eutectic and
the eutectoid point.
(5pt)

Explain the phase transformations during slow-cooling of 1.0%C steel from the melt.
Determine the phase compositions and amounts using the lever rule at T=800C.
(6pt)
melt - two phase regime: precipitation of fcc austenite - single phase regime: austenite, tow-phase
regime: Fe
3
C-precipitation in fcc austenite: C concentration in fcc austenite drops to 0.8% at 727C,
where it transforms to pearlite - at RT: two phase microstructure consisting of Fe3C and pearlite
(lamellar Fe
3
C and bcc ferrite)

lever rule at 800C: right-hand side: austenite, left-hand side: Fe
3
C
C
Fe3C
=(c
0
-c

)/(c
Fe3C
-c

)

17. Why does one use Al alloys for high-strength aircraft applications? Explain how the
strength of Al alloys can be increased using the example of the Al-Cu phase diagram.
(7pt)
low density, corrosion resistant =>high strength due to particle strengthening

solution heat treatment - quenching - ageing: precipitation of fine particles - increase in strength since
dislocation have to cut the precipitates

eutectoid point =pearlite
eutectic point
18. Draw the monomer and the polymer chain of ethylene. By which characteristics are
the mechanical properties of polymer materials determined?
(5pt)









e.g. (average) molecular weight, shape, structure (e.g. linear, branched, crosslinked, networked),
configuration (regularity - isomerism)

19. Which material would you choose for (a) a crank shaft of an internal combustion
engine, (b) a helicopter rotor blade and (c) a complex housing of a cheap DVD player?
Give reasons for your decision. Which engineering activities are required to ensure a
safe in-service operation?
(9pt)
(a) e.g. medium carbon steel 42CrMo4 - heat-treatable, good mechanical properties (wear/fatigue
resistant)
(b) SiC/carbon-fibre reinforced epoxy - high stiffness, low density
(c) polypropylene - easy manufacturing
e.g. FEM calculation of stress distribution during service, material testing - mechanical data, corrosion
data - near-service testing - life prediction
20. Order the following materials by (a) their modulus of elasticity, (b) their costs and (c)
the ease to recycle them: low carbon steel, Al
2
O
3
, pure gold.
(3pt)
(a) highest Young's modulus: Al
2
O
3
, lowest: gold
(b) cost: highest: gold, lowest: low-carbon steel
H H
H H
C
C
H
H H
H H
C C
H H
H H
C C
H
H
H C