BFF1113, Engineering Materials 2014-2015 SEM-2

Last Date of Submission 22nd May 2015

(Total Marks: 100)

1. Describe the significance of structures and machine components made of two materials with different
coefficients of thermal expansions.

2. Define the term below and explain in brief: (a) Annealing, (b) Normalizing (c) Quenching and (d)
tempering

3. Using the figure below, estimate the following quantities for a 20%Cu-80%Ni alloy: (a) Liquidus
temperature, (b) solidus temperature, (c) the % of Nickel in the liquid at 1400oC, (d) the major phase
at 1400oC and (e) the fraction of solid at 1400oC.

4. Neatly sketch Cu-Zn binary phase-diagram and make schematic sketches of the microstructure and
label the phases for 20%Zn that would be observed for conditions of very slow cooling at the following
temperatures: 1100C, 950C, 900C and 700C. Also, calculate the percentage of solid-phase for 10,
20, 30% Zn and indicate their approximate compositions.

5. It has been found that a 1070 steel, when austenitized at 750oC, forms a structure containing pearlite
and a small amount of grain boundary ferrite that gives acceptable strength and ductility. What changes
in the microstructure, if any, would be expected if the 1070 steel contained an alloying elements, such
as Mo or Cr? Explain.

6. Define polymorphism? Explain polymorphism in metals.

7. Describe in brief the definition, the subgroups, general properties, and application for each type of
these: (a) Ferrous metal alloy, (b) Non-ferrous metal alloy, (c) Refractory metal alloy, (d) Precious
metal, (e) Amorphous metal, and (f) Metal foam

8. Explain the process of solidification of a polycrystalline metal, using neat sketches. Which one is
suitable for turbine blade applications: polycrystalline or single crystal grain structure of the same
metal. Justify your choice.

9. Elaborate the Hume-Ruthery rules for solid-solution of metals.

10. Explain why ceramics are weaker in tension than in their compression. And how ceramics can be made
tougher?

11. Investigate and list the ceramics used for high temperature superconductor applications.

12. Explain why thermoplastics are easier to recycle than thermosets.

13. (a) Describe the five stages in the formation of a cup-and-cone ductile fracture of a metal.
(b) A structural component in the form of a wide plate is to be fabricated from a steel alloy that has a
plane strain fracture toughness of 77.0 MPa m and a yield strength of 1200 MPa. The flaw size
resolution limit of the flaw detection apparatus is 4.1 mm. If the design stress is one half of the yield
strength and the value of Y is 1.0, determine whether or not a critical flaw for this plate is subject to
detection.

(c) Define the passivation of a metal or alloy. Give examples of some metals and alloys that show
passivity.
14. Name the following polymers that would be suitable for the fabrication of hot-coffee cups:
polyethylene, polypropylene, poly(vinyl chloride), PET polyester, and polycarbonate. Why?

15. Would a composite material with strong and stiff matrix and soft and flexible reinforcement have any
practical uses? Explain.

16. For a continuous and oriented fiber-reinforced composite, the moduli of elasticity in the longitudinal
and transverse directions are 19.7 and 3.66 GPa, respectively. If the volume fraction of fibers is 0.25,
determine the moduli of elasticity of fiber and matrix phases.

17. Explain the types of corrosion and suggest the methods to prevent various types of corrosion. What
are the design considerations for preventing corrosion of a pipe of petroleum well located in the deep
sea water.

18. What is inter-granular corrosion, which of the following stuctures has better resistance to this type of
corrosion? (a) Fine grain poly-crystalline (b) Single crystal (c) Amorphous structure. Explain.

19. Define the Pilling-Bedworth Ratio (PBR). What is the PBR for MgO and Al2O3. and explain how PBR
effects the corrosion of Aluminium and Magnesium metals

20. Glass is a sustainable, fully recyclable material which provides great environmental benefits such as
contributing to mitigating climate change and saving precious natural resources. It is also highly
appreciated in many applications for its inert nature and its contributions to safeguarding peoples
health and well-being.
(a) Elaborate how glass can help in energy saving, save natural resources and safeguard peoples
health and well-being,
(b) Make a list of the advantages and disadvantages of using glass as a container; include such
factors as cost, recyclability, and energy consumption for container production.
(c) Discuss why it is important for a manufacturing engineer to study economic, environmental
and society issues in materials engineering.