207 ~s oa = Ss - A782), UNIVERSITI KEBANGSAAN MALAYSIA PEPERIKSAAN AKHIR SEMESTER I SESI AKADEMIK 2009-2010 IJAZAH SARJANAMUDA DENGAN KEPUJIAN KOD KURSUS TAJUK ARAHAN KKKFII54 SAINS BAHAN 1. Kertas ini mempunyai Bahagian A & B. Jawab SEMUA soalan Bahagian A dalam Borang OMR. yang diedarkan. 3. Jawab Soalan 1 Bahagian B dalam buku jawapan yang diedarkan. 4. Jawab Soalan 2 ATAU Soalan 3 Bahagian B dalam buku Jawapan yang sama dengan Soalan 1. 5. Jumlah Markah Bahagian A adalah 60 markah 6. Jumlah Markah Bahagian B adalah 40 markah. 7. Kertas soalan ini tidak dibenarkan dibawa keluar dari Dewan Peperiksaan. NOMBOR PENDAFTARAN a TT ] } | | | J NOMBOR PENDAFTARAN (dengan perkataan) (dengan angka) Kertas soalan ini mengandungi 19 muka surat bercetak, tidak termasuk muka surat iKKKFIISS SECTION A (60 marks) Answer ALL Questions (Each question carries equal marks) 1. Fora BCC erystal lattice, the arrangement of atoms on the (0 1 0) plane will look as follow: "SB SS OB 7B KS 2. Figure 1 shows a unit cell and a plane PQRS. What is the Miller index for the plane? z Q A. 12) B. 21) c. O12) P D. 21) E 2 % E. 012) 7 ure | Referring to Figure 1, if the unit cell is an FCC crystal lattice, how many atoms will have their centres on the plane PQRS? moow> auaenKKKFIIS4 Increasing a load applied to a solid material beyond its yield strength may cause the following: 1. decrease in the number of dislocations II slip of crystal planes IIT increase in strength IV reduction of grain size V increase in ductility A B. c D. E. 1, 11, I and 1V I Mand Ut Mand It Mand V Vonly Figure 2 shows some mechanical properties of a metallic material. What are the properties of the material that we can deduce from C and D respectively” A. B. E. Young’s modulus and toughness Yield stress and tensile stress Tensile stress and ductility ‘Young's modulus and tensile stress Yield stress and failure stress ratio 0.30. POOR> 538.2 GPa 345.0 GPa 159.2 GPa 103.5 GPa 79.6 GPa Stress <> Strain Figure 2 . Calculate the shear modulus of a material with a Young’s modulus of 207GPa and Poisson'sKKKFIISS Figure 3 shows the stress-strain curves of metal alloys X and Y. Which of the following statements related to X and Y is correct?” A. Xis tougher than Y B. Yis brittle C. The Young’s modulus of X is smaller than Y D. The yield strength of X is higher than Y E, Xand Y have similar ductility . Alloy X Alloy Y e Figure 3 t o as fe ——t Yo), ° 6 Figure 4 Figure 4 shows the stress amplification effect due to stress concentration at a crack tip on the surface of a brittle plank. A stress (6) of 50 MPa was applied axially on the brittle plank. If10. KKKFIIS4 the length of the surface crack is @ and the radius of the curvature tip is p, the maximum stress Gm experienced by the plank at the tip of the crack may be approximated by the following equation: a)’ 222) p If the radius of the tip curvature p is 0.03mm, and the crack length is 3.5 mm, the stress concentration factor K is A. 1080.1 B. 233.3 C. 116.7 D. 216 E. 108 Figure 5 shows atoms in a unit cell of a face-centred cubic crystal lattice. CEG is a slip plane along a slip direction as indicated in the figure. The slip system of the plane can be written as A111) (001) B.(101) [111] C1 gio) Slip direction D.(110) [110] BE. (110) (100) Figure 5 What will happen when two edge dislocations of opposite signs meet (L meets --) ? ‘The dislocations will be attracted to each other and become a larger dislocation. ‘The dislocations will combine and diminish. ‘The dislocations will repel each other and stop moving. ‘The dislocations will combine and become a mixed dislocation. The dislocations will stop and reverse directions. Poop>KKKFIIS4 11. Figure 6 shows the tensile properties of ductile irons versus the Brinell hardness number. Ina design, the material required is an iron with a minimum tensile strength of 600 MPa and the yield strength is at least 30% below the tensile. If the Brinell hardness number (BHN) of the material selected must be at least 250, which is the most suitable grade of iron for the application? 200 160 Low 0 a «co Strength. ksi x0) 40 | Tensile strength 3 id sirengih 60-40-18.annealed i pomp | | ti, 16018) aaa DA aR BR Hardness, BHN properties of ductile iron versus hard Tens Figure 6 A. 60-40-18 annealed iron B. 65-45-12 annealed iron C. 80-55-06 as cast D. 10-70-03 air quenched E, 120-90-02 oil quenched 12. Grain size reduction, solid solution alloying and work hardening or strain hardening are ‘materials strengthening processes involving the concept of changing the materials crystal structure decreasing the internal energy of the materials increasing resistance to dislocation movement reducing the dislocation in materials adding vacancy defects in materials Poow>KKKFIIS4 13, Table 1 shows data from an experiment on an iron alloy. The Young’s modulus of the alloy calculated from the experimental data is, Table 1 ‘Stress (6) MPa 300 600 900 Strain (©) 2.778 x 10" 5.556 x 10 9.897 x 107 A. 69.11 GPa B. 84.28 GPa C. 88.55 GPa D. 99.46 GPa E. 107.99 GPa 14. Under a cold work a 12.5 mm diameter rod has been reduced to 11.4 mm. What percentage of the cold work has been done on the rod? 15. A. 8.80% B. 9.66% C. 10.72% D. 16.80% E. 20.23% Which of the stress-strain curves below refers to the toughest material? LP Let16. 7. KKKFIIS4 80 109 200 5 nee 2 pa ; i 20 = i r00f/— 80 40 d 0 "255 105 2 105 200 Temparre (0 Figure 7 Figure 7 shows the impact energy from a Charpy V-Notch test of steel specimens with different percentages of carbon. What can be deduced from the graph? ‘A. High carbon steel shows ductile-to-brittle transition at a specific narrow range of temperatures. A ductile-to-brittle transition temperature does not exist for carbon steel alloys. Low carbon steel alloys exhibit a ductile-to-brittle transition behaviour. All carbon steel alloys must contain carbon by weight between 0.01% to 0.67%. Charpy V-Notch test is not suitable to test carbon steel specimens with carbon content higher than 0.22%. moos Which of the following correctly describes the eutectoid reaction in an Fe-FesC system? A. Transformation of liquid phase at 4.30w1% C into two solid phases of ferrite and cementite at 1147°C. B. Transformation of a si RPC. C. Transformation of a solid phase of less than 0.76w1% C into two solid phases when cooled at 727°C. D. Transformation of a solid phase of more than 0.76w1% C into two solid phases when cooled at 727°C. E. Transformation of solid phase at 4.30wt% C into two solid phases of ferrite and cementite at 1147°C phase of 0.76w1% C into two solid phases when cooled atKKKFIISS enone 0) emote) 20, so ° w wo @ w Tod oo Campetion(t A) oe Figure 8 Figure 8 shows a type of phase diagram. Use this Figure to answer questions from 18 to 22. 18. With the information given, the phase diagram refers to a ‘A. unitary-binary system B. binary isochronous copper-silver system C. eutectoid copper-silver system D. binary copper-silver eutectic system E. _ peritectic copper-silver alloy system 19. Line L, Line Mand Line N respectively refers to: A. _ liquidus, solidus and solvus B. _ solvus, liquidus and solidus. C. solidus, solvus and liquidus D. eutectoid, eutectic and pro-eutectoid E, lever line, slip line and ruler line 20. Consider an alloy with nominal composition of 40 wi% Ag being cooled from a temperature of 1000°C. At the instant when the temperature reaches 780°C, the phase (or phases) present will most probably be liquid B+ Ag solid Ag+a solid + liquid solid a+ liquid liquid B + solid B21. 2. 23, 24, 25, KKKFIIS4 Assuming the numbers given on Line K refer to compositions and assuming these ‘compositions to be the same at 780°C, for the phase or phases present in question 20, which of the following is(are) the correct phase(s) and its(their) composition: A B. c. D. E, liquid 71.9 wi% Cu + B 8.0 wt% Ag 8.0 wt% Ag + liquid 71.9 w1% Ag 271.9 1% Ag liquid 91.2 wi% Cu +a 71.9 wt% Ag liquid 71.9 wi% Cu With reference to the alloy in question 21, it is assumed that at 778°C the composition is the same as that at 779°C, What would be the phase(s) present at 778°C and its (their) amount if the original alloy weighed | kg? A. 1000 gm B. «615 gm-+ liquid 385 gm C. B1000 gm D. 615 gm+B 385 gm E. 4385 gm+ 615 gm The kinetics of a transformation refers to the ‘A. formation of a few phases as a result of transformation. B. dependence of the transformation on time. C. mechanical properties of the transformed phase. D. eutectic reaction only. E. _ melting of the eutectoid composition. Choose the FALSE statement regarding the time-temperature transformation (TTT) diagram for a eutectoid steel. A. B, moo The phase which exist at a certain temperature and time can be determined. ‘The amount of transformed phase for a given temperature and time can be approximated. The same TTT diagram can be used for all steel compositions. The starting of the pearlite transformation is earlier at 600°C compared to 700°C ‘No transformation happens above the eutectoid temperature. The continuous cooling transformation (CCT) diagram is used for conditions roOR> of very high cooling rate only. of very low cooling rate only. when the temperature of 550°C is maintained for 10° seconds followed by quenching. when continuous cooling at a controlled rate is applied. when the alloy is continuously heated,26. 28. 29, 30. KKKFIIS4 Precipitation hardening is a process for increasing the hardness and strength of an alloy with the homogeneous presence of alloying atoms in the matrix of the first phase of the alloy. Not all alloys can be precipitation hardened and among the criteria for precipitation, hardening is: A. The solubility of the second phase in the first phase must be low. B. The solubility limit of the second phase must decrease rapidly with temperature. C. The solubility limit of the second phase is constant with temperature. D. The solubility limit of the second phase increases with temperature E. The second phase must not be soluble at all in the first phase. ‘The normalization process is carried out on steel alloys for the following purpose(s): 1. tomake the steel softer and more ductile. Il. to obtain a more homogeneous pearlite phase. IIL. to reduce the pearlite grain size. TV. to increase the hardness of the steel. A. Tand IIT B. Wand Itt C. 1, Mand It D. Tand IV FE. Iland IV Metal alloys can be divided into two major groups of ‘A. copper and brass. B. glass and ceramics. C. metals and non metals. D. ferrous and non ferrous metals. E. _ heavy and light metal alloys. Which of the following is/are the correct statement(s) about ceramics: 1. Ceramics are compounds between metallic and nonmetallic elements II New ceramics are usually simpler chemically than traditional ceramics; for example, oxides, carbides, nitrides, and borides. IIL. Fine ceramics refers to porcelain and traditional pottery. IV. The traditional ceramies products and the processes to make them date back thousands of years. A. Land I B. IandIV C. I, Mand IV D. I, Hand IV E. 1,11, Illand IV Ifa glass sheet is tempered, what will happen when a part of the surface is seratched? ‘A. The crack grows exceedingly fast and causes catastrophic failure. B. The growth of the crack from the surface scratches is suppressed. C. The glass shatters into tiny fragments immediately. D. The crack will heal and eventually disappear. E. The internal stresses will cause the crack to propagate in all directions, 1031. 32, 34, 35 KKKFIIS4 A. A glass-ceramic is fully crystalline from heat treatment. B. A glass-ceramic is partially crystalline from heat treatment, C. A glass-ceramic is fully amorphous. D, E A glass-ceramic is transparent, A glass-ceramic is opaque. Which of the following is NOT an example application for advanced ceramics? 1. Cutting Tool II. Dental Implants IIL Cosmetics IV. Floortiles V. Die blanks A. LILI B. IL MLIV Cc. Vonly D. IV.V E. ILIV In the manufacturing of ceramic components, it is usual to mark a ceramics as green. Green ceramic is defined as: A. The state whereby ceramic is coloured green to mark its recyclability. B, The mould that is painted green to indicate water absorbing behaviour. C. The product that has been shaped but not yet fired. D. The additives that is used in the making of ceramics products. E. The mixed powders prior to cementation. Which of the following are some of the physical characteristics of ceramics? 1. In general, ceramics are lighter than metals and heavier than polymers. II, The melting temperatures of ceramics are higher than most metals. IML, All ceramics are insulating materials. IV. The thermal expansion of ceramics is somewhat less than for metals, but effects are more damaging because of brittleness, A. Land Il B. IL, Hl and IV C. 1, Mand 1V D. 1, land IV E. 1,11, Wand IV ‘Why is the tensile strength of ceramics much lower than that under a compressive stress? . Slip may occur in ceramics under tensile loading, Plastic deformation is common in ceramics under tensile loading, ‘There is no stress amplification associated with any existent flaws during compression. Ceramics decompose upon excessive tensile loading. ‘The tensile load is always less than the compressive load. mo Om>36. 37. KKKFIIS4 Figure 9 is a well known processing technique in the making of ceramic substrates for integrated circuits. What is the name of the manufacturing process? A. Slip Casting B. Particulate Forming C. Sintering D. Tape Casting E. Cementation Warm air source Slip source Doctor blade Zi La & ns Support structure Reel of carrier film Take-up reel Figure 9 irconia a particularly excellent candidate for use as dental implants compared to other bioceramies? A. Zirconia offers better corrosion resistance compared to other type of ceramics. B. With zirconia, the prosthetics can be made aesthetically pleasing by mimicking the colour of the original teeth. C. Zirconia offers better biocompatibility. D. Dental implants and prosthetics made from zirconia have better compressive strength. Zirconia makes white teeth. 12Stress (MPa) yw 8 38. 39. 40. KKKFIIS4 Strain Figure 10 Figure 10 shows the stress-strain behaviour of three types of polymers. Which of the following is the correct label for the specific behaviour as shown by the three curves? aplastic, b — elastomer , ¢ brittle polymer a~—clastomer, b — brittle polymer, ¢ - plastic a brittle polymer, b — elastomer, c - plastic a—brittle polymer, b — plastic, ¢- elastomer a plastic, b- brittle polymer, ¢ - elastomer ronm> Choose the correct statement about crystallinity in polymers A. As crystallinity is increased, the density decreases. B. Polymers can be easily made 100% crystalline through a special process. C. The crystallized region of a polymer is in the form of rosettes. D. If the polymer is transparent in the amorphous state, it becomes opaque when partially crystallized, E Crystallization decreases the strength and stiffness of polymers. Which of the following cite the correct function for the respective additive? 1. Fillers ~to strengthen polymer Il. Lubricants — to reduce friction and improve flow TIL, Flame retardants — to reduce flammability of polymer IV. Ultraviolet light absorbers ~ to reduce degradation from sunlight A. Land IT B. Il, ll and IV C. 1, Mand IV D. 1, Mand IV E. 1,01, land IV B41. 42. 43. 44, 45, KKKFIIS4 Why are elastomers capable of large elastic deformation when subjected to relatively low stresses? 1. Their molecules are tightly kinked when unstretched. II. They have a linear chain-like structure that can stretch easily. II. Their molecules are arranged in a folded lamella structure. IV. Their degree of cross-linking is substantially less than thermosets. A. Land Il B. Iland1V €. Land IV D. 1, and IV E. HandIV Which method is most likely used for making plastic bags? A. Melting and Casting Press and Blow Compression and Transfer Moulding Injection Moulding Blown-Film Extrusion FOOD ‘Thermal conductivity is A. The resultant change of volume due to heating. B. The property that characterises the ability of a material to transfer heat. C. The vibrational thermal energy of a material D. The ability of a material to absorb heat. E. The energy required to inerease the temperature of the material, How is heat transported in solid materials? 1. By lattice vibration waves (phonons) Il By free electrons IIL By conducting ions IV. By volumetric changes A. Tand Il B. Il, Ill and IV C. Il, ILand 1V D. 1, and Iv E. 1,11, Wand IV Which of the following is NOT true about the electrical behaviour of mat A. Current occurs from the flow of electrons in most solids. B. The net motion of ions also produces a current in ionic materials. C. The arrangement of the outermost electron bands and the way in which they are filled influence the electrical properties of the solid D. The electrical conductivity of a material is the reciprocal of the resistivity. E. _ All the electrons in each atom move when an electric field is applied.46. 47. 48. KKKFIIS4 What is the difference between the energy band structure of an insulator and a semiconductor? AL B. c mo Figure 11 shows schematically the electrochemical reaction occurring in zine when immersed in an acid solution, The anode reaction takes place in the region i iiand ii mooR> ‘The difference between these two materials is the magnitude of the band gaps. There is an overlap between an empty band and a filled band in that of an insulator but not a semiconductor. There is no difference between the energy band structures of an insulator and a semiconductor. Band structure does not occur in insulators. There is an overlap between an empty band and a filled band in that of a semiconductor but not an insulator. Figure 11 ‘Table 2 shows the standard emf series. Metals that will easily oxidize will be those at the top of the series at the bottom of the series in the middle of the series both at the top and the bottom of the series in the whole range of the series 15KKKFLIS4 Table 2 ‘Standard Electrode Reaction Electrode Potential, V° (V) Fes et one re a ee Au +36 —> Au +1420 0,+4H" +4e —> 2H,0 +1.229 POY +20 —> Pt ~H12 Ag +e —> Ag +0.800 Fe* +e —> Fe 40.771 0;+2H0 +4¢ —> 40H) 40.401 Cut +2¢ —> Cu +0.340 2H’ 42e —> Hy 0.00 Pb* +2e —> Pb 0.126 Sn? 42e —> Sn 0.136 NEY eS Ni -0.250 Co +26 —+ Co 0.277 Cd 420 —» Cd -0.403 Fe2+ +2e —> Fe -0.440 Crt 43e —> Cr 0.744 Zn 2e —> Zn 763 AP’ +36 —> Al 662 Mg’ +2e¢ —> Mg 363 Nat +e —> Na 24 Kote — K 2.924 Referring to Table 2 again, what will happen if a chromium electrode and an iron electrode immersed in their respective ionic solutions were to be connected? A. Only the iron will corrode. B, Both the iron and chromium will corrode. C. Chromium will corrode while iron ions will enter the iron electrode. D. Chromium will corrode and chromium ions will enter the chromium electrode, E, Iron and chromium will remain as they are. The reaction in question 49 will generate a voltage of: A. +0304V B. +1.184V C. -1.184V D. -0.304-V E. No voltage generated 16KKKFIIS4 SECTION B (40 marks) Instructions: ‘Answer Question 1 (25 marks) and EITHER Question 2 (15 marks) OR Question 3 (15 marks). If you answer both Questions 2 and 3, only the first of them that is in your answer script will be marked, Question 1 (25 marks) ‘The data in Table 3 is obtained from a tensile test on a magnesium specimen with an original diameter of 12 mm. Table 3 Load/Foree | Gauge Length | Comments (mm) 0 30.0000 3,000 30.0296 10,000 | 30.0592 15,000 | 30.0888 20,000 [30.15 25,000 [30.51 26,500 | 30.90 27,000 [31.50 Maximum Toad 26,500 [32.10 25,000 32.79 Fracture After fracture, the gauge length became 32.61mm and the diameter 11.74mm. a) Plot the stress-strain graph. (5 marks) b) From the graph in (a) above or otherwise by suitable calculation, determine the: i) Young’s modulus (3 marks) ii) 0.2% offset yield strength (3 marks) iii) tensile strength (2 marks) iv) ductility in % elongation (3 marks) ¥) ductility in % reduction of eross section area (3 marks) vi) engineering stress at fracture (3 marks) vii) true stress at fracture (3 marks) 7KKKFIISS Question 2 (15 marks) Tenpntie (0) Figures 12 and 13 are for this question. Figure 12 shows the complete isothermal transformation diagram for iron-carbon alloy for eutectoid composition and Figure 13 shows the hardness curves for different carbon concentrations and microstructures. a) b) ‘Assume a steel specimen with eutectoid composition is cooled from 760°C to 550°C in 0.5 seconds and maintained at this temperature. Use the figures to estimate i, the time for 50% transformation of austenite to pearlite. (3 marks) the time for 100% austenite to pearlite transformation. (3 marks) the hardness of the alloy when fully transformed to pearlite, (3 marks) Your answer must include a sketch of Figure 12 and Figure 13 to show how you obtained the answers. (3 marks) ‘Sketch the final microstructure that will be obtained. (3 marks) et g Trccite Mos) oa ae aie Figure 13 Figure 12 18KKKFIIS4 Question 3 (15 marks) A portion of the phase diagram for Fe-FesC for the solid region can be represented by the following data: a) b) Transformation temperature for Fe to the y phase - 912°C Eutectoid temperature 727°C Eutectoid composition 0.76 wt% carbon Maximum solubility of carbon at eutectoid temperature 0.02% Solubility of carbon at room temperature almost 0% Plot the phase diagram for this portion. You must plot on a graph paper. (you can {join the points by straight lines). (5 marks) For a carbon composition of 0.4 wt%, determine/caleulate the minimum temperature for austenitizing. (2 marks) the composition of all the phases present at 750°C. (3 marks) the weight of all the phases present at 750°C given the original weight of the steel is kg. (5 marks) ‘SELAMAT MAJU JAYA’