2014

METALLURGICAL ENGINEERING MT

MT: METALLURGICAL ENGINEERING Duration: 2:30 Hrs Please read the following instruction carefully: Maximum Marks: 70

Answering a question

1. Write appropriate answer AND option on provided A4 answer sheet. 2. Submit your rough sheet to invigilator. 3. You have to write answer for FOUR 1 mark Question and TWO 2marks question given in the blanks. No option will be given. Paper specific instruction 1. There are a total of 45 questions carrying 70 marks. Questions are of multiple choice type or numerical answer type. A multiple choice type question will have four choices for the answer with only one correct choice. For numerical answer type questions, the answer is a number and no choices will be given. 2. Questions Q.1 Q.20 carry 1mark each. Questions Q.21 Q.45 carry 2marks each. The 2marks questions include two pairs of common data questions and two pairs of linked answer questions. The answer to the second question of the linked answer questions depends on the answer to the first question of the pair. If the first question in the linked pair is wrongly answered or is not attempted, then the answer to the second question in the pair will not be evaluated. 3. Questions not attempted will result in zero mark. Wrong answers for multiple choice type questions will result in NEGATIVE marks. For all 1 mark questions, mark will be deducted for each wrong answer. For all 2 marks questions, mark will be deducted for each wrong answer. However, in the case of the linked answer question pair; there will be negative marks only for wrong answer to the first question and no negative marks for wrong answer to the second question. There is no negative marking for questions of numerical answer type. 4. Calculator is allowed. Charts, graph sheets or tables are NOT allowed in the examination hall. 5. Do the rough work in the Scribble Pad provided. However GATE 2014 is to be held on 2nd Feb through computer based online examination which also includes the Engineering Mathematics and General Aptitude for 30 marks .Mode of exam differ from MOCK GATE 2014.

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014 USEFUL DATA Universal Gas Constant, R: 8.314J mole -1 K-1 Stefan Boltzmann Constant () = 5.66710-8 m-2K-4 Q.1 Q.20 carry ONE mark each

METALLURGICAL ENGINEERING MT

Q.1 Vacuum treatment done for plain carbon steel is to (A) Only to remove the dissolved gasses in steel (B) To reduce the sulfur and phosphorus in steel (C) To reduce the carbon content in steel (D) Both A & C Q.2 Stainless steel making process involves (A) Addition of Ni to stainless steel is to enhance the corrosion rate and also stabilize the austenite structure. (B) The high temperature and lower partial pressure is greater for preferential oxidation of carbon than chromium. (C) Foamy slag practices highly desirable. (D) Ferro silicon is added to reduce the temperature requirement of process.

Q.3 Eventhough FCC Iron has more packing density than BCC Iron, Solubility of carbon in FCC Iron more because (A) Interstitial sites are larger (B) More no. of interstitial site for every Fe atom (C) Both A & B (D) Neither (A ) nor ( B) Q.4 Resolving power of metallurgical microscope can be increased by (A) Reducing wave length of light (B) Using the high refractive index of objective (C) Both A & B (D) Neither (A) nor (B) Q.5 Reason for break out of the solidified shell during continuous casting of steel is (A) Slow casting speed (B) Large super heat (C) Shallow oscillation mark (D) Both B & C

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014 Q.6 Weld pool or puddle penetration can be improved by (A) Increasing Lorentz force (B) Using surface active element (C) Reducing arc length (D) All these above.

METALLURGICAL ENGINEERING MT

Q.7 Characteristic of slag which is oxide melts containing at least two opposite chemical nature (A) The basicity and oxidizing power of slag are independent properties (B) Acid slag are network former while basic slag network breaker (C) Depolymerization of slag done by basic oxide. (D) All of these Q.8 Which law state that It is impossible to lower the temperature of an object to absolute zero in a finite number of steps (A) Law of mass action (B) Second law of thermodynamics (C) Third law of thermodynamics (D) Zeroth law of thermodynamics

Q.9 In secondary metallurgy area (LRF & VD) Ar /N2 Stirring done in order to improve the (A) Mass transfer coefficient (C) Both A & B (B) Reduce the thickness of reaction interface (D) None of these.

Q.10 Which technique is the most suitable for upgrading the copper ore of chalcopyrite? (A) Differential floatation (C) Only Gravity concentration (B) Magnetic separator (D) Froth floatation

Q.11 Which method is widely used for controlling the failure in sheet metal forming is (A) Swift flat bottom test (C) Forming limit diagram Q.12 Vulcanization of elastomers is achieved by (A) Non reversible chemical reaction by adding of Sulphur compound at high temperature (B) Reversible chemical reaction by adding of Sulphur compound at high temperature (C) Non reversible chemical reaction by adding of Sulphur compound at low temperature (D) Reversible chemical reaction by adding of Sulphur compound at low temperature (C) Olsen and Erichsen test (D) Compressive test

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014

METALLURGICAL ENGINEERING MT

Q.13 An ideal penetrant in liquid penetration test should have (A) High surface tension, low viscosity and low contact angle (B) Low surface tension, low viscosity and low contact angle (C) Low surface tension, high viscosity and high contact angle (D) High surface tension, high viscosity and high contact angle Q.14 Calculate the wave length of electron beam if applied voltage is350kV. Q.15. S11, S12 and S44 (stress tensor) of certain metal are 0.520, 0.770 and -0.058 (10-11 m2/N) respectively, property of metal is .. (A) Anisotropy (C) None of above (B) Cant determined (D) Isotropy

Q.16 The collapsible toothpaste tubes generally produced by (A) Direct extrusion (C) Impact extrusion (B) Indirect extrusion (D) Forging

Q.17 Consider a slip system = 45 and =30 .Deformation of such a metal takes place when a stress of 500MPa is applied. Calculate the critical resolved shear stress..MPa Q.18 What is the factor of safety------------------When material made of Mg alloy with yield strength () of 200Mpa Assume : Distortion Energy Criteria
60 MPa

120 MPa

Shear stress =30 MPa

200MPa

Q.19 Number of slip system in HCP crystal is ... Q.20 When oil or other fluid is permeated into the pores of a sintered PM part is called (A) Impregnation (D) Compaction (B) Densification (D) Infiltration

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014 Q.21 to Q.45 carry TWO marks each

METALLURGICAL ENGINEERING MT

Q.21 0.2 cm thickness of pure Ni sheet exposed to oxygen atmosphere at 1273K and oxidation of Ni sheet follows a parabolic path given by k= 4.0 10 -12 cm2/s. Calculate the time required for pure Ni sheet completely oxidizes. Ans.sec Q.22 P91 steels are widely used in petro chemical industry at around 600 C and metal fails at an applied stress of 10,000 psi (Assume Larson -Miller parameter is 34.3). Calculate time required to metal fails Ans.. Years Q.23 Match the Steel Making Principle in Group I with it correspond Favorable Condition in Group II Group I (P) Manganese removal (Q) Phosphorus reaction (R) Sulfur reaction (S) Carbon reaction Group II (1) Low FeO (2) High FeO (3) High Basicity (4) High Oxygen potensitial

(A) P-2,Q-4,R-3,S-1 (C) P-3,Q-2,R-1,S-4 Q.24 Determine the order of reaction

(B) P-2,Q-3,R-1,S-4 (D) P-3,Q-4,R-2,S-1

Consider the reaction and following data obtained from experiment 2HI = H2 + I2 Exp.No [HI] 1 0.1 2 0.05 Rate( mole /Ls) 4 10-5 510-6

(A) 2

(B) 3

(C) 0

(D) Data insufficient.

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014

METALLURGICAL ENGINEERING MT

Q. 25 A hypo eutectoid steel 0.5% C is heated to 950 C and hold for 1 hr at this temperature & quenched in molten salt bath to 727 C and held for 50s and same sample quenched in water to 350 C and held for 50s and finally quenched to room temperature. What will be final microstructure of the steel? (A) Fully martensite (B)Martensite + Ferrite (C) Martensite + Bainite +Ferrite (D) only Pearlite Q.26 For cubic with lattice parameter (a) of 3.92 , First six diffraction peaks from X-RD pattern obtained from Experiments with Cu K radiation(= 1.5 ) are given below. Find the crystal structure of metal

(A) SC

(B)

BCC

(C)

FCC

(D) Cant determine

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014 Q.27 Extraction of Al from Indian bauxite ore involves

METALLURGICAL ENGINEERING MT

(A) High SiO2 in bauxite is not desirable because during leaching silica forms insoluble residue with Al2O3. (B) Leaching of bauxite done at room temperature and high pressure (5 to 25 atm ) (C) It is possible to reduce calcined Al (OH)2 to Al by C at high temperature . (D) Both A & C Q.28 Match the Purification method in Group I with it correspond Principle in Group II Group II (P) Fire refining (Q) Selective distillation (R) Liquation (S) Zone refining (A) P-2,Q-4, R-3,S-2 (C) P-3, Q-4, R-2,S-1 Group II (1) Differential in solubility (2) Differential in melting point (3) Differential in oxygen affinity (4) Differential in boiling point (B) P-2,Q-3,R-1,S-4 (D) P-3,Q-4,R-2,S-1

Q.29 200T of liquid steel contained in refractory lined cylindrical ladle which is open at top and free broad of the ladle is 1.5 meter and internal diameter and outer meter are 2.5 m and 3.5m respectively. Calculate the rate of temperature drop of liquid steel (K/s) Assume: There is heat transfer loss neither by conduction nor convection & Temperature at mouth of ladle is 500K Given data: specific heat of steel = 750 J kg-1 K-1 Emission of steel = 0.5; Initial temperature of ladle = 1600 C; Master view factor (F) =0.5

(A) 0.1926

(B) 0.013

(C) 0.011

(D) 1.5

Q.30 Martensite reaction or transformation involves (A) Depends only on Temperature ,not the time (B) Depends on carbon to form BCT structure. (C) Amount of retained austenite increased with rise in carbon& alloying element. (D) Diffusion controlled phenomena. (A) A , C (B) A, D (C ) A,B , C (D) C, D

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014

METALLURGICAL ENGINEERING MT

Q.31 .The time taken by extrusion machine to extrude the Magnesium alloy from 250mm to 50mm diameter at 673K was 1 sec for every 100mm distance. Calculate the flow stress required to extrude an alloy (in MPa). Given: Work hardening coefficient (n) =0.2 and Constant (K) =220 (A) 60 (C) 427 (B) 327 (D) 227

Q.32 Assertion (A): Pure TiO2 is being converted into gaseous TiCl4 by passing chlorine gas along with Coke < TiO2 > +2<C> +2{Cl}2={TiCl4 }+ 2{CO} Reason(R): Purpose of coke addition is to lower the free energy of formation of the reaction. (A) A is false and R is true (B) A is true and R is also true but R is not the reason for A (C) A is true and R is also true but R is the reason for A (D) A is false but R is true

Q.33 Identify the correct combination of following statement on Strengthening of material (A) Alloying element: Creating the compressive stress field by interstitial atom or creating the tensile stress field by substitute atom (B) Grain refinement: Coarse grain sized material has less obstacle to move dislocation than fine sized material and fine grain sized materials have more corrosion rate than coarse. (C) Strain hardening: Increase the number of dislocation by multiplication of dislocation (FR source) (D) Only grain boundary strengthening mechanism increase the both strength and ductility of material. (A) A,B,C, D (B) A,B,D (C) A,B ,C (D) B,D

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014

METALLURGICAL ENGINEERING MT

Q.34 Match the Softening Mechanism in Group I with it corresponding metal in Group II Group I (P) Dynamic recovery (Q) Dynamic recrystallization (R) Dynamic strain hardening (S) Recrystallization Group II (1). Low carbon steel (2). Low SFE metal (3). BCC metal (4).Cold worked metal

(A) P-2,Q-4,R-3,S-1 (C) P-3,Q-2,R-1,S-4

(B) P-2,Q-3,R-1,S-4 (D) P-3,Q-4,R-2,S-1

Q.35 If low carbon steel is kept at 1250C in a carburizing atmosphere for 10hrs to achieve a concentration of 0.5 % at a depth of 0.5mm .Calculate the time require to reach same carbon concentration at a depth of 3.5mm at 1300C Given: Pre exponential factor = 2.010-4m2/s and Activation energy = 150kJ/mole /K

(A) 200hrs

(B) 100 hrs

(C) 188 hrs

(D) 288 hrs

Q.36 Match the Casting deign in Group I with it correspond function in Group II (P) Riser (Q) Chills (R) Padding (S) Draft (1) Compensate for shrinkage of casting (2) Promote directional solidification (Extract heat in certain location) (3) To support the core (4) Pattern can easy withdrawn mould from mould

(A) P-2,Q-4,R-3,S-2 (C) P-1,Q-2,R-3,S-4

(B) P-2,Q-3,R-1,S-4 (D) P-1,Q-4,R-2,S-3

Q.37 Estimate the energy required for unit volume(MJ/m3) to extrude 150mm diameter of steel slab into 15mm diameter of rod .Given =15Mpa and efficiency of extraction machine is 70 % (A) 98.67 (B) 49.35 (C) 34.5 (D) 15

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

2014 Linked Answer Questions Statement for linked answer question 38 and 39

METALLURGICAL ENGINEERING MT

Chemical analysis of input materials for BOF steel making process as given below Element (wt %) C Si Mn P S Molten metal 3.8 2.5 1.0 0.04 0.04 Solid charge 0.20 0.02 0.25 0.03 0.03

Q.38 To produce steel with composition of 0.15 %C, 0.01% Si, 0.25 % Mn and P & S each 0.03 % by BOF steel making process. Calculate the amount of Hot metal in kg to be charged per ton of steel production. Given: there is 2 % Fe loss in slag and 200 kg of solid charge per 1 ton of steel production. (A) 816 kg (B) 1220 kg (C) 881 kg (D) 1280 kg

Q.39 Hematite iron ore (92 % purity) are charged into blast furnace for producing the pig iron with 3.8 % C, 2.5 % Si, 1.0% Mn and P & S each 0.03 % for BOF steel making. Estimate the amount of ore require to producing hot metal for Steel making shop. Assume there is no Fe loss during molten metal production. (A) 816 kg (B) 1 427 kg (C) 1081 kg (D) 1267 kg

Linked Answer Question Statement for linked answer question 40 and 41 2<Al> + 1.5 {O2} =<Al2O3> <C >+ 0.5 {O2} = {CO} H = -1679876 J & S= -321.78 J H = -111712.8 J & S= 87.65 J

Assume: standard condition 1 atm pressure and temperature at interest Q.40 Estimate the minimum temperature required for reducing the Al2O3 by Carbon under standard condition to form CO. (A) 2399.75 C (B) 2299.75C (C) 4375.8 C (D) 2990.8 C

Q.41 Calculate the standard free energy (J/ mole) change at minimum temperature under equilibrium condition with P CO = 0.05 atm. (A) 192234.43 J (B) 57278.76 J (C) 1344737.6 J (D) 1568163.2

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

10

2014

METALLURGICAL ENGINEERING MT

Common data for questions Common Data for question 42 and 43 An Ag Cu phase diagram drawn using thermodynamic database software (Factsage).

Q.42 In the Ag Cu phase diagram, Melting point of Ag and Cu are 962 and 1082 C respectively. A eutectic temperature and location of eutectic are given in this phase diagram. Calculate the freezing range of alloy with X Ag = 0.13 (A) 192.5 K (B) 120 K (C) 133K (D) 200 K

Q.43 A liquid alloy (Ag-Cu) of eutectic composition of 0.42 mole fraction undergoes the eutectic reaction into and phase of mole fraction of 0.13 and 0.95 respectively .The ratio of relative amount of and phase is .

(A) 4.29

(B) 1.827

(C) 2.348

(D) 0.35

Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

11

2014

METALLURGICAL ENGINEERING MT

Common data for questions Common Data for question 44 and 45 Initial steel slab thickness = 500mm Coefficient of friction () = 0.5 Roll diameter = 550mm The slab wide = 600mm

Flow stress at entrance is 150Mpa where as exit is 250Mpa Q.44 Determine the Coefficient of friction () when steel slab is reduced into1.5mm as maximum possible reduction

(A) 0.00545

(B) 0.90

(C) 0.0540

(D)0.0738

Q.45 Calculate the rolling load (in MN) if steel slab is hot rolled 55 % from initial slab Assume: Coefficient of friction () = 0.5

(A) 40

(B) 50

(C) 60

(D) 200

**********END OF THE QUESTION PAPER *******

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Government College of Engineering, Salem, TN.

AMMASI A Trainee Scientist, CSIR NML, Jamshedpur, India.

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