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a)
b)
Niobium (Nb) has an atomic radius of 0.143 nm and a density of 8.57 g/cm3.
Determine whether it has a face centered cubic (FCC) or body centered cubic (BCC)
crystal structure. (Atomic weight : 92.91 g/mol, Avogadros No. : 6.022 x 1023 atoms/mol)
(5 marks)
c)
[122]
(ii)
[021]
(iii)
(321)
(iv)
(201)
(8 marks)
d)
Vacancy and grain boundary are the type of defects found in solid metal. Explain;
i)
ii)
e)
Describe with the aid of sketches the ingot structure when metal is produced by the following
casting conditions;
i)
ii)
(2 marks)
1. the differences in grain structure between cold worked and recrystallized metal.
(4 marks)
2. the dislocation density and residual stress between cold worked and
recrystallized metal.
(3 marks)
3. the effect on the strength, ductility and hardness affected by this process?
(4 marks)
-2SKMM 1613
b) (i)
Sketch (in one graph) and briefly describe a typical stress and strain curve for metal,
ceramic and polymer.
(ii)
(6 marks)
A tensile stress is to be applied along axis of a cylindrical brass rod that has a diameter of
10 mm. Determine the magnitude of the load required to produce a 2.5 x 10 -3 mm change
in diameter if the deformation is entirely elastic. Assume the Poison ratio for brass is 0.34.
(6 marks)
ii)
iii)
b) i)
Base on data in Figure 1 construct a complete phase diagram of copper (Cu) nickel (Ni)
on a graph paper provided . Label completely.
Figure 1
-3SKMM 1613
ii)
ii)
Sketch the room temperature microstructure for 0.4%C steel. Also calculate
percentage of proeutectoid ferrite.
(10 marks)
b) Based on Figure 2 :
i)
Name the heat treatment process for 0.4 % steel for treatment (a), (b) and (c)
-4SKMM 1613
Figure 2
Question 5 (25 marks)
a) i)
ii)
(7 marks)
b) What are the main alloying elements in maraging steel?. Describe how to produce this alloy
steel.
c) i)
(4 marks)
Give two examples of non ferrous metals and list their properties and applications
(4 marks)
ii)
Suggest and explain two methods to strengthen these non ferrous metals
.
(4 marks)
d) Suggest with reason a suitable non-metallic engineering materials for the following applications:
i) High performance bicycle frame
ii) Cutting tools
iii) Frying pan holder
(6 marks)
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Question 1 (15 marks)
(a)
For each of the following compound, state with reason whether the bonding is metallic,
covalent or ionic. (Given : Atomic number for N=7, H=1, Al=13, C = 6 )
(i) NH3
(b)
(ii) Al
(iii) C2 H6
(9 marks)
Show that the atomic packing factor (APF) for Face Centered Cubic (FCC) is 0.74
(6 marks)
Question 2 ( 13 marks)
(a)
Rhodium has an FCC crystal structure, an atomic radius of 0.1345 nm and an atomic
weight of 109.9 g/mol. Calculate the density of rhodium.. (Given: Avogadros Number is
6.023 x 1023 atoms/mole).
(b)
(5 marks)
Draw in a separate cubic unit cell the following directions and planes;
(i) [ 3 2 1 ]
(ii) ( 1 3 3 )
(iii) ( 1 3 3 )
(iv) ( 1 2 3 )
(8 marks)
(3 marks)
(b)
Explain with the of sketches the solidification of pure metal with the addition of grain
refiner agent.
( 5 marks)
(c)
(5 marks)
Question 4 (9 marks)
(a)
Name and explain two strengthening mechanisms. The explanation should include how
dislocations are impeded for each of the strengthening techniques.
(5 marks)
(b)
Two castings of the same material were produced by using preheated sand mould and
metal mould respectively. Explain with reasons which casting is stronger and harder..
(4 marks)
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Question 1 (10 marks)
a)
Explain the differences between covalent bonding and metallic bonding in engineering
materials.
(2 marks)
b)
For each of the following compound, state with reason whether the bonding is
covalent or ionic. (Atomic number, Z : H = 1, Mg = 12, O = 8, C = 6)
i) MgO
c)
ii) C2H6
(4 marks)
Molybdenum (Mo) has a BCC crystal structure with a density of 10.28 g/cm3 and atomic mass of
95.94 g/mol. Determine the atomic radius of this metal.
(Avogadros No.=6.023 x 1023 atoms/mol)
(4 marks)
ii. [ 1 2 1]
ii) ( 0 0 1 )
(6 marks)
b)
Determine the Miller indices for the directions P, Q and planes R , S in the following unit cells;
(6 marks)
c)
Compare the diffusion mechanism between interstitial and vacancy atom. Which type of the
diffusion mechanism is more rapid? Give two reasons.
(4 marks)
Name and explain two strengthening mechanisms. The explanation should include how
dislocations are impeded for each of the strengthening techniques.
(4 marks)
(b)
Two castings of the same material were produced by using preheated sand mould and metal
mould respectively. Explain with reasons which casting is stronger and harder.
(4 marks)
(c)
Calculate the percentage of cold work for the cold worked copper rod shown in Figure 1. If the
expected percentage of cold work is 40%, what is the final diameter of the rod?
(4 marks)
Figure 1
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ii.
Choose one of these strengthening mechanism and describe with the aid of
sketches.
(8 marks)
b) i.
ii.
discuss the differences between cold working and hot working in terms of
microstructure, mechanical properties and surface finish.
(8 marks)
Question 2 (16 marks)
(a)
ii.
(b)
ii.
iii.
Explain with the aid of sketches the solidification process form liquid state to room
temperature.
iv.
(12 marks)
Figure 1
(4 marks)
(b)
Describe the expected mechanical properties, microstructure, and heat treatment method for
the following heat treatment processes.
i.
Normalising
ii.
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Question 1 (12 marks)
(c)
Consider the magnesium (Mg) - lead (Pb) phase diagram in Figure 1. For 50%Mg-50%Pb alloy :
v.
(2 marks)
vi.
vii.
viii.
Sketch the cooling curve for the alloy and the room temperature microstructure.
( 4 marks)
( 3 marks)
Figure 1
(d)
(2 marks)
ii.
(6 marks)
With the aid of sketches explain the hardenability curves for 0.5% carbon steel and 4340 alloy
steel (1.85Ni-0.80Cu-0.25Mo)
(e)
(4 marks)
ii.
iii.
(3 marks)
(4 marks)
Figure 2
(2 marks)
(b) Briefly describe two factors that affecting the formation of carbon in cast iron either in the form
of graphite or cementite.
(4 marks)
(2 marks)
(ii)
(4 marks)
(iii)
Cast Iron A
Cast Iron B
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Question 1 (25 marks)
(f)
Figure 1 shows a part of Fe-C phase diagram for steel. With the aid of a suitable sketches :
(i)
Explain phase transformation for 0.3% carbon steel from 1000oC to room temperature.
(ii)
Explain phase transformation for 1.2% carbon steel from 1000oC to room temperature.
(iii)
Figure 1
(g)
For the following heat treatment processes, describe the treatment process, their expected
microstructure and mechanical properties.
(i)
(ii)
(h)
What is a suitable heat treatment to be used to strengthen small carbon steel components such
as screws, wire and nails. Describe the treatment method.
(5 marks)
Briefly describe two factors that affecting the formation of carbon in cast iron either in the form
of graphite or cementite.
(5 marks)
(b)
(i)
(ii)
Figure 2
(9 marks)
List four effect of the addition of alloying elements on carbon steel. Explain two of these effects.
(4 marks)
(b)
Give four types of alloy steels and examples of applications. What is a suitable alloy steel to be
used as surgical instruments. List the main alloying elements.
(7 marks)
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QUESTION 1 (10 marks)
(i) ionic
(iii) metallic.
(6 marks)
(b) For each of the following element/compounds, state whether the bonding is metallic, covalent or
ionic;
(4 marks)
(a) Determine the Miller indices for planes drawn in the following cubic unit cells
(3 marks)
z
(i)
(ii)
x
x
(b) Draw the following direction vectors and planes in separate cubic unit cells.
(i) [ 1 0 1]
(ii) [ 2 2 1]
(iii) (0 1 1 )
(iv) (3 2 1)
(8 marks)
(a) Describe and illustrate the solidification process of metal with impurities.
(5 marks)
(b) Explain with the aid of relevant sketches the substitutional and interstitial diffusion mechanisms
in solid metals.
(4 marks)
(c) Explain the difference between point defects and linear defect.
(2 marks)
QUESTION 4 ( 18 marks)
(a) Explain what is meant by slip system and whether all metals have the same slip system.
(4 marks)
(b) Explain briefly why metals such as magnesium (Mg) and zinc (Zn) which have hexagonal close
packed (HCP) crystal structures are more brittle than metals such as aluminium (Al) and copper
(Cu) which have face-centred cubic (FCC) crystal structures.
(4 marks)
(ii) List the FOUR main strengthening mechanisms and provide a comparison between
them in terms of the type of barrier that will result in increased strength
(10 marks)
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Question 1 (25 marks)
(a)
What is the relationship between the length of the side a (also known as the lattice constant) of
the body-centred cubic (BCC) unit cell and the radius, r, of its atoms? Tantalum at 20oC is BCC
and has a lattice constant of 0.33026 nm. Calculate its atomic radius.
(3 marks)
(b)
[ 1 1 0]
ii)
[2 0 3]
iii)
(2 3 2)
iv)
(1 2 0)
(8 marks)
(c)
Briefly explain with illustration dendrite formation in the solidification of a metal. Describe with
the aid of schematic drawing of ingot structures when metal is produced by casting;
i)
ii)
iii)
(8 marks)
(d)
In reality metals are never perfect and contain various types of defects which affect many of
their physical and mechanical properties. Identify these defects with brief explanation and
illustrations.
(6 marks)
-3SME 1613
i)
What are the information can be obtained from a stress strain curve?
ii)
With the aid of a sketch of stress strain curves, explain the difference between a
ductile and brittle materials. Give an example of material for each.
(6 marks)
(b)
The amount by which this specimen will elongate in the direction of the applied
stress.
ii)
(c)
(6 marks)
i)
(2 marks)
ii)
( 3 marks)
iii)
Suggest and explain a method in order to improve its ductility after cold work.
How does the ductility can be increased by this method?
(8 marks)
-4SME 1613
Question 3 (25 marks)
Copper (Cu) and Silver (Ag) form an alloy with limited solid solubility system. The melting points of Cu
and Ag are 1085oC and 970oC respectively, with eutectic temperature and composition of 779oC and
71.9% Ag. At eutectic temperature, the maximum solid solubility of Ag in Cu is 8 % and Cu in Ag is 8.8%.
Assume solid solubility is 0 at room temperature.
(a)
Plot and label the phase diagram of Cu-Ag on a graph paper provided.
(8 marks)
(b)
ii)
iii).
(4 marks)
iv)
Calculate the relative amount of pro eutectic and eutectic phase just below
the eutectic temperature ( TE-T).
(4 marks)
v)
Discuss with the aid of sketches, solidification process of this alloy in equilibrium
from 1100oC to room temperature. Sketch the cooling curve and room
temperature microstructure of the alloy.
(9 marks)
Name and briefly explain FOUR different phases (microstructures) of carbon steel.
(4 marks)
-5SME 1613
(b)
Briefly explain the heat treatment procedure by drawing the cooling path on the TTT diagram
provided (Figure 1) to obtain the following microstructure.
(c)
I)
ii)
(d)
i)
100 % martensite
ii)
iii)
(9 marks)
(4 marks)
(4 marks)
For the following carbon steel, name and explain a suitable surface hardening process.
i)
ii)
marks)
(4
Give a suitable example of the application each made of polymer, ceramic and composite
materials. Explain why.
(6 marks)
(j)
i)
metals.
ii)
Explain how the strength and hardness of non heat treatable and heat- treatable
aluminium alloys can be increased?
(7 marks)
-6SME 1613
(c )
Figure 2 shows microstructure of three different cast irons. Identify the type of cast iron,
properties and example of application and describe how each type is produced.
(12 marks)
(X)
(Y)
(Z)
Figure 2
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QUESTION 1 (11 marks)
(a) Explain with the aid of relevant sketches the difference between atomic bonding in copper (Cu) and
atomic bonding in magnesium oxide (MgO).
(4 marks)
(b) Calculate the atomic packing factor for the body centred cubic (BCC) unit cell, assuming the atoms
are hard spheres.
(4 marks)
(c) The lattice constant for BCC vanadium at 20OC is 0.3039nm and its atomic mass is 50.94 g/mol.
Calculate the density of vanadium.
(Given: Avogardos Number is 6.02 x 1023 atoms/mol)
(3 marks)
(a) Determine the Miller indices for planes drawn in the following cubic unit cells
(3 marks)
(i)
(ii)
(b) Draw the following direction vectors and planes in separate cubic unit cells.
(i) [ 1 1 0]
(ii) [ 3 2 1]
(iii) (1 1 0 )
(iv) (2 2 1)
(8 marks)
(c) Explain with the aid of relevant illustrations point defects often found in metals.
(6 marks)
(b) What factors affect the diffusion rate in solid metal crystals? Name the two main
mechanisms of diffusion of atoms in solid metals.
(4 marks)
QUESTION 4 (9 marks)
(a) Explain how grain boundaries impede dislocation motion and why a metal having
finer grains is stronger than one with coarser grains.
(5 marks)
(d) Two previously undeformed cylindrical specimens A and B of an alloy are to be strained hardened by
reducing their cross-sectional areas. For specimen A, the initial and deformed radii are 17 mm and
12 mm respectively. Specimen B, with an initial radius of 13 mm, must have the same deformation
ratio as specimen A. Compute the radius of specimen B after deformation.
(4 marks)
QUESTION 5 (9 marks)
(a) Cite the primary differences between elastic and plastic deformation behaviours.
(2 marks)
(b) For the tensile stress-strain behaviour for the cylindrical brass specimen with initial
diameter of 12.8mm and 250 mm in length is shown in Figure 1. Determine the
following:
i.
ii.
iii.
iv.
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Question 1 (25 marks)
(a) Differentiate between metallic and covalent bonding and give examples.
(4 marks)
(b) Molybdenum (Mo) has a BCC crystal structure with a density of 10.28 g/cm3 and atomic mass of
95.94 g/mol. Determine the atomic radius of this metal.
(Avogadros No. = 6.023 x 1023 atoms/mol)
(6 marks)
(c) Draw in a separate unit cells the following Miller indices:
(i)
[103]
(ii)
[122]
(iii)
(212)
(iv)
(201)
(6 marks)
(d) (i)
(ii)
(iii)
(iv)
Give two examples of engineering processes where diffusion plays an important role.
(9 marks)
(3 marks)
(4 marks)
(iii) For alloy 90% Cu 10% Sn calculate the relative amount of phases at 900oC .
(3 marks)
(iv) Discuss with the aid of sketches, solidification of this alloy (90%Cu-10%Sn) in
equilibrium condition from 1200oC to 400oC.
(5 marks)
(v) Discuss with the aid of sketches, phase transformation for 70%Cu-30%Sn from
700oC to 400oC.
(6 marks)
Figure 1
A plain carbon steel containing approximately 0.6% carbon was heat treated as follows:
Heated to 900oC and quenched in cold water.
Heated to 900oC and slowly cooled in the furnace.
(a) Name the heat treatment process and describe with the aid of sketches the microstructure obtained
by these treatments and predict the mechanical properties.
(12 marks)
(b) Which heat treatment would you consider best with reaqsons for the following applications :
(i)
(ii)
(c)
Small, thin pieces of 0.5mm thick hot-rolled strip of 1080 steel are heated for 1 hour at
900oC and then given the heat treatments shown in Figure 2 ( TTT Diagram) with the
respective cooling paths.
(i)
(ii)
Name the treatment and suggest an example of application for treatment (R) and (S).
(3 marks)
ii.
(4 marks)
Figure 2
Question 4 (25 marks)
(a)
(i)
(ii)
List two non-ferrous alloys that are suitable for the following applications:
(1)
(2)
(iii)
With the aid of a suitable sketches explain a suitable heat treatment process to
improve the mechanical properties of Al-4.5%Cu (Figure 3) for aircraft applications.
(5 marks)
Figure 3
(b)
(c)
hardness
(ii)
ductility
(iii)
melting temperature .
(3 marks)
List three properties of thermoplastic and thermosetting polymers and suggest two
applications for each.
(d)
(4 marks)
Suggest the most suitable non-metallic engineering materials for the following components
and explain why.
(i) High performance bicycle frame
(ii) Cutting tools
(iii) Frying pan holder
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(8 marks)
(vi)
(vii)
marks)
(viii)
(2.5 marks)
(6
i.
i.
Discuss with the aid of sketches, solidification of this alloy in equilibrium condition.from
1200 C
(5.5 marks)
ii.
(3 marks)
(3 marks)
Exam question
(d)
Describe with the aid of sketches the microstructure obtained by these treatments
(4 marks)
(e)
(f)
Which treatment would you consider best for (1) cutting tools (2) dynamically stress
engineering components (3) 0.02 % C steel sheet for making car body pressings
(3 marks)
(4 marks)
(g) Small, thin piece of 0.5mm thick hot-rolled strip of 1080 steel are heated for 1 hour at 900C
and then given the heat treatments shown in Figure 1 ( TTT Diagram) with the respective
cooling path.
i.
Determine the microstructure of the samples after each heat treatment
(4 marks)
iii.
iv.
Name the treatment and suggest example of application for treatment (C) and
(D)
(5 marks)
Explain how heat treatment ( B ) is conducted.
(5 marks)
Test 2
Question 2 (25 marks)
(a)
Sketch and label Fe-C phase diagram for steel up to 1130 C.. List 4 microstructure of
carbon steel.
(6 marks)
(b).
(c).
i.
With the aid of sketches explain phase transformation when it is slowly cooled
from to room temperature.
(3 marks)
ii.
For the following heat treatment, give a suitable heating temperature, heat treatment
method and microstructure & properties expected.
i.
ii.
iii.
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Question 1 ( 17 marks)
(a)
i.
Briefly explain two factors effecting the formation of carbon either as graphite or
cementite in cast iron.
(4 marks)
ii.
For white cast iron briefly explain on microstructure and properties and a method to
improve its ductility.
(4 marks)
(b)
Sketch the microstructure and describe how each type of the following cast iron is produced :
i.
ii.
iii.
( 9 marks)
ii.
What is the difference between tools steel and high speed steel?
(6 marks)
(4
marks)
(b)
List three type of stainless steel and explain how each type of these stainless steel is
strengthened. Justify your answer.
(6 marks)
Distinguish between thermoplastic and thermosetting. Give two examples of product for each
type of plastic.
(5 marks)
(b)
(c)
List three types of composite. Give two examples of matrix materials, reinforcement materials
and product for each type of the composites.
(6 marks)
(6 marks)
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Question 1 (20 marks)
a)
Explain the differences between covalent bonding and Ionic bonding in engineering
materials. Give two example of material for each type of bonding
(6 marks)
b)
Molybdenum (Mo) has a BCC crystal structure with a density of 10.28 g/cm3 and atomic
mass of 95.94 g/mol. Determine the atomic radius (R) of this metal.
(Given : a = 4/ R 3, Avogadros No.=6.023 x 1023 atoms/mol)
(6 marks)
c)
Determine the Miller indices for the directions P, Q and planes R , S in the following unit
cells;
( 8 marks)
Question 2 (12 marks)
a)
Draw and briefly explain cooling curve and solidification process for the following metals
i.
ii.
b)
Sketch and briefly describe two types of crystal defect which are form during the
solidification process.
(5 marks)
a)
b)
Explain how the ductility of steel can be improved after the cold working process. Sketch
the microstructures and explain each stage of the treatment process.
(7 marks)
Two previously undeformed cylindrical specimens A and B of an alloy are to be strained
hardened by reducing their cross-sectional areas. For specimen A, the initial and
deformed radii are 20 mm and 14 mm respectively. Specimen B, with an initial radius of
15 mm, must have the same deformation ratio as specimen A. Compute the radius of
specimen B after deformation.
(4 marks)
a)
Differentiate between:
i. Tensile strength and yield strength
ii. Elastic deformation and plastic deformation
(4 marks)
b)
c)
From stress strain curves for three different materials in Figure 1, choose which material
has following property and why?
i. highest elastic modulus
ii. highest ductility
iii. highest toughness
Figure 1
(3 mark)
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Question 1 (20 marks)
ii.
(6 marks)
Figure 1
(14 marks)
i.
Draw and label the phase diagram for steel from 0 1130oC.
ii.
Describe the change in microstructure for 0.4%Carbon steel when it is slowly cooled
from the austenitic region to room temperature.
iii.
(b)
For the following heat treatment for 0.6% carbon steel , explain in terms of heat treatment
procedure, microstructure and properties expected.
i.
full annealing
ii.
(8 marks)
(c)
Explain the advantages of these heat treatment processes and describe how can these
processes can be carried-out ?
i.
martempering
ii.
austempering
(8 marks)
XXXXXXXXXXXXXXXXXXXXX
Figure 1
(d)
The diffusion rates for carbon in titanium were determined in the Table 1.
(8 marks)
Temperature (C)
Diffusion coefficient, D ( m2/s)
Table 1
736
2 x 10-13
782
5 x 10-13
835
x
i)
Evaluate the pre-exponential constant (D0) and the activation energy for diffusion, (Q,
J/mol)
ii) Calculate the rate of diffusion, x at 835 C
Given that the diffusion coefficient, D = D0 exp ( -
),
+ L
78.5% Zn
+L
Cu
Zn
Figure 2
(b) A Part of copper (Cu) zinc (Zn) phase diagram is shown in Figure 2.
(ix) Identify phases (a) to (f)
(3 marks)
(x)
Hypoeutectoid steel
(b)
A steel rod containing 1.5 wt% carbon is heated to 1000 oC for 90 minutes and slowly cooled to
room temperature. At temperature 700 oC:
i)
Figure 3
(7 marks)
(c)
Figure 4 shows heat treatment process applied 0.6% carbon steel. Name and identify the
treatment, microstructure, and properties in treatment (i) and (ii).
(6 marks)
Figure 4
(d)
Determine the microstructure and its percentage at the end of process (i) to (iv)
ii.
iii.
Suggest ONE application for each steel produced by process (iii) and (iv)
(9 marks)
Figure 5
(b)
Explain briefly;
i)
how malleable cast iron being produced and state its special properties and
application.
ii)
the different between malleable cast iron and nodular cast iron.
[8 marks]
(c)
(d)
Name THREE types of stainless steel, cite its composition and main properties. Which of
the stainless steel can be heat treated and why?
[7 marks]
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(d)
Consider the Lead (Pb) Stanum (Sn) phase diagram in Figure 1. For 50% Pb-50%Sn alloy :
ix.
x.
xi.
xii.
Sketch the cooling curve for the alloy and the room temperature microstructure.
( 18 marks)
Figure 1
Question 2 ( 21 marks)
(b)
(b).
Based on Fe-Fe3C phase diagram for steel, explain the phase transformation when 0.4%C steel is
heated at 950oC and slowly cooled to room temperature.
(5 marks)
(c).
For the following heat treatments, describe the heat treatment method and name the
microstructures and properties expected.
iv.
v.
vi.
Sketch and label a typical Time-Temperature Transformation Diagram (TTT Diagram) for
eutectoid steel. Show the cooling path and explain a procedure to obtain the following
microstructure:
i).
ii)
iii)