UNIVERSITY OF MALTA

FACULTY OF ENGINEERING
B.ENG. (HONS.) COURSE
MECHANICAL ENGINEERING STREAM
YEAR III and IV SEMESTER II
JUNE 2015 SESSION OF EXAMINATIONS

MME 3210

Materials Processing Techniques

Tuesday 5th June 2015

TIME: 08.30 am 10.35 am

Reading time: 8.30 am to 8.35 am
Duration of examination: 8.35 am to 10.35 am

This paper contains FIVE questions. You are to attempt FOUR questions.

Stationery: Use of calculators is allowed

1.

(a) Make a list of eight process performance measures by which different

manufacturing processes may be compared to each other. Write brief notes on each
and make reference to specific processes.
(16 Marks)

(b) Explain how the choice of a materials processing technique for a particular product
is influenced by both the ratings of its performance measures and the product
design specification.
(9 Marks)

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2.

(a) Distinguish between bulk and sheet forming processes. List two processing
techniques that fall under each of these two categories.
(4 Marks)

(b) Indicate the casting/moulding process that is normally used for the manufacture of
the following products. For each case explain how the product requirements have
influenced the choice of the process.
(i)
(ii)
(iii)
(iv)
(v)

Aluminium alloy car cylinder head;

Platinum rings;
Plastic cutlery;
Steel pipe;
Large PVC plastic water storage tank.
(15 Marks)

(c) In each of the products listed below give the principle reason why forming
(including pressing and sintering) is used rather than casting.
(i)
(ii)
(iii)

Tungsten racing weights for chassis;

Low alloy steel spanner;
Long Aluminium alloy channel for window frames.
(6 Marks)

3.

(a) Dendritic microstructures are a common occurrence in single phase alloy castings.
Describe the mechanism responsible and the conditions required for this type of
solidification.
(10 Marks)

(b) Both upper and lower bound analysis are used to predict the loads required for bulk
deformation processes. Briefly explain the main principles of these analytical
methods and give an example where each would be the most applicable and why.
(10 Marks)

(c) The ability for a liquid (that solidifies by freezing) to flow through all the mould
passages and reach all the parts of the mould is described in terms of the liquid's
fluidity.
(i)

List six factors that affect fluidity.

(3 Marks)

(ii)

Give two reasons why very high fluidities are achieved in pressure die
casting.
(2 Marks)

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4.

(a) For bulk forming operations, the product quality, forming loads and materials
formability depend on the forming temperature. Explain. (Make direct reference to
cold, warm and hot forming temperature regimes).
(12 Marks)
(b) Explain the dependence of the strain rate sensitivity exponent (m) on the
homologous temperature (T/Tm) for metallic materials.
(6 Marks)

(c) Write notes on the construction and usefulness of forming limit diagrams for sheet
metal forming.
(7 Marks)

5.

(a) State whether the following statements are true or false.

i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.

Tensile hydrostatic stresses are important during bulk forming as they prevent
crack formation.
Mass feeding is the only feeding mechanism that results during solidification of
long freezing range alloys.
Spherulitic growth in polymers is analogous to dendritic growth in alloys.
Squeeze casting is used to produce high quality products.
All metallic materials can display superplastic behaviour.
The plastic strain ratio (R) can be obtained from a torsion test.
Closed die forging and open die forging are both very flexible processes.
The solidification time for injection moulding is proportional with the square of
the component thickness.
Rolling processes can produce discrete products.
Pressure die casting is synonymous to high density cast products.
Hydroplastic forming is possible with all ceramic materials.
Conventional powder processing often results in fully dense components.
Hot isostatic pressing can produce very high quality tool steels.
A cast microstructure can be converted to a wrought microstructure during cold
forging.
Considre's construction predicts that an increased work hardening rate results
in increased uniform strain.
(15 Marks)

(b) Powder processing presents a number of advantages compared to solid state

forming. List five of these advantages.
(5 Marks)

(c) With the help of a sketch, describe the densification mechanisms that occur during
liquid phase sintering.
(5 Marks)

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