Applied Science 278 Final Exam 14 April 2011

THE UNIVERSITY OF BRITISH COLUMBIA

Department of Materials Engineering
APPLIED SCIENCE 278
Engineering Materials

FINAL EXAMINATION
April 14th, 2011

This is a Closed Book Examination.

The use of calculators having stored information of relevance to this course is forbidden.

Time: 2.5 hours

Answer all questions (total marks=100). The complete exam is 7 pages in length.

Some useful formulae, material data and a phase diagram are given on the last 2 pages
of the exam. The use of sketches or schematic diagrams are encouraged wherever
these will aid in solving or discussing a problem.
Show all work !! Good Luck !

Marks
10 Q1. Sketch typical engineering and true stress-strain curves for a ductile metal.
6 (a) On the curves identify the following regions: elastic deformation, work hardening,
yield stress, ultimate stress, necking.

Work hardening

0.5 marks each on

each curve, for a
total of 6 marks

elastic necking (f not required)

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 Applied Science 278 Final Exam 14 April 2011

2 (b) With the aid of your sketch, discuss the significance of:
(i) toughness
(ii) modulus of resilience

Toughness is the energy

required for failure

Modulus of resilience is the

measure of elastic energy
storage
2 (c) What is heterogeneous yielding and how can you tell from a stress-strain curve?

15 Q2. You are provided with data on 70% Cu 30% Zn brass in Figure 1.
9 (a) On one figure, draw your best estimate of what the engineering stress-strain
curve should look like for material that has been cold-worked (i) 0% (ii) 20% (iii)
50%.

From Figure 1, we can extract the following information:

coldwork sy UTS ef
0 10 45 70
20 50 60 25
50 60 80 2

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 Applied Science 278 Final Exam 14 April 2011

We then use this to create schematic engineering stress-strain curves:

90
80
70
60
50 0%

40 20%

30 50%

20
10
0
0 0.2 0.4 0.6 0.8

The one piece of information we do not have is the final failure stress so that has been
guessed. For each curve, one mark for getting the yield stress, the UTS, and the strain
to failure right on the stress-strain curve, along the lines of what is above.

3 (b) Briefly discuss why the strength increases with increased cold working.

As the dislocation density increases with cold work, the stress required to get
dislocation motion increases as the dislocations interact and impede each others
motion.

3 (d) What would Figure 1 look like if instead of cold working it were hot working?
Why?

If hot working, then the structure would be continuously recovering and recrystallizing,
and there would be no increase in dislocation density, hence no increase in required
stress, hence no work-hardening. All three lines (tensile strength, yield strength,
elongation to failure) would be ~ flat lines equal to the undeformed condition.

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 Applied Science 278 Final Exam 14 April 2011

Figure 1 Mechanical properties as a function of cold work

15 Q3. A tin-bismuth alloy of composition 60 wt%Sn-40 wt%Bi is slowly cooled from a

temperature of 250C. See Figure 2.
3 (a) At what temperature does the first solid phase form?

See diagram: 174 C

3 (b) What is the composition of this solid phase?

See diagram: 13% Bi, 87% Sn weight percent

3 (c) At what temperature does complete solidification of the alloy occur?

See diagram: 139 C

3 (d) What is the composition of the last liquid remaining prior to complete
solidification?

See diagram: 57% Bi, 43% Sn weight percent

3 (e) Sketch the resulting microstructure and describe the major features.

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Applied Science 278 Final Exam 14 April 2011

Above 13 C, primary beta Sn particles (composition 21 wt% Sn or less, depending on

temperature) in a sea of eutectic grains (with beta Sn and pure Bi layered structure per
temperature). Below 13 C, transformation to alpha Sn.

Figure 2 Sn-Bi Binary Phase diagram

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 Applied Science 278 Final Exam 14 April 2011

11 Q4
5 (a) A Southwest Airlines Boeing 737 recently had a (non-catastrophic) fuselage
failure at about 35,000 landing/take-off cycles. The design had assumed that
fatigue would not be an issue until approximately 60,000 cycles. Assuming that
the aluminum data in Figure 3 is applicable, how much higher than expected
were the actual stresses?

Draw a vertical line at 35,000 cycles, one at 60,000 (remember log scale), see intercept
on S-N curve, values are 300 and 284 respectively (approx.). So ratio is
300/284=1.056 Therefore stresses were 5-6% higher than expected
3 (b) Assuming that the loading is tensile with R=0, and the fracture toughness of the
material is 44 MPa , what is the critical crack size assuming that you can use
K Y a with Y=1.

Stress amplitude is 300 MPa with R=0, so max stress is 600 MPa,therefore plugging in
we have 44=1 x 600 root(pi x a). Thus a = 1.7 mm
3 (c) Describe, with the aid of sketches as appropriate, the mechanism of fatigue crack
growth.

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 Applied Science 278 Final Exam 14 April 2011

Figure 3 S-N Curve for various materials under reversed loading

12 Q5. For a BCC Fe lattice structure with atomic radius 0.124 nm, and given =0.155 nm
and n=1, calculate for the (110), (200), and (211) planes:

4 a) interplanar spacing

First calculate unit cell lattice parameter, which for BCC is 4root(3)/3 x 0.124 = 0.2866

0.2866
dhkl nm
h2 k2 l2
1
2

Thus (110) -> .2027 nm (200) -> 0.1433 nm and (211) -> 0.1170 nm

4 b) diffraction angle (2)

n
sin
2dhkl

Thus (110) -> sin()=0.3824 so =22.5 and 2=45 degrees

Thus (200) -> sin()=0.5408 so =32.7 and 2=65.4 degrees

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 Applied Science 278 Final Exam 14 April 2011

Thus (110) -> sin()=0.6623 so =41.5 and 2=83 degrees

4 c) The atomic weight of Fe is 55.85 g/mol. What is the density of BCC Fe in g/cm3?

BCC two atoms per cell. Thus density = 2*55.85/6.023x10^23/(0.2866)^3=7.88 g/cm^3

15 Q6. A continuous fibre unidirectional composite laminate has 60% by volume of carbon
fibres in an epoxy resin matrix. Assume that the values of E and the UTS are 200
and 3 GPa for the carbon fibres and 4.0 and 0.10 GPa for the epoxy.
3 (a) Calculate the modulus (E) of the laminate parallel to the fibres

E=200*0.6+4*0.4=121.6 GPa
3 (b) Calculate the modulus (E) of the laminate perpendicular to the fibres.

1/E=0.6/200+0.4/4=0.103 Thus E=9.7 GPa

3 (c) Calculate the fraction of the total load carried by the fibres when both the fibres
and matrix are being loaded elastically parallel to the fibres.

Ff E f / Em
=
Fc E f / Em Vm / Vf
= (200/4)/(*200/4)+(0.4/0.6))= 0.987
4 (d) Assuming neither the matrix or fibres deform plastically, which breaks first on
continuous loading when loaded parallel to the fibres?

Strain to failure of fibre = 3/200=1.5%

Strain to failure of matrix = 0.1/4=2.5%

Fibre fails first

2 (e) Sketch the deformation you will get if this unidirectional laminate is loaded at 45

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 Applied Science 278 Final Exam 14 April 2011

10 Q7. A type 1 cement typically has the following composition:

C3S 55%
C2S 20%
C3A 12%
C4AF 9%
3 (a) Discuss the strengthening role of each constituent during the setting and
hardening processes.

need just one line per component do not need full description above
2 (b) Discuss the role of air entrainment agents.

Allows material to withstand the effects of freeze/thaw cycles. Water in the concrete
migrates to air bubbles and is frozen in the void as a result, stress associated with
water expansion on freezing is minimized.
2 (c) What is the purpose of a slump test?

To define the workability (and indirectly strength) of a batch of concrete. It is easily

done onsite and on a given batch (so good for quality control/consistency checking).
3 (d) Compare and contrast the failure mechanisms of concrete and reinforced
concrete when loaded in bending.

In unreinforced concrete, the moment the tensile strength of concrete is exceeded

on the tensile face of the beam, a crack initiates and propagates rapidly, leading to
overall failure of the beam at a very low load. With reinforced concrete, the concrete
on the tensile side cracks, sheds the load on the rebar, which then carries the tensile

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 Applied Science 278 Final Exam 14 April 2011

loads, until a combination of shear cracks, debonding of the rebar, crushing of the
concrete on the compression side leads to overall stable softening failure of the
beam. [only a brief version of the above needed]

12 Q8
3 (a) Describe, with the aid of a sketch, how the properties of a polymer such as
strength or softening temperature, are affected by increasing molecular weight.
Why?

The lower the molecular weight the easier the molecules can slip by each other. As
the molecules become long enough, then this effect becomes asymptotic to the
response of the entangled molecules.

2 (b) Why does semi-crystalline PE become transparent when deformed?

PE is initially translucent as it is semi-crystalline and the crystalline regions scatter

light. During deformation the crystalline regions break up, and when the crystal size
becomes less than the wavelength of light the material becomes transparent.

]
4 (c) Sketch the specific volume-temperature response of a polymer with structure
which is (i) amorphous (ii) 50% crystalline (iii) 100% crystalline. Mark and explain
all significant features.

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 Applied Science 278 Final Exam 14 April 2011

Tm is the melting point of the crystal structure, and Tg is the glass transition
temperature of the amorphous areas. Melt is where the crystal structure goes from
ordered to liquid (disordered) and glass transition is when the amorphous areas become
much stiffer due to the loss of rotation mobility of the longer parts of the chains, leading
to glassy brittle behaviour.

3 (d) What are elastomers, and what is it about their molecular structure that gives
them their properties.

Elastomeric materials have rubber-like elasticity, and they can be deformed to large
deformations and will spring back to their original form. To be classed as elastomeric is
must meet the following criteria

1. it must not crystallise easily, elastomeric materials are amorphous

2. chain bond rotations are relatively free, to allow easy uncoiling
3. onset of plastic deformation must be delayed, crosslinking restricts chains from
passing each other
4. the elastomer must be above its Tg

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Applied Science 278 Final Exam 14 April 2011

Useful Formulae Q DPn nn

Mn
s K 2 n exp
y RT m
x

z z Qv DPw n w
Mw
N v N exp
RT m
E 2G1 E
theoretical
L Nd sin( )
1 y 2 10 2
Ur y
2 2E R cos cos rd n
y u or r n i.e. d
toughness f a
1
2
o 1 2
2
m t
T 1

t

t o exp

1
T ln1 a 2
t
m 2 o Er ( t )
t o
T K Tn 1
2 E s 2
Ewll Es
c s
nA / N A a
=
Vc 2

2 E s p
1
2 Ew Es
n 2d sin c s
a
a E c E f V f E mVm
d hkl
h K
f y
1
2
k 2 l2
2
y
2r Ec
Em E f
EmV f E f Vm
rate Ae Q RT
K Y a
2 Ff Ef Vf
t recrx Ae Q RT K =
B 2.5 Ic Fm Em Vm
y
1 Ff E f / Em
o k yd 2 =
E f / Em Vm / Vf
max min Fc
a
2
s K1 n *f d
lc
2 c
R min
max
NA=6.023 x 1023 atoms/mol Ec=KEfVf + EmVm
R = 8.314 Jmol-1K-1 M n xi M i
M w wi M i

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 Figure A.1 Iron Carbon Phase diagram

Table A1 Characteristics of selected elements

Element Symbol Atomic Number Atomic Weight(gmol-1) Density (gcm-3)
Aluminum Al 13 26.98 2.71
Bromine Br 35 79.90 -
Carbon C 6 12.011 2.25
Chlorine Cl 17 35.45 -
Copper Cu 29 63.55 8.94
Fluorine F 9 19.00 -
Gold Au 79 196.97 19.32
Hydrogen H 1 1.008 -
Nickel Ni 28 58.69 8.90
Nitrogen N 7 14.007 -
Oxygen O 8 16.00 -
Titanium Ti 22 47.88 4.51
Tungsten W 74 183.85 19.3
Zinc Zn 30 65.39 7.13