EMM- 2-Marks

1. S t a t e G i b b ' s p h a s e r u l e ? ( M a y 2 0 1 4 )
The Phase rule allows one to determine the number of degrees of freedom (F) or variance
of a chemical system in equilibrium. This is useful foe interpreting phase diagrams.
F=2+C–P
Where, F = Number of degrees of freedom
C = Number of chemical components
P = Number of Phases in the system.

2. State Hume Rothery's rules for formation of substitutional solid solutions.

To exhibit unlimited solid solubility, the solute and solvent elements should obey
the following general rules of Hume Rothery. They are
1. Size factor: The atoms must be of similar size, with less than the 15% difference in
atomic radius
2. Crystal structure: The materials must have the same crystal structure.
3. Valance: The atoms must have the same valence

3.Differentiate Isomorphous and Eutectic reactions. (May 2012)

Isomorphous s ystem represents all alloys wherein the two metals

have complete solubility in solid and liquid states. These s ystems
form a loop t ype equilibrium diagram.
e.x Cu-Ni; Au-Ag; Au-Ni etc.

Eutectic reaction is defined as a phase transformation in which all

the liquid phase transforms on cooling to two solid phases
simultaneousl y.
e.x Fe-C; Pt-Ag; Cu-Zn etc.
4. Define solid solution.
Solid solution is a type of alloy in which the atoms of alloying elements are distributed in
the base metal and both have similar crystal structure. The composition of alloying
elements may vary but the structure should be similar to the base metal.
e.x Ag-Cu; Cu-Zn; Fe-C etc.

5. Define substitutional and interstitial solid solution. (Nov 2010)

Substitutional : Atoms of allo ying elements occup y the atomic sites

of the base metal.
Interstitial : Atoms of allo ying elements occup y the in terstitial
sites of base metal. This t ype of solid is formed when atomic size
of the allo ying element is much smaller as compared to that of the
base metal.
6. What is quenching? List some of the quenching medium generally used in
industries. (May 2014)

Quenching is the rapid cooling of a workpiece to obtain certain material properties. It

prevents low-temperature processes, such as phase transformations, from occurring by
only providing a narrow window of time in which the reaction is both thermodynamically
favorable and kinetically accessible. For instance, it can reduce crystallinity and thereby
increasing the hardness of both alloys and plastics.
When quenching, there are numerous types of media called quenchants. Some of the more
common include: air, nitrogen, argon, helium, brine (salt water), oil and water. Experience
shows that olive oil is particularly efficient as a good quench.

7. Define critical cooling rate.(Nov 2012)

It is the cooling rate which just avoids entering the pearlite and bainitic
region. It can also be defined as the rate of coo ling necessary to just
suppress the diffusion transformation and avoid the nose of T.T.T curve.

8 . D e f i n e h a r d e n a b i l i t y a n d c a s e d e p t h . (May 2012)(Nov 2014)

Hardenability is defined as the ease with which a desired depth of hardness can
be attained in steel.
Case depth is the thickness of the hardened layer on a specimen.

9. Define recrystallisation. (N14)

Recrystallization is a process by which deformed grains are replaced by a new set of

undeformed grains that nucleate and grow until the original grains have been entirely
consumed. Recrystallization is usually accompanied by a reduction in the strength and
hardness of a material and a simultaneous increase in the ductility.

10. Write the importance of spheroidising annealing. (Nov 2011,May 2012)

This heat treatment increases machinabilit y of steels and softens them.

The microstructure after this treatment shows globules of cementite or
carbides in the matrix of ferrite. This heat treatment is mainl y given to
high carbon & alloy steels.
11. What is the effect of the grain size on the mechanical properties of the
materials? (M14)

Grain size has high influence on mechanical properties of material, viz.

ductility, strength, toughness etc.. The fine grained structure has better
mechanical properties as compared to coarse grain structure.
1 2 . W h a t i s c r e e p ? ( M 1 3 ) (N11) (M11)

Creep is defined as the slow and progressive deformation of material with time
under a constant stress at temperatures approximately above 0.4 Tm. Tm is melting point of
material in ⁰K

13. What is S-N diagram? What is the significance of it? (M14)

Fatigue test results are expressed in terms of stress (S) and the number of
cycles required for failure (N).

1 4 . D i f f e r e n t i a t e b e t w e e n F a t i gu e a n d C r e e p t e s t s . ( N13 )

S .N o F at i gu e t e st C r ee p t e st

1 . In t hi s t es t , sp e ci m e n i s In t hi s t es t , sp e ci m e n i s s ubj e ct ed
s ubj e ct ed t o fl u ct ua t i n g & c yc l i c t o co nst an t t e nsi l e s t r ess .
s t r es s.

2 . Da t a o bt ai n e d b y f a t i gu e t e st a r e Da t a o bt ai n e d b y f a t i gu e t e st a r e
pl ot t e d on S - N cu r v e. pl ot t e d on c r ee p c ur ve .

3 . Gr a ph i s pl o t t ed b et we e n Gr a ph i s pl o t t ed b et we e n c re e p
m ax i m um st r es s(S ) & no . of t est de fo rm at i on o r st ra i n and t i m e .
 c yc l es fo r f a i l u r e. ( N)

15. Define toughness. (N11)

Toughness is the total amount of energy absorbed by the material before its failure.

16. W h a t a r e s u p e r a l l o y s ? ( M a y1 4 )

A superalloy, or high-performance alloy, is an alloy that exhibits several key

characteristics: excellent mechanical strength, resistance to thermal creep deformation, good
surface stability and resistance to corrosion or oxidation. The crystal structure is typically face-
centered cubicaustenitic. Examples of such alloys are Hastelloy, Inconel, Waspaloy, Rene
alloys, Haynes alloys, Incoloy, MP98T, TMS alloys, and CMSX single crystal alloys.

17. W h a t i s p r e c i p i t a t i o n h a r d e n i n g ? ( N o v 1 0 , N o v 1 3 , N o v 1 4 )

Precipitation hardening, also called age hardening, is a heat treatment technique used to increase
the yield strength of malleable materials, including most structural alloys of aluminium,
magnesium, nickel, titanium, and some stainless steels. In superalloys, it is known to cause yield
strength anomaly providing excellent high-temperature strength.

18. What is inoculation? (Nov10)

It is the best method of reducing the size & improving the distribution of graphite flakes by the
addition of a mall amount of materials called as “inoculation”. The materials like calcium
silicate, silicon carbide, metallic calcium, aluminium, titanium are combination of these
materials.

19. What are the primary effects of chromium, and copper as alloying elements in steel?
(May14)

Chromium is added to the steel to increase resistance to oxidation. This resistance

increases as more chromium is added. 'Stainless Steel' has approximately 11%
chromium and a very marked degree of general corrosion resistance when compared
with steels with a lower percentage of chromium. When added to low alloy steels,
chromium can increase the response to heat treatment, thus improving hardenability
and strength.

Copper (0.1-0.4%): Most often found as a residual agent in steels, copper is also
added to produce precipitation hardening properties and increase corrosion resistance.

2 0 . B r i e f a b o u t a n y t w o t yp e s o f p o l ym e r s . ( N 1 3 )

i Li n e a r p o l ym e r – U n i t s j o i n e d t o g e t h e r e n d t o e n d t o f o r m
a single long chain.
 ii B r a n c h e d p o l ym e r – P o l ym e r s w i t h s i d e c h a i n s a t t a c h e d t o t h e
main ones.
2 1 . W h a t a r e t h e a p pl i ca t i o n s o f P ol y S t yr e n e s? ( N 1 3 )
Used for low cost transparent mouldings such as CD cases, Ball
p o i n t p e n s , t o ys e t c .
22. W hat i s P ol ym eri z at i on? (N11)

It i s defi n ed as t he process of form i ng l ar ge pol ym er b y l i n ki ng t o get her

m onom ers.

e.x wood, resi n, st arch, N yl on et c.

23. Distinguish polymer and ceramic with respect to mechanical and physical properties. (N10)

Natural polymers are derived from plants & animals. Mechanical properties of polymers are
low. Also polymers are light in weight.

Ceramic is a compound formed by combination of in-organic and non-metallic materials.

Ceramics are hard and brittle materials and used for high temperature applications.

24. W hat are si al ons? S tat e t hei r appl i c at i ons.(M14)

S i al on i s deri ved from t he i ngredi ent s i nvol ved such as si l i con,

al um i ni um ox ygen & ni t rogen. It i s fo rm ed b y bl endi ng si l i c on ni t ri de
wi t h di fferent propo rt i ons of al um i ni um ox i de, al um i ni um nit ri de &
yt t ri um ox i de.
Appl i cat i ons:
i. Used for cut t i ng t oo l m at eri al s, wi re & t ube drawi n g di es, ro ck
and coal cut t i n g equ i pm ent s et c.

PART-B
1. (a) What are the properties and application of different types of Cast
Iron? Explain in brief. (May 10,May 11)
Cast irons are generally coming under ferrous alloys with carbon contents
above 2.14% to 6.7%. But in practice, most of the cast irons contain c arbon
content between 3 & 4.5% and in addition other alloying elements.

Grey cast iron

Properties

Grey cast irons are weak & brittle in tension.

Tips of graphite flakes are sharp & pointed and are cause for stress
concentration.
Strength & ductility are high under compressive load.
Have high resistance to wear.

Ductile cast iron

Properties

These are stronger & ductile than the grey cast iron.
They have properties approaching towards steel.
Here the alloying elements were added to spheroidise carbon du ring slow
cooling.
These type of iron finds its applications in machine castings subjected to
bending and vibrations and other applications where strength and ductility are
important.

White cast iron

Properties

Since more cementite is present, the white iron is very hard & brittle.
They are unmachinable.
They have very less ductile properties.
They can be used only where hard & wear resistance surface is required like
rolling mills.

Malleable cast iron

Properties

They have relatively high strength & appreciable ductility and malleability.
It exhibits excellent machinability.
It offers good shock resistance properties.
This material is highly resistant to corrosion.
It offers high strength and toughness.
 .
(b) Explain with a phase diagram of Eutectoid & Peritectic reaction.(NOV
11)

Eutectoid reaction

It is an isothermal reversible invariant reation in which a solid phase is

converted into two or more intimately mixed solids on cooling.

The reaction on heating & cooling gives,

γ –solid α solid + β solid

The in the eutectoid phase diagram indicating the composition of eutectoid

and this temperature of transformation is known as eutectoid point.

Examples for eutectoid systems are Cu -Zn; CU-Al; Al-Mn; Cu-Be etc.

Another important example of eutectoid system occurs in the iron carbon

system.

In this austenite, a solid solution of carbon - γ iron decomposes into pearlite ,

an infinite mixture of alpha iron & iron -carbide. This reaction is basis for
much of the heat treating of steels.

On heating & coolig,

γ (Solid) α solid1 + Fe 3 C
Peritectoid Reaction

It is an isothermal reversible invariant reaction in which a solid phase reacts

with a second solid phase to produce yet a third solid phase on cooling.

The reaction on heating & cooling can be given as,

γ –solid + β Solid α Solid

2. With the help of neat sketch explain the two types of solid solution. ((May
2013, Nov 11, Nov2012)

Solid solution
 A solid solution is simply a solution in the solid state that
consists of two or more elements atomically dispersed in a single phase
structure.
When two metals are melted together and crystallized , a single
crystal structure may form. In the unit cell of this crystal, both the metal atoms
are present in proportion to their concentration.

Types of solid solution

(i) Substituitional solid solution

a)Random
b)Ordered
(ii) Interstitial solid solution
Substitutional solid solution
This type of solid solution is formed when some of the solvent atoms (base
metal atoms) are replaced by solute atoms (alloying element atoms) in a crystal
lattice.
Substitutional solid solution occurs when the solute and solvent atoms are
equal or approximately equal in diameters.
Examples are Cu-Ni where Cu has radius of 1.28 A and Ni radius is 1.24.
Both copper & Nickel have FC structure. The structure of the solvent is unchanged,
but the lattice may be distorted by the presence of solute atoms, particularly if there
is significant difference in atomic radii of the solute & solvent atoms.
Random solid solution
Here, the solute atoms do not occupy specific position but are randomly
distributed in the lattice structure of the solvent. The concentration of the solute
atoms vary throughout the lattice structure of the solvent.
Ordered solution
When the atoms of the solute material occupy similar lattice points within the
crystal structure of solvent material, the solid solution is called ordered
substitutional solid solution.
Interstitial solid solution
Interstitial solution are formed when the solute atoms are very small in comparison with
the solvent atoms. The solute atoms occupy the holes or interstices between he solvent atoms. In
general carbon, nitrogen, hydrogen and boron having small atomic diameters form interstitial
solid solutions with the base metal atoms.
3. Explain jominy test (or) End quench harden ability test with the help of
the neat sketches. (April 2010, May 2011, May 2012, May 2013)
One standard procedure that is widely used to determine hardenability is the
Jominy end-quench test.
In this test a cylindrical specimen of diameter 25.44mm and length 100 mm is
austenised (heated to austenite region)
After removal from the furnace , it is qui ckly mounted in a fixture.The lower end
is quenched by a jet of water of specified flow rate and temperature.
Thus , the cooling rate is maximum at the bottom end and diminishes along the
length of the specimen.
After the specimen is cooled to room tempera ture , shallow flats 0.4 mm deep are
ground along the specimen length.
Rockwell hardness measurements are made for the first 50 mm along the flat. For
the firt 12.8 mm , hardness readings are taken at 1.6 mm intervals and for the
remaining 38.4 mm ,every 3 .2 mm.
A hardenabilty curve can be drawn when hardness is plotted in y axis and the
position from the quenched end in x axis as shown in fig 3 & fig.4.
From this curve we can see that the quenched end is cooled most rapidly and
exhibits the maximum hardnes s. 100 % martensite is formed at the quenched end.
Cooling rate decreases with the distance from the quenched end and the hardness
also decreases as shown in fig.4
4. Explain the different types of mechanical properties and mechanism of
plastic deformation by slip and twinning. (May 2010, Nov 2011, Nov 2012, May
2013) (16)
 5. Explain briefly about charpy impact test.

Charpy impact test

In this test, certain mass is released from some distance above the impact
point which strikes the specimen.
Charpy test is conducted on te same impact testing machine.
In charpy test, the weight of the pendulum is 20.932 kg and the length of the arm
is 0.825m.

For charpy impact test the pendulum is released from an angle of 140 ⁰.

In this test, a standard specimen which is square prism of size 10mm x 10mm x
55mm, V-notched at the centre is used. In some cases, key hole notch or U -notch
is also used.
Testing procedure
1. The specimen is placed in the vice of the anvil.
2. The pendulum hammer is raised to known standard height depending on
the type of specimen to be tested.
3. When the released, its potential energy is converted into kinetic energy
just before it strikes the specimen.
4. Now the pendulum strikes the specimen. It may be noted that the izod
specimen is hit above the v-notch and the charpy specimen will hit behind
the V-notch.
5. The pendulum after rupturing the specimen, rises on the other side of the
machine.
6. The energy absorbed by the specimen during breaking is the weight of the
pendulum times the difference in two heights of pendulum on either side of
the machine.
7. Now the energy, the notched impact strength, in foot -pounds or metre-kg is
measured from the scale of the impact testing machine.
6. What do you understand by polymerization? With the help of suitable
examples, Compare and contrast the process of addition polymerization and
condensation polymerization. (May2013)
(16)
Polymerisation

It is defined as the process of forming large polymer by linking together the

monomers. E.x wood, resin, starch, Nylon etc
7. What are the properties and Application of PVC, PET, PP and PC?
Explain.
a) PVC (May 2013, Nov 2011)
Properties
i) Normally rigid, but may be made flexible with plasticizers
ii) Often copolymerized.
iii) Susceptible to heat distortion.
iv) Have good flame, electrical, chemical, oil, abrasion and weather
resistance.
Applications
i) Used in furniture, water proof coatings, bags & folders,gaskets.
ii) Floor coverings, pipe, phonograph records.
iii) In industries used for corrosion resistance coat for metals.

b) PET

P ol yet h yl ene t e raph t hal at e al so known a s pol yest e r i s a l i ne ar

pol yest e r m ade b y t he condensat i on pol ym eri z at i on of et h yl ene
gl ycol and t erapht ha l i c aci d.

C haract e ri st i cs
i. The y ar e hi gh st r en gt h, hi gh st i ffness t herm opl ast i cs.
ii. The y ar e produc ed a s fi bres, as t ransp ar ent t hi n fi l m s and as
m oul di ng m at eri al s.
i i i . The y poss ess ex cel l ent fat i gu e & we ar s t rengt h.
i v. The y can b e rei nfo r ced wi t h gl ass fi bre.
v. The y poss ess good r esi st ance t o hum i di t y, a ci ds, gre ase, oi l s &
sol vent s.

Appl i cat i ons

i) Fi bres, phot o gr aphi c fi l m s, recordi n g t a pes, bever a ge cont ai ners ,
soft dri nks bot t l es, el ect ri c al conne ct or s part s for dom est i c goods
and aut om ot i ve com ponent s.
(c) PP (Polypropylene) (May 2012)
Properties
i) Resistance to heat distortion.
ii) Excellent electrical properties & fatigue strength.
iii) Chemically inert & relatively inexpensive
iv) Poor resistance to UV light.
v) More stiff & stronger than polyethylenes.
vi) Good chemical & thermal resistance.
Applications
i) Sterlizable bottle
ii) Packaging fil
iii) TV cabinets
iv) Luggage
(d) PC (Polycarbonate)
Properties
i) They are dimensionally stable
ii) They have low water absorption quality.
iii) They are transparent.
iv) They have very good impact resistance and ductility.
v) They have low fatigue & wear resistance.
Applications
i) Safety helmets, goggles, lenses, light fittings etc.
ii) Head lamp mouldings, kettle mouldings, instrument casings &
machine housings, kitchen wares etc.