HARARE INSTITUTE OF TECHNOLOGY

SCHOOL OF ENGINEERING AND TECHNOLOGY

B-TECH INDUSTRIAL AND MANUFACTURING ENGINEERING

EIM 212 ENGINEERING MATERIALS: CONVENTIONAL

END OF SEMESTER 1 EXAMINATION NOVEMBER/DECEMBER 2013

Duration: 3 hours

Instructions to Candidates:
1. Answer any four questions.
2. Each question carries 25 marks.
3. Where applicable, use large clearly labeled diagrams
4. Start each Question on a new page

Requirements:
1. Answer booklet
2. A non-programmable calculator

Page 1 of 6
QUESTION 1
a) Outline (with examples) some of the important properties of the various classes of
engineering materials. [8]
b) Provide a list of properties for structural materials used in:
i. Space applications [3]
ii. Protective sports helmet [3]
iii. Aircraft turbine engines [3]
c) Name various types of cubic class of crystalline structures and explain their
characteristics. Give the values of parameters which distinguish them from each other.
[8]
[Total: 25 Marks]
QUESTION 2
a) Explain Schottky and Frenkel imperfections schematically. Give examples of material
systems in which these defects may occur. [6]
b) Point defects are present in some engineering material. Give and explain one example
where these defects are beneficial and one example where they are deleterious. [6]
c) Differentiate between interstitial and substitutional solid solutions. Explain in detail the
factors that tend to enhance formation of substitutional solid solutions? [6]
d) Support the notion that diffusion is essential in some industrial processes using two
examples of your choice.
[Total: 25 Marks]
QUESTION 3
a) The mechanical behavior of a material reflects the relationship between its response or
deformation to an applied load or force. Some important mechanical properties are
mechanical strength, hardness and ductility. Give a summarised description of the above
properties as they are applied in Materials Engineering. [3]
b) For most metals that are stressed in tension and at relatively low levels, stress and strain
are proportional to each other through relationships for linear properties such as the
Poisson’s ratio, ѵ, and the Modulus of Elasticity, E. Using the technical definitions and
relevant mathematical manipulations, give details about the above-stated parameters
with respect to isotropic materials. [4]
Page 2 of 6
c) A tensile stress is to be applied along the long axis of a cylindrical brass rod that has a
diameter of 10 mm. Determine the magnitude of the load required to produce a
2.5x10-3mm change in diameter if the deformation is entirely elastic. Take the value for
Poisson’s ratio for brass as 0.34 and Modulus of Elasticity as 97GPa. [5]
d) The rod in c) above is now required to exhibit more elastic behaviour during its
performance. Suggest a detailed laboratory procedure, including equipment, that can be
used to improve the elastic tendency by the alloy in question. [5]
e) Consider the following extract and attempt the questions that follow:
“The moulding process is today used in shell to produce parts that require high
quality, such as cradles of engines, transverse suspension parts and structural
nodes for frames and auxiliary frames in passenger cars. This fact has presented
the challenge of designing alloys with higher mechanical properties. For relevant
parts into clashes which need high ductility (elongation > 10 per cent) an option
for achieving these properties is the heat treatment of an alloy Al - Si low-
iron…….”

Adapted from The Magazine for Sheet Metal Forming: Ductility and Strength in
alloys of moulding in shell for the automotive industry (03/04/2007)

i) Possibly the manufacturers in this case are looking for highest mechanical
strength and highest ductility for their products. Critically analyse the
reason for the author to perceive it as a challenge to achieve the best of the
properties stated herein. [5]
ii) Suggest practical remedies for such a challenge. [3]

[Total: 25 Marks]

Page 3 of 6
QUESTION 4
Figure Q4, below, shows surface morphologies of fractures of metals presented for failure
investigation.
Figure Q4: Metal fracture morphologies

i) ii)

iii)

a) Assume the position of a metal forensic practitioner and give an assessment feedback
on the metal failure circumstances that resulted to the presented morphologies. [15]
b) Prepare relevant remedies that would minimise the failure shown in iii). [4]

Page 4 of 6
 c) Creep failure occurs under steady load. Explore the relationship between creep failure
and temperature and devise the necessary criteria to curb the factors that lead to creep
failure. [6]
[Total: 25 Marks]

QUESTION 5
a) Consider an impellor in which failed whilst pumping slurry ore in a mine. The cast
impellor is made of 0.8% Carbon steel.
i) Explain the objectives of heat treatment and design the heat treatment operation
for the impellor? [10]

ii) Describe precautions necessary while heat treating to avoid defects [3]

iii) What are the effects of tempering on the mechanical properties [2]

iv) Besides heat treatment how can the engineers improve the life of the impellor
[2]

b) Describe how does holding “soaking” time affect the properties of steels during heat
treatment process? and explain the objectives of annealing? [6]

c) The figure Q5 shows a phase diagram for a mysterious compound X.

Explain why compound X cannot be boiled at a temperature of 2000 C? [2]

[Total: 25 Marks]

Page 5 of 6
QUESTION 6
a) Briefly explain with an aid of a diagram the electrochemical reactions occurring in a
typical corrosion cell. [5]
b) i) List and explain four measures to reduce the effects of galvanic corrosion. [8]

ii) From the galvanic series (Table Q7), cite two metals that may be used to galvanically
protect steel (Esteel =-0.49V). [2]

Table Q6

c) Briefly explain why cold-worked metals are more susceptible to corrosion than non cold
worked metals. [4]
d) A brine solution (NaCl aqueous) is used as a cooling medium in a steel heat exchanger.
The brine is circulated within the heat exchanger and contains some dissolved oxygen.
Suggest and explain three methods for reducing corrosion of the steel by the brine. [6]
[Total: 25 Marks]

END OF QUESTION PAPER

Page 6 of 6