Interview Guidance Material Mechanical Engineering

INTERVIEW
GUIDANCE MATERIAL
MECHANICAL
ENGINEERING
MATERIAL SCIENCE
Material Science
9. Fatigue:
Material Properties and Testing Failure stress versus number of load cycles
behavior of material under changing
Material Properties: mechanical load as a function of time OR
Failure of material under repeated or reversal
1. Strength: stresses is called fatigue.
Strength is defined as the ability of a material
that can withstand to mechanical load or that 10. Toughness:
can resist the maximum stress. Toughness is defined as the ability of the
material to absorb energy up to fracture
2. Stiffness: during the plastic deformation.
It is the ability of material that can resist
mechanical deformation or deflection under 11. Hardness:
load/stress. Stiffness is measured in terms of Hardness is the property which is usually
modulus of elasticity in the elastic region. defined as the ability of a material to resist
3. Elasticity: scratching, abrasion, cutting (or machining)
The elasticity is the ability of material that and indentation (or penetration).
can regain its original shape after removal of
external load. 12. Machinability:
The ease with which a given material may be
4. Plasticity: worked or shaped with a cutting tool is called
If a material does not retain the original shape machinability.
after removal of load is known as plasticity.
13. Weldability:
5. Ductility: Weldability is the ability of material to be
Ductility is the ability of a material that can joined by welding.
undergo plastic deformation before failure.
6. Malleability: 14. Castability:
Malleability is the ability of a material that Castability of metal refer to the case with it
can undergo plastic deformation without can be cast into different shapes and is
failure under a compressive load. concerned with the behavior of metal in its
molten state.
7. Brittleness:
Brittleness is the ability of a material that can 15. Hardenability:
resist mechanical load without plastic Hardenability is defined as the ability of steel
deformation. to develop its maximum hardness when
subjected to the hardening (heat treatment)
8. Creep: process. Good hardenability is indicated by a
Time versus strain behavior of a material greater depth of hardening below the surface.
under constant mechanical load is called as
creep.
ACE Engineering Publications Hyderabad • Delhi • Bhopal • Pune • Bhubaneswar • Lucknow • Patna • Bengaluru • Chennai • Vijayawada • Vizag • Tirupati • Kolkata • Ahmedabad
2 ISRO_Interview Guidance - 2020
16. Strain hardening: 4. Vickers Test :

The strengthening effect produced in metals  Applicable to medium hard materials.
by plastic deformation (i.e. cold working) is  The indentor used in this method is a diamond
called strain hardening or work hardening. of square based pyramid with an included
angle of 1360 between the opposite faces.
Hardness Measurement:
Vickers hardness number is given by
Resistance offered by the material against
mechanical deformation. 1.854 P
V.H.N =
d avg
Hardness can be determined by following
methods: P = load at which indentation produced
1. Mho test/ Scratch test: davg = Avg. diagonal of indentation produced
2. Brinell hardness test:
3. Rock well test: 5. Knoop test / Micro hardness test:
4. Vickers test:  Applicable to Low Hard Materials.
5. Knoop test/ Micro hardness test:  This method is applicable to material with
6. Shore Method low hardness & indentation sensitivity.
7. Barcol Method  In this method to obtain the indentation 1 to
1000 grams weight will be used instead of
1. Mho test/ Scratch test: kgs. Hence, it is called as micro hardness test.
 Mho test is a Qualitative method but not
Quantitative. 6. Shore Method:
 Applicable to soft plastic, thermo plastic,
 It will give relative value of the hardness of
rubbers etc.
partial but not the exact value.
7. Barcol Method:
2. Brinell hardness test:  Applicable to hard plastics, thermosets,
 Applicable to medium hard materials only. composites etc.
2P Crystal structures and Defects

BHN =
D(D  D  d ) 2 2
Materials are classified as:

BHN = Brinell hardness number
D = Diameter of indenter (i) Crystalline:
d = Indentation diameter (x2 – x1) which  A crystalline solid has a regular geometry of
is taken from micro scope atoms or ions or molecules in a three
P = Load at which Indentation Produced. dimensional space. Ex: metals and alloys
3. Rock well Test: (ii) Non-crystalline solids:

 A non-crystalline solid or amorphous solid
 Applicable to all types of material. (Universal doesn’t have a regular geometry of
method). arrangement of atoms or ions or molecules.
 The indentor used is a diamond cone called Amorphous substance does not have a sharp
brail with an apex angle 1200 . melting point. Ex: talc and powder.

3 Material Science
 Space lattice: 2. Body centered cubic structure (B.C.C):

A space lattice is defined as an infinite array
of points in three dimensions in which every
point has surroundings identical to that of
every other point.
 Unit cell:
A unit cell is a part of the material which
explains whole structure of the material.
N V
Atomic packing factor = atoms atoms
Vunit cell
Where, Natoms = Number of atoms in unit cell Number of atoms in the unit cell of B.C.C
Vatom = Volume of an atom Structure:
Vunit cell = Volume of unit cell 1
8 atoms at the corners  = 1 atom
Crystal Structure of Metals: 8
1 centre atom = 1 atom
1. Simple cubic structure:
 Total = 2 atoms
r Atomic packing factor of B.C.C. structure:
Atomic packing factor
r
Volume of atoms in the unit cell
=
a Volume of unit cell
 a 3 3 
 
 8 
=   =  3  0.68
Number of atoms in the unit cell of simple 3
Cubic structure: a 8
1
8 atoms at the corners   1atom 3. Face centered cubic structure (F.C.C.):
8
Therefore the unit cell of simple cubic
structure contains one atom.
Atomic packing factor or packing efficiency of

Simple cubic structure:

=
Volume of unit cell
a 3 / 6 
= 3
=  0.52
a 6

Number of atoms in the unit cell of F.C.C. Atomic packing factor of H.C.P. structure:
structure:
1 =
8 atoms at the corners  = 1 atom Volume of unit cell
8
1 4r 3
6 face centered atoms  = 3 atoms 6
2 = 3
 Total = 4 atoms 3a sin 60 o  h
2
3
4  a 
Atomic packing factor of F.C.C. structure: 6  
3 2
=
 Atomic packing factor 3a 2 sin 60 o  h
Volume of atoms in the unit cell a
= =
Volume of unit cell 3h sin 60 o
a 3 2
 2 The h/a ratio for an ideal HCP crystal
= 6 = = 0.74 structure consisting of uniform spheres
3
a 6 packed tightly together is 1.633.
Hexagonal close packed structure (H.C.P.): Therefore, substituting h/a = 1.633

We get
Atomic packing factor = 0.74
Structure No. of Co- Atomic

Atoms ordination packing
no. factor
Simple 1 6 52 %
cubic
Body 2 8 68 %
centered
Face 4 12 74 %
centered
Number of atoms in the unit cell of H.C.P.
structure: Hexagonal 6 12 74 %
closed pack
1 Diamond 8 4 34 %
12 atoms at the concerns  = 2 atoms
6 Miller indices:
1
2 face centered atoms  = 1 atom  These indices which identify a family of
2 planes in crystal structure.
3 middle layer atoms = 3 atoms
 Total = 6 atoms

5 Material Science
The features of miller indices: 1. Point defects:

i) It not only defines a particular plane but a  If the defect is confined to a single atom in
set of parallel planes. the lattice called as point defect.
ii) Plane which is parallel to any one of the
Ex: Vacancy, Displacement of atoms,
principle axes has intercept of infinity and
Impurities / Inclusions
whose miller index is zero.
(i) Substitutional Inclusion:
Plastic Deformation of Metals: The foreign atoms will occupy the position of
 The change that occurs in metals or alloys lattice atom by removing the lattice atom
under the action of applied forces is called called as substitutional
deformation of metals.
(ii) Interstitial inclusion:
Imperfections in Metal Crystals:  The foreign atom will occupy the empty space
available within the lattice, without disturbing
 An ideal crystal is the one in which atoms are the position of lattice atoms.
arranged in a perfectly regular manner and is
perfect without any defects. (d) Frenkel Defects:
 Real crystals are not perfect and contain
defects such as lattice distortion and various  Frenkel defect arises when an ion moves form
imperfections. a regular site to an interstitial site.
(e) Schottkey Defect:
Types of imperfections or defects:  A pair of vacant ion sites i.e., one cation and
The various types of crystal imperfections are: one anion which are missed in an ionic crystal
is called a Schottky defect.
1. Point defects
a) Vacancies 2. Line defects:
b) Displacement of atoms  If the defect is confined to more number of
c) Impurities/ Inclusions atoms in a lattice is known as line defect.
d) Frankel defect Ex; Crack formation in a material
e) Schottky defect
(a) Edge Dislocation
2. Line defects:  By applying force on the lattice along the line
a) Edge Dislocation of defect the lattice can break or crack easily
b) Screw Dislocation known as edge dislocation.
3. Surface or Grain boundaries defects (b) Screw Dislocation

a) Grain boundaries  If the movement of atom planes is following a
b) Tilt boundaries translation motion followed by rotational
c) Twin boundaries motion is known as screw dislocation.
4. Volume defects: Stacking faults Burgers Vector: 

 The burgers vector ‘ b ’ is the vector which
defines the magnitude and direction of slip.

Burger Circuit:
Phase Diagrams
 In a lattice by moving equal interval of
distances by moving a closed path, if a circuit
Basic Terms:
is drawn called as burger circuit.
Phase:
 Any homogenous, physically distinct and
Deformation of metals:
mechanically separable portion of a system is
(i) Elastic deformation: known as a phase.
 Elastic deformation is a temporary Phase Rule:
deformation which disappears after the  The number of degrees of freedom (F) of the
deforming load is removed. system is related to the number of
(ii) Plastic deformation: components (C) and of phases (P) by the
 Plastic deformation is a permanent phase rule equation: F = C – P + 2
deformation which remains even after the Where, P is the number of phases,
deforming load is removed. F is the number of degrees of freedom and
C is the number of components.
Mechanisms of Plastic Deformation Phase Diagrams:
There are two important mechanisms:  Phase diagrams are the charts which show the
(a) Plastic deformation by slip and relationship between the composition,
(b) Plastic deformation by twinning temperature and structure of any alloy series.
(a) Plastic deformation by slip:
Types of Phase Diagram:
 If a tangential force is applied on lattice, the
(i) Temperature Vs Composition Phase
top atomic planes will move with respect to
Diagram (Equilibrium condition of phase
bottom atomic planes, known as displacement
diagram)
of atomic planes, also known as slip
phenomenon. (ii) Temperature Vs Time Phase Diagram (Non-
(b) Plastic deformation by twinning: Equilibrium condition of phase diagram)
 If an angled force is applied on the lattice a Types of phase Transformations
single lattice splits into two identical sub
lattices, known as twinning phenomenon. The following are the most important types of
phase diagrams which may be applied to
understand and interpret more complex alloy
systems.
(a) Eutectic system:
 This reaction is reversible.


Cooling
Liquid   Solid1  Solid 2
Heating

7 Material Science
(b) Peritectic System: steel which contains Pearlite and Cementite

 The reaction is reversible which is hard and brittle. It is having a pearl
like lusture when viewed through microscope.

Cooling
Liquid + Solid   New Solid  Bainite: It is the product of isothermal
Heating
decomposition of austenite and it cannot be
produced by continuous cooling Bainite is
(C) Eutectoid system: aggregate of ferrite and carbide. Also it is
 This reaction is reversible. tougher.
 Martensite: This is obtained by rapid cooling

Solid 
Cooling
 Solid1 + Solid2
Heating of austenite. It is extremely hard and possess
acicular needle like structure. It is magnetic
(d) Peritectoid system: and has carbon content up to 2%. It is
 This reaction is reversible. extremely hard and brittle. The decomposition
of austenite below 320oC starts the formation

Cooling
Solid1 + Solid2   New Solid3 of martensite.
Heating
 Troostite: It differs from pearlite only in the
Micro constituents of iron and steel: degree of fineness of structure and carbon
 Austenite(-iron): It is solid solution of
content. It is produced by transformation of
ferrite and iron carbide in gamma iron which tempered martensite. Troosite is weaker than
is formed when steel contains carbon up to martensite.
1.8% at 1130oC. On cooling below 723oC it  Sorbite: Sorbite microstructure constitute a
starts transforming into pearlite and ferrite. mixture of ferrite and finely divided cementite
Austenite is non-magnetic and soft. It exists produced on tempering martensite above
in FCC crystal structure. 450oC. Pearlite, Troostite and Sorbite all are
 Ferrite: It is a BCC iron phase with very
ferrite cementite mixture having a lamellar
limited solubility of carbon. The solubility of structure.
carbon in ferrite is 0.08% at 723oC. Ferrite  Ledeburite: Ledeburite is the product of
does not harden when cooled rapidly. It is eutectic reaction. Thus Ledeburite is a
very soft and highly magnetic. At room eutectic mixture; consist of alternate layers of
temperature ferrite contains maximum austenite and cementite. It contains 4.3
0.0025% C only. percent carbon and is formed at about
 Cementite: Cementite is actually Fe3C, 1130C.
which contains 6.67%C by weight, which is
extremely hard and brittle in nature. Iron-Iron carbide equilibrium diagram:
Cementite increases gradually with increase From the figure shown below:
in carbon percentage. It is magnetic at below  The iron-iron carbide equilibrium diagram
200oC.Cementite contains orthorhombic concerns transformations that occur in alloys
crystal structure. having compositions from pure iron to
 Pearlite: It is combination of about 87% of cementite (6.67 % of carbon). Besides it
ferrite and 13% of Cementite. Steel with 0.8% establishes a correlation between the micro
carbon is wholly Pearlite, less than 0.8% is structure and properties of steel and cast irons
hypo eutectoid contains ferrite and Pearlite and provides a basis to understand the
and is soft. More than 0.8% is hyper eutectoid principles of heat treatment.

 Carbon is added to iron, to improve the cementite, which is more hard and brittle
strength of iron as interstitial inclusion. So phase.
that the strength of iron can be improved. The  If % of carbon = 0 to 2.11 % → Steel
maximum solubility of carbon in iron is 6.67  If % of carbon = 2.11 to 6.67  cast iron
%, called as critical concentration.  Brittleness & Hardness of cast iron will be
 If Carbon is added to iron, it forms iron more compared to steel.
carbide (Fe3C) phase, also known as
A
1538
+L B
1495  +
Liquid
1398
Liquid + Austenite
Liquid + Cementite
C
Austenite ()
1145 F
E
(Austenite+Fe3C)
G AC3 ACm
910
Cementite (primary) +
Labebusite
Austenite +Ledeburite Ledeburite (Austenite+Fe3C)
(Austenite+Fe3C)
-iron
723 K
P(0.025) S
Labebusite(Pearite+Fe3C)
Cementite + Pearlite Pearlite+Ledeburite Cementite (primary) +

Ferrite + Pearlite
Temperature
(Pearlite+Fe3C) Ledeburite (Pearlite+Fe3C)

Pearlite
0
0.008 0.8 2.11 4.3 6.67
Hypoeutectoid Hyper eutectoid Hypo eutectic Hyper eutectoid

% carbon
Steels Cast irons

Iron–Iron carbide equilibrium diagram
 In any phase, if carbon content is high  iron   Fe contains very small carbon content
carbide (free iron volume is less)  it exhibits  highly ductile phase.
more hardness.   Fe is difficult to produce because addition
 HFe < Hsteel < Hcast iron of very small carbon content in iron lattice at
Also (H)iron <(H)LCS<(H)MCS<(H)HCS<H)CI high temperature with uniform distribution is
About –Fe: very difficult  most unstable phase and
 The max solubility of carbon in iron is difficult to exist.
0.008% at 14950C.  Structure is B.C.C

9 Material Science
About –Fe (Austenite): (iii) The eutectoid (point S) reaction:

0
 Max solubility of carbon is 2.11% at 1145 C. The eutectoid reaction occurs at a temperature
of about 723C .
 The min temperature above which  iron can Ferrite  Cementite
form 7230C at .77% carbon. 
Cooling
Austenite  
 Solid  Heating Eutectoid mixture  pearlite 
 By varying carbon content form 0 to 2.11%,
variety of steels can be produced in Austenite
phase either by heating or cooling process, the NOTE: Iron –carbon phase diagram will explain
grain size of  Fe can be modified  strength the phase transformations that are happening with
respect the carbon content in iron like formation
can be changed. of steel or cast iron, but do not explain about the
 Structure is FCC production aspects of steel and cast iron.
  Fe is non magnetic in nature.
About –Fe (ferrite): Heat Treatment Process of Steels
 The maximum solubility of carbon is 0.025%
at 7230C. “Heat treatment” is defined as combination of
 The min solubility of carbon is 0.0025 % at operations involving heating and cooling of a
room Temperature. metal or alloy under certain conditions that can
 As it contains very less % of carbon, its produce better properties.
properties are similar to pure iron.
 Structure is B.C.C Heat treatment is done for the following
 Magnetic in nature.
reasons:
(a) To relieve internal stresses that are produced
 Easily producible.
by welding, casting, forging cold working etc.
The iron-iron carbide equilibrium diagram (b) Hardening or strengthening of metals or
has three invariant reactions as follows: alloys
(i) The peritetic (point B) reaction: (c) To Increasing the ductility and toughness of
The peritectic reaction occurs at a temperature metals
of about 1492C and its equation may be (d) To changing the grain size
written as : (e) To improving machinability

Cooling
  liquid   Austenite
Heating (f) To improve corrosion resistance
The peritectic point is at 0.18 percent carbon. (h) To increase in wear and tear resistance
(ii) The eutectic (point C) reaction:
The eutectic reaction occurs at a temperature Types of heat treatment processes:
of about 1130C and its equation may be
written as: The following are the important types of heat
treatment processes
Cooling
 Austenite  Cementite
Liquid 
Heating Eutectic mixture  Ledeburite  I. Hardening
The eutectic point is at 4.3 percent carbon.

II. Annealing  Holding at this temperature for considerable

(a) Full annealing time, to complete phase transformation and
sudden cooling in water or oil.
(b) Process annealing
(c) Spheroidisation annealing
(d) Diffusion Annealing II. Annealing:
III. Normalizing (a) Full annealing:
Full annealing carried out for the following
IV. Tempering process:
(a) Mar-tempering (i) To soften the steel,
(b) Aus-tempering (ii) To relieve the internal stresses, and
(iii)To refine the grains and reduce the
Special heat treatment includes the surface hardness
and case hardening of steels and thermo  Applicable to hardened steels with %C = 0 to
mechanical heat treatment. 2.11% (LCS, MCS & HCS)
 Heating the hypo-eutectoid steel to a
1. Surface hardening temperature 30 to 50oC above A3 (lower
(a) Flame or torch hardening critical point) and the same amount above A1,3
(b) Induction hardening (lower critical point) for hyper eutectoid steel.
 Slow cooling in the furnace.
2. Case hardening
(a) Carburizing
(b) Nitriding III. NORMALISING:
(c) Cyaniding  The most common reason for normalizing is
(d) Carbonitriding to adjust mechanical properties to suit the
service conditions.
I. Hardening :
 The other purpose of the normalizing are:
 Hardening is applicable to steels with carbon (i) To relieve the internal stresses,
% 0 to 2.11% (LCS, MCS & HCS).
 The purpose of hardening, followed by (ii) To refine the grain structure, and
tempering are: (iii) To improve the machinability
(i) To develop high hardness, wear resistance  Normalizing involves heating the steel to
and ability to cut other materials. 50oC above the upper critical temperature,
(ii) To improve strength and toughness. (for hypo-eutectoid steel) and to 50oC above
 The hardening process consists of heating the the lower critical temperature (for hyper
hypo-eutectoid steel (%C =0 to 0.8%) to a eutectoid steel).
temperature 30 to 500C above the Upper  Holding at this temperature for shorter time to
Critical temperature. For hypereutectoid steels prevent grain growth and finally, cooling in
(% C = 0.8 to 2.11 %) to a temperature 30 to air.
500C above the Lower Critical temperature.

11 Material Science
IV. TEMPERING: iv) Sub - zero treatment:

 Applicable to steels with %C=0 to 0.4 %  Subzero treatment is usually carried out in the
(LCS, MCS & HCS) temperature range of –30 to –1200C and
holding time at this temp is 1 to1.5 hours.
 Tempering is a final operation in heat
treatment. Steels acquire the required Surface Hardening and Case Hardening:
mechanical properties as a result of In many engineering applications such as gears,
tempering. CAMS etc, it is desirable to have a hardened
 The primary objects of tempering are: surface to resist wear and tear. This can be
(i) To reduce the thermal stresses, achieved by hardening the surface layers of the
(ii) To stabilize the structure of the metal article leaving the rest as such.
(iii) To reduce the hardness, brittleness, and
(iv) To increase toughness and ductility 1. Surface hardening:
These methods are:
Depending on temperature, the process can be (i) Flame Hardening
classified into three types. (ii) Induction Hardening
(i) Low –temperature tempering (150 –250oC)
(ii) Medium – temperature tempering 2. Case hardening:
(350–450oC)  Applicable to L.C.S only. By incorporating C
(iii) High – temperature tempering or N2 atoms on to the outer envelope (case) of
(500 –650oC) the low carbon steel component, it will be
turned as hard by forming Fe3C or Fe3N phase
known as case hardening.
(a) Mar-tempering:
(a) Carburising:
 Applicable to steel with %C = 0 to 0.4%.
 Carburizing is a method of enriching the
 The process consist of heating the steel to the
surface layer of low carbon steel with carbon
hardening temperature and then cooled
in order to produce a hard case.
suddenly (at above the critical rate of cooling)
down to a temperature just above ‘Ms’ point (b) Nitriding:
(temperature at which martensite formation  Nitriding is the process of enriching the
begins and is nearly equal to 240oC). surface of steel with nitrogen by holding for a
prolonged period at temperature of ammonia
(b) Aus-tempering: (NH3).
 Applicable to steel with %C = 0.8.
 Aus-tempering of steel is carried out by (c) Cyaniding
heating the steal above the upper critical  During cyaniding the surface of steel is
range to make it all austenite form. enriched with carbon and nitrogen by
 It is then quenched at a critical cooling rate in incorporating carbon & Nitrogen atoms
a oil bath maintaining a temperature range simultaneous on to the outer envelope of the
7230C. low carbon steels it will be turned as hard
by form iron carbide & iron Nitride phases.

Types of strain Hardening Process (b) Re-crystallization:

(i) By control grain size
 Re-crystallization is a process by which
(ii) By Hot working &cold working
deformed grains are replaced by a new set of
(iii) By Solid Solution hardening
un deformed grains that nucleate and grow
(iv) Precipitation hardening
until the original grains have been entirely
consumed.
Recovery, Re-crystallization & Grain Growth:
(a) Recovery: (c) Grain Growth:
 When a sample is heated from room  Grain growth refers to the increase in size of
temperature recovery occurs first. During grains (crystals) in a material at high
recovery there is a change in the stored temperature.
energy without any obvious change in the  This occurs when recovery and re-
microstructure. crystallization are complete.
Plastics
Polymers are a large class of materials consisting of many small molecules (called monomers) that
can be linked together to form long chains, thus they are known as macromolecules.
 Materials made by C,H and O atoms only are called as polymers.
 They are light weight and anti-corrosive.
Types of polymer
(i) Thermo plastics (ii) Thermosets (iii) Rubbers / Elastomers
Thermo plastics Thermosets

Rubbers/Elastomers
Polymer turns as soft by heating Polymer turns as hard by heating
Polymer turns as hard by
heating.
Note: Hardness of rubber is
proportional to the temperature
to which it is heated.
At room temperature they are At room temperature they are At room temperature they are
available as solids available as liquids available as liquids
Recyclable Non Recyclable Non Recyclable

By heating→ strength losses By heating→ strength gains By heating→ strength gains
By cooling → strength gains By cooling → no change By cooling → no change
Shape change →during cooling Shape change → during heating Shape change →during heating
Servicing temp=1500C 0
Servicing temp=300 C Servicing temp=3000C
Ex: : Polyethelene , Poly styrene, Ex: epoxy resin, phenolic resin, Ex: butyl rubber (soft rubber),

13 Material Science
Polyvinyl chloride, poly carbonate Cyanate ester resin, vinyl ester nitrile rubber( high temperature
resin sustainable), Styrene butadiene
rubber ( Car tyre rubber)
Hardening process of Hardening process of thermoset Hardening process of rubber is
thermoplastic is called as is called as polymerization. called as vulcanization.
polymerization.
Environmentally hazardous Environmentally hazardous than By heating = gaining strength.
thermoplastic By cooling = No change
Structure is linear Structure is cyclic Structure is partially linear &
CH2 – CH2 – CH2 Cyclic partially cyclic
CH2 – CH2 – CH2 – CH2
(Strength)Rubber < (Strength)thermoplastic < (Strength)thermosetting
Types of Rubber:  U-V Stabilizer: Improve stability to the

(i) Butyl rubber: Soft rubber  eraser, seals, plastic against sun radiation exposure.
gaskets, tubes  Fillers: Improves mechanical strength of the
(ii) Nitrile rubber: High temperature sustainable polymer.
(seals at high temperature) appears red in
color. Types of filler:
(iii) Styrene butadiene rubber (SBR): very (i) Powder

hard rubber. Used for making of car tyres. (ii) Fiber
Note: Any polymer + additive = Plastic (iii) Layers
(i) Powder:
Additives:  By embedding powders in a plastic material
 It is the compound used to improve the strength of the plastic can be improved
mechanical or thermal or any other property known as particulate composite material.
of the polymer.
(ii) Fibers:
Types of additives:
 The material with more length and less
 Asbestos: Increase thermal resistance of
diameter (l/d is more) is called as fiber.
polymer & mouldability
Improve mechanical strength of polymer.
 Mica: Mica is a material to improve thermal
Ex: carbon fiber, glass fiber, boron fiber,
conductivity & electrical resistance of
graphite fiber, aramid/Kevlar fiber.
polymer
 Hardener: Improve hardness of the polymer. (a) Fiber reinforced Plastics (FRP):
Ex: Fevi stick gum  By incorporating fibers or reinforcement in
 Plasticizer: It improves toughness of the plastic material, the strength can be
polymer. improved tremendously, known as ‘fiber
 Dyes & Pigments: which impose color to reinforced plastic’ (FRP), which is a called as
plastic. composite material.
Ex : Home plastic materials like bucket color is
given by dyes & pigments.

Types of fiber reinforced plastics: Types of composites Materials:

(i) Carbon fiber reinforced plastics (CFRP) (i). Metal matrix composites:
(ii) Glass fiber reinforced plastics (GFRP) If fibers are embedded in a metallic material
(iii) Graphite fiber reinforced plastics (GrFRP) called as metal matrix composites.
(iv) Kevlar fiber reinforced plastics (KFRP)
Metal matrix composites posses
(i) CFRP: – High strength
– High servicing temperature (1000oC)
 If carbon fiber is reinforced in the plastic,
– High ductility
known as CFRP..
– High corrosive resistance
(ii) GFRP :
 If glass fiber is reinforced in the plastic called (ii). Polymer matrix composites:
as GFRP.
If fibers are embedded in a plastic material
called as plastic matrix composites
(iii) GrFRP :
 If graphite fiber is reinforced in the plastic Polymer matrix composites posses
called as Gr-FRP. – Light weight
– High strength
Production methods of plastic parts: - – Low ductility
(1) Casting/Molding process – Anti corrosive
a) Compression molding (for T.S & T.P) – Servicing temperature up to 300oC
b) Transfer molding (for T.S only)
c) Injection molding (for T.P only) (iii). Ceramic matrix composite:
d) Blow molding (for T.P only)
If fibers are embedded in a ceramic material
(2) Forming process called as ceramic matrix composites
a) Vacuum forming (for T.P only) Ceramic matrix composite posses

(or) Thermo forming
b) Extrusion forming (for T.P only) – High strength
c) Roll forming/Calendaring (for T.P only) – High temperature sustainability
– Brittle in nature
(3) Laminating process – Poor ductile
a) Compression moulding (for T.S only)
b) Filament winding (for T.S only)

15 Material Science
Applications of plastics:
S.No Plastic Properties & Purpose Applications

Good tensile strength,
Films, sheets, Pipes, carry
Servicing temperature<
1 Polyethylene bags, water bottles, Tubes
150oC, high moisture
etc.
resistant
High tensile strength, more Cloths, fabric, boat hall,
2 Polyester flexible, wear resistant & washing tubes, fan blades,
weather resistant hammer handles etc.
sound proof plastic,
3 Polystyrene refrigerator outlet envelope
moisture resistance
high electric resistance,
moisture resistance,
4 Polyvinyl chloride(PVC) Pipes
sustainable temperature
up to 150
Impact resistant, light
5 Polycarbonate weight, highly transparent, spectacles, helmet covers
sustain upto 150oC
Transparerent plastic,
6 Acrylics moisture resistant& scratch Paints
resistant
low friction coefficient,
external coatings on car
Polytetrafluroethelene moisture resistant and
7 bodies, gasket, coatings,
(PTFE) or Teflon scratch resistant
plastic wheels or gears.
Good tensile strength with wires, threads & ropes,
8 Nylon
little ductility plastic rods
Laminating sheets, roofing
Heat resistant, flame
9 Phenolics panels, telephone
resistant, chemically inert
envelopes, heat sheets.
Impact resistant, moisture Seat covers, rain coats,
10 Vinyls
resistant bottles
Good compressive
Sponges, foams (plastics
strength, soft in nature,
with porosity) for furniture
11 Poly urethane good cushioning property,
cushioning seat covers, life
scratch resistant, impact
jacket etc.
resistant

(ii) Mechanical Method:

 By Impacting / Shotting / machining / turning
Power Metallurgy
/ milling / crushing / grinding etc brittle
materials can be converted into powders of
Definition: Production of components by using small size particles.
initial materials as Powders is known as ‘Powder
Metallurgical Process’. (iii) Chemical Method:
 By removing oxygen from any of the
Powder metallurgy is applied in the following material, it turns as brittle in nature so that
cases. powders can be produced also called as
(i) Two metals with large difference in melting reduction process.
points and to form an alloy of ‘Z’  To produce fine powders, this method is used,
Ex: M1 + M2  Z but production rate is less and expensive.
Al + Fe  X
For Al M.P = 660C (2) Mixing or blending of powders:
For Fe M.P = 1538C  Initially powders will be mixed in dry
condition using mechanical mixers/stirrers.
(ii). One is metal and another is metal do not After that a solvent of low boiling
form as molten liquid. temperature is added (ex: acetone, alcohol and
Ex: Iron + Tungsten carbon tetra chloride etc)
 In wet condition of the powder mixture is
(iii). One is metal and another is a decomposable called as paste/pulp.
compound
Ex: Fe + SiC (3) Compaction:
 The wet condition of the powder mixture
(iv) Two metals with large difference in density
(Paste) is kept in the mould of required shape
then to form an alloy
of the component and subjected to a
Ex: Brass + Al
compaction (or) compression load (P) under
Brass density 8.6 gm/cc
press.
Al density 2.7 gm/cc
 Due to compaction load, powder mixture will
gain the shape of the component, known as
The sequence of operations in powder
‘compact’.
metallurgy:
(1) Production of powder from bulk material. (4) Sintering:
(2) Mixing / blending of powders.  In green condition the compact posses low
(3) Compaction (making into appropriate shape) strength therefore, by heating the compact
(4) Sintering strength can be achieved.
 The method of achieving strength in the
1. Production method of powders: compact by heating process is called as
‘Sintering Process’.
(i) Atomization:
 Sintering is performed in the presence inert
 To produce metallic powders from their
atmosphere like Nitrogen/argon gases or in
molten liquids, this method is used.
the presence of vacuum to avoid
contamination of O2 with compact.

17 Material Science
Advantages and Disadvantages of powder  Moderate corrosion resistant

metallurgical process:  Melting point is 1200oC – 1000oC
 Any combination of materials can be mixed  Easily hardenable
in the form of powders and components can  Connecting rods, tubes, pipes, Crank
be produced. shafts, gears, rifle barrels, rollers.
 Production of powder metallurgical
components is expensive than alloy (3) High Carbon Steels:
formation.
 % C = 0.45 – 2.11 %
 Powder metallurgical components posses  Highly hard
high compressive strength and low tensile  Difficult to machine without addition of
strength. sulphur.
 Powder metallurgical components are brittle  Low fracture toughness
and hard hence they can not sustain under  Difficult to weld
shock and impact environment.  High corrosion resistant
o o
 Melting point is 1000 C – 900 C
 Hammers, screw drivers, wrenches,
Steels and Cast Irons mandrels, dies, punches, chisels, blades,
 Stainless steels produced by adding chromium
to any steel
Based on the % of carbon present in the steel,
i.e, any steel + Chromium  stainless steel
steels classified as :
 Any steel + alloying elements  Alloyed
(1) Low Carbon Steels: Steel
 % C = 0 – 0.25 % Based on the % of alloying element steels
 Highly ductile again classified as follows:
 Easily machianable (1) Low Alloy Steels:
 High fracture toughness
 If the % of alloying elements is less than
 Easily weld able 5% called as “low alloy steels”.
 Corrosion resistant
(2) Medium Alloy Steel:
 Highly melting point i.e.1400oC–1300oC
 If the % of alloying elements is 5% – 10%
 Difficult to hardness / Difficult to heat
treatment called as “medium alloy steels”.
 Used in making screws, bolts, rivets, (3) High Alloy steel:
plates, automobile external bodies,
machine parts, Cranks, levers, axels.  If the % of alloying elements is 10% –
15% called as “high alloy steels”.
(2) Medium Carbon Steel: Note:
 As it is condition, all steels can undergo
 % C = 0.25 – 0.45 %
corrosion easily. Hence by adding chromium
 Medium hard & Medium ductile the corrison resistance can be improved, but
 Moderate fracture toughness the strength more or less remains the same.

L.C.S + Cr (10-25%) i.e,  = .000023mm/oC

 Stainless steel form of L.C.S  Used in design of components where high
M.C.S + Cr (10-15%) dimensional accuracy at high temperature
 Stainless steel form of M.C.S required.
 Cylinder head bolts, valve seatings,
H.C.S + Cr (5-10%)
cylinder liners for aero engines
 Stainless steel form of H.C.S
 To improve the corrosion resistance of L.C.S, (5) High speed steel (HSS):
more chromium should be added because it
 Contains all properties of H.C.S
contains low carbon content inside, but in
 High temperature sustainability & high
case of HCS small chromium content is
hardness
sufficient.
 High wear resistance & high corrosion
resistance
Types of stainless steel
 High melting points.
(1) Ferrite Stainless steel:  Used as cutting tool bits, milling cutters,
gear cutters, saw blades, punches
 Contains all properties of L.C.S
 Highly corrosion resistance.
(6) Maraging Steel:
 Suitable for high temp & high pressure
application  Contains all properties of L.C.S
 Posses good surface finish & Mica  High fracture toughness
appearance.  High temp sustainability, high hardness &
high strength
(2) Austinitic Stainless steel:  High wear resistance
 Used for aero engines, aircraft
 Contains all properties of L.C.S
components, bicycle frame’s all aerospace
 High corrosion resistant
components, centrifuges.
 Posses good toughness & machinability.
 Corrosive in nature, but by doing nitriding
 Highly impact & shock resistant
process, corrosion resistance can be
improved.
(3) Martensitic Stainless Steel:
 Contains all properties of H.C.S Types of cast iron
 Highly corrosion resistance
1. Gray Cast iron:
 Moderate ductility & Machinability
 Appears as dark porous structure
 ductile in nature
(4) Low Thermal expansion steel / invar steel:  Iron carbide particles exist as flake
 Contains all properties of H.C.S structure (randomly oriented, randomly
 Possess moderate toughness & shaped)
machinability.  Used for production of pipes, Agriculture
 Easily hardenable. implements, Cylinder block of IC engines,
 Highly corrosion resistance. break drums, machine tool beds
 Low Thermal expansion coefficient,

19 Material Science
2. White cast iron: Alloying elements and their effects:

 Appears in white color 1. Chromium
 Hard & brittle in nature  Increase Corrosion resistance
 Posses high wear resistance & high  Increase Wear resistance
abrasion resistance  Increase tensile strength
 Used as Bearing Surfaces, Rollers for  Increase resistance to heat
Crushing equipments, Rings of wheels,  Reduces machinability
Railway break locks, Liners for cement
mixture, Ball mills 2. Copper
 Increasing toughness
3. Malleable Cast iron:  Increase resistance to corrosion
 Posses good malleability.
 Shock & impact resistance 3. Magnesium
 Good tensile strength  Increase machinability
 Softer than white Cast Iron  Produces graphite in spheriodal form
 Used in automobile parts, Rail & Road  Increase ductility
Equipment, Gears, Cans, Pipe fitting,
Plates & Sheets 4. Manganese
 Stabilizes austenite
4. Nodular (Spherical) cast iron:  Acts as deoxidizer
 Easily machinable  Refines the graphite and pearlite
 Ductility is similar to malleable cast iron  Refines the grains.
 Corrosion resistance is similar to gray cast  Increases the basic mechanical properties
iron when added in low percentage.
 Its tensile strength is greater than gray cast 5. Molybdenum/ Cobalt
iron.  Improve tensile strength, fatigue strength
 Used in hydraulic cylinders, valves, and hardness
cylinder heads for compressors, diesel  Refines the graphite and pearlite
engines, connecting rods and high  Improves heat resistance
pressure pipe.  Act as austenitizer
 Increases hardness and promotes uniform
5. Chilled Cast iron:
,
microstructure
 Gray with outer envelope of white CI
phase is known as chilled cast iron 6. Nickel
 Outer surface is hard & inner surface is  Austenitizer (Stabilize austenite)
soft.  Refine pearlite and graphite
 Used as drawing dies, rollers for rolling  Improves the toughness of castings
equipments & sheet mills, sand blast  Refine the grains
nozzles  Resistance to corrosion
Alloyed cast iron:
Cast iron + alloying element 7. Vanadium/ Tungsten
 Alloyed Cast iron  Promotes heat resistance
 Carbide stabilizer

 Increases strength and hardness 03. A plain carbon steel has BHN of 180. What
 Improves wear resistance are values of RC, VHN and ultimate
 Reduce graphitization
strength?
 Increases the basic mechanical properties
when added in small percentage BHN
Ans: R C   18, VHN  BHN  180
10
8. Zirconium
 Graphitizer Ultimate Strength
 De-oxidizer  3.48  BHN MPa  620 MPa
 Reduces hardness
9. Silicon 04. What properties need to be considered for

 Promotes the formation of free graphite applications calling for following
 It produces sound castings free from requirements:
blowholes
(i) rigidity
10. Phosphorous (ii) Strength for no plastic deformation
 It aids fusibility and fluidity under static load
 It induces brittleness
(iii) Strength to withstand overload
11. Sulphar without fracture.
 Machinability (iv) wear resistance
12. Boron (v) reliability and safely.
 Highest hardness Ans: (i) Rigidity-Elastic modulus and yield
strength
Interview Questions (ii) Strength (for no plastic deformation
under static loading)-yield point
(iii) Strength (overload) – Toughness and
01. What is the difference between isotropic
impact resistance
and anisotropic materials?
(iv) Wear resistance- Hardness
Ans: If a material exhibits same mechanical
(v) Reliability and safely-Endurance limit
properties regardless of loading direction, it
and yield point.
is isotropic, e.g., homogeneous cast
materials. Materials lacking this property
05. Explain the effects of alloying chromium
are anisotropic.
and nickel in stainless steel.
02. What are orthotropic materials? Ans: Addition of nickel and chromium increases
Ans: It is a special class of anisotropic materials the tensile strength and increase in
which can be described by giving their resistance to corrosion takes place.
properties in three perpendicular directions
e.g. wood; composites.

21 Material Science
06. Mention two types of dislocation. 12. Whether individual components in

Ans: Dislocation refers to a break in the composite material retain their
continuity of the lattice. In edge dislocation, characteristics or not?
one plane of atoms gets squeezed out. In Ans: Yes.
screw dislocation the lattice atoms move
from their regular ideal positions. 13. An elastomer is a polymer when its
percentage elongation rate is ….?
07. What are the principal constituents of brass? Ans: Greater than 100%.
Ans: Principal constituents of brass are copper
and zinc. 14. If percentage elongation of a material is
more than 200%, it is classed as …?
08. What is Curie point? Ans: Rubber.
Ans: Curie point is the temperature at which
ferromagnetic materials can no longer be 15. Why is the maximum value which the
magnetized by outside forces. residual stress can reach is the elastic limit
of the material?
09. Specific strength of materials is very high Ans: A stress in excess of elastic limit, with no
when they are in fibre size but lower when external force to oppose it, will relieve itself
they are in bar form-why? by plastic deformation until it reaches the
Ans: Crystal structure has ordered, repeating value of the yield stress.
arrangement of atoms. Fibres are liable to
maintain this and thus have high specific 16. Why fatigue strength decreases as size of a
strength. As size increases, the condition of part increases beyond around 10mm.
ordered and repeating arrangement can’t be Ans: Perfection of material conditions is possible
guaranteed because of several types of at lower sizes and as size increases, it is not
defects and dislocations and thus the possible to attain uniform structure of the
specific strength gets lower. material.
10. What is the percentage of carbon in cast 17. Distinguish between creep and fatigue.
iron? Ans: Creep is low and progressive deformation of
Ans: 2.5% a material with time under a constant stress
at high temperature applications. Fatigue is
11. Which elements is added in steel to increase the reduced tendency of material to offer
resistance to corrosion? resistance to applied stress under repeated
Ans: Chromium. or fluctuating loading condition.

18. While normal carburizing and nitriding principal stress, and maximum strain are
surface treatments increase fatigue strength used.
excessive treatment may decrease the
fatigue strength. Why? 21. What for GFRP stands for?
Ans: Normal carburizing/nitriding treatments Ans: Glass fibre reinforced plastic.
increase volume due to phase
transformation at surface and introduce 22. Describe in brief the arrangement of atoms
residual compressive surface stress and thus in metals/alloys.
increase the fatigue strength. By excessive Ans: All metals and alloys have their atoms
treatment the high compressive stresses are arranged in a regular order, at the point of a
introduced but these are balanced by high space lattice which is periodically repeated
internal tensile stresses of equal value and in three directions. The smallest unit of this
the subsurface fatigue cracks may develop lattice is a unit cell. A crystal is composed
in the regions of high tensile stress and of these unit cells, piled upon one another
speed but if load is applied at a high like, bricks, and re-producing at their
velocity then failure. corners the points of the lattice.
The edges of the unit cell (parallelepiped)
19. List at least two factors that promote are denoted by .a, b and c and the angles
transition from ductile to brittle fracture. between the edges by ,  and . Common
Ans: Manner of loading, and the rate of loading crystal systems correspond to following
promote transition form ductile to brittle shapes of unit cells.
fracture. A machine member may have (1) cubic with a = b = c and  =  =  = 900,
ductile failure under static loading but may and (2) hexagonal with a = b  c and
fail in brittle fashion when the load is  =  = 900 and  = 1200.
fluctuating. Similarly a material may
evidence ductile failure under tensile 23. Which is the common element between
loading at ordinary testing speed but if load brass and bronze?
is applied at a high velocity then failure may Ans: Copper.
be brittle.
24. What does following alloy designation
20. Which theories of failure are used for (a) indicate FG 250?
ductile materials, and (b) brittle materials? Ans: Grey cast iron with tensile strength of 250
Ans: For ductile materials, theories of failure MPa.
used are maximum shear stress theory, and
25. How is ceramic defined?
maximum energy of distortion theory; while
Ans: It is a solid formed by combination of
for brittle materials, theory of maximum
metallic and non-metallic elements.

23 Material Science
26. Give one example of metal classified as per 32. Hydrogen cannot be removed easily from
structure as BCC, FCC, HCP and CCP. molten steel. What harm hydrogen has on
Ans: BCC (body centred cubic) structure- property of steel?
Molybdenum Ans: Execessive hydrogen results in the
FCC (face centred cubic) structure-Aluminium formation of small fissures often described
HCP (hexagonal closed packed) structure-Zinc as hairline cracks or flakes in the steel.
CCP (cubic closed packed) structure-copper. Large forgings in alloy steel are particularly
sensitive to this phenomenon.
27. What is the name of solid solution of carbon
in alpha iron and delta iron? 33. What is allotrope? In what forms of cubic
Ans: Ferrite and austenite respectively. pattern, iron exists?
Ans: Some elements exist in more than one
28. Explain the difference between pearlite and crystalline form. Each form is known as
cementite? “allot-rope”. Iron exists in two forms of
Ans: Pearlite is eutectoid mixture of ferrite and cubic pattern, namely body centered cubic
cementite. Cementite is chemical compound (bcc) and face-centered cubic (fcc).
of iron and carbon.
34. What is the difference between alpha iron,
29. Give one example each of the following delta iron and gamma iron?
proportion of materials-demensional, Ans: The bcc form of iron exists between room
physical, technological and mechanical. temperature and 9100C, and between
Ans: Roughness, enthalpy, toughness, and 14000C and the melting point at 15390C.
hardness respectively. The lower temperature form is known as
“alpha” iron and the higher temperature
30. For which parts the Wahl factor and Lewis form as “delta” iron. The face-centered
form factor used? cubic form existing between 9100C and
Ans: For springs and gears respectively. 14000C is referred to as “gamma-iron”.
31. How oxygen can be removed from steel 35. What is the difference between the points of
during melting? What are fully killed steels? inflexion and contraflexure.
Ans: Oxygen can be removed by adding elements Ans: In homogeneous material the composition is
such as manganese, silicon or aluminium same throughout and in isotropic material
which, because of their high affinity for the elastic constants are same in all
oxygen, react with it to form non-metallic directions.
oxides which rise into the slag. Steels which
have had most of their dissolved oxygen 36. Explain the difference between ferrite,
removed are called “fully killed steels”. austenite and graphite?

Ans: Ferrite is the solid solution of carbon and 38. What do you understand by critical points in
other constituents in alpha-iron. It is soft, iron-carbide diagram?
ductile and relatively weak. Ans: The temperature at which the phase changes
Austenite is the solid solution of carbon occur are called critical points (or
and other constituents in gamma-iron. It temperature).
exists in ordinary steels at elevated
temperatures, but it is also found at ordinary 39. What is satellite?
temperature in some stainless steels. Ans: It is a non-ferrous cast alloy containing
Graphite has a hexagonal layer lattice. cobalt, chromium and tungsten.
37. Explain the terms-solid solution, eutectic, 40. Which rays are produced by cobalt-60 in
eutectoid and peritectic. industrial radiography?
Ans: Gamma rays.
Ans: Solid Solution. When a homogeneous
mixture of two (or more) atomic forms 41. What are killed steels and what for these are
exists in solid state, it is known as solid used?
solution. Ans: Killed steels are deoxidized in the ladle with
Eutectic. A mixture of two (or more) silicon and aluminium. On solidification no
phases which solidify simultaneously from gas evolution occurs in these steels because
the liquid alloy is called an eutectic. Alloys they are free from oxygen.
in which the components solidify
simultaneously at a constant temperature the 42. What is critical temperature in metals?
lowest for the given system, are called Ans: It is the temperature at which the phase
eutectic alloys. change occurs in metals.
Eutectoid. Eutectoid alloys are the alloys
for which two solid phases which are 43. Car tyres are usually made of
completely soluble become completely Ans: Styrene-butadine rubber.
insoluble on cooling before a certain
temperature called eutectoid temperature. 44. What is the structure of pure iron and
Peritectic. A peritectic transformation whether it is soft or hard?
involves a reaction between a solid and Ans: Ferrite and it is soft.
liquid that form a different and new solid
phase. This three phase transformation 45. Which elements increase the corrosion
occurs at a point called peritectic point. resistance of steel?
Ans: Chromium and nickel.

25 Material Science
46. What causes hardness in steel? How heat alpha and delta ferrite is formed, which
treatment alters properties of steel? consequently reduces temperature range
Ans: The shape and distribution of the carbides in over which austenite is formed. Such
the iron determines the hardness of the steel. elements are silicon, chromium,
Carbides can be dissolved in austenite is the molybdenum, tungsten, titanium and
basis of the heat treatment of steel. If steel is niobium.
heated above the A1 critical temperature to
dissolve all the carbides, and then cooled, 49. What is the role of silicon as alloying
suitable cooling through the cooling range element in steels?
will produce the desired size and Ans: Silicon contributes greatly to the production
distribution of carbides in the ferrite, of sound steel because of its deoxidizing
imparting different properties. and degasifying properties. When added in
amounts up to 2.5%, the ultimate strength of
47. What are the major effects of alloying the steel is increased without loss in
elements? ductility. Silicon in excess of 2.5% causes
Ans: brittleness, and amounts higher than 5%
(1) To alter the transformation temperatures make the steel non-malleable.
and times Resistance to oxidation and surface stability
(2) To modify the room temperature and of steel are increased by the addition of
elevated temperature strengths of given silicon. These desirable effects partially
structures by (a) stiffening the crystal and compensate for the tendency of silicon to
(b) introducing complex precipitates which lower the creep properties of steel. Silicon
tend to harden the steel. increases the electrical resistivity of steel
(3) To modify the type of oxide film formed on and decreases hysteresis losses.
the surface of the steel and thereby affect its
corrosions resistance. 50. What is coaxing ?
Ans: It is the process of improving fatigue
48. What is the difference between austenite properties by first under-stressing and then
stabilizers and ferrite stabilizers? increasing the stress in small increments.
Ans: Austenite stabilizers have the effect of
extending the temperature range over which 51. What do you understand by eutectic?
austenite is formed. Such elements are Ans: It is mechanical mixture of two or more
carbon, manganese, nickel, copper and phases which solidify simultaneously from
cobalt. the liquid alloy.
Ferrite stabilizers have the effect of
extending the temperature range over which

52. Explain the difference between grey iron 70/30 brass has excellent deep drawing
and white iron. What is mottled iron? property and is used for making radiator
Ans: The carbon in cast iron could exist at room fins.
temperature as either iron carbide, or as
graphite which is the more stable form. 56. What for admirality brass used?
Irons containing carbon as graphite are soft, Ans: Admirality brass with 29% zinc and 1% tin
easily machinable and are called “grey has good corrosion resistance and is used
irons”. Irons with carbon present as iron for condenser and feed heater tubes.
carbide are extremely hard, difficult to Aluminium is also added to brass to
machine and are called “white” irons. Irons improve corrosion resistance.
with fairly equal proportions of graphite and 57. What is the maximum use of magnesium?
iron carbide have intermediate hardness Ans: Magnesium is used to alloy with aluminium
and are called “mottled” irons. and as an additive for making SG
(Spheroidal Graphite) iron
53. What do you understand by sulphur print?
Ans: Sulphides, when attached with dilute acid, 58. What for zinc finds applications?
evolve hydrogen sulphide gas which stains Ans: Galvanizing consumes the largest
bromide paper and therefore can be readily proportion of zinc. Zinc is resistant to
detected in ordinary steels and cast irons. corrosion but is attacked by acids and
While sulphur is not always as harmful as is alkalies. Zinc alloys are suited for making
sometimes supposed, a sulphur print is a die casting since the melting point is
ready guide to the distribution of segregated reasonably low.
impurities in general.
59. List two effects of manganese in plain
54. What is the different between brass and carbon steels.
bronze? Ans: Manganese increases tensile strength and
Ans: Brass is an alloy of copper with zinc; and hardness. It decreases weldability.
bronze is alloy of copper with tin.
60. Name the strongest and weakest type of
55. What is the effect of addition to zinc in atomic bonds.
copper? What is the use of 70/30 brass? Ans: Matellic bond is strongest and molecular
Ans: By addition o zinc in copper, both tensile bond also known as Vander Waals bond is
strength and elongation increases, The weakest.


Interview Guidance Material Mechanical Engineering

Uploaded by

Copyright:

Available Formats

Interview Guidance Material Mechanical Engineering

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Interview Guidance Material Mechanical Engineering

Uploaded by

Copyright:

Available Formats

INTERVIEW

16. Strain hardening: 4. Vickers Test :

2P Crystal structures and Defects

Materials are classified as:

3. Rock well Test: (ii) Non-crystalline solids:

 Space lattice: 2. Body centered cubic structure (B.C.C):

Atomic packing factor or packing efficiency of

Atomic packing factor

Hexagonal close packed structure (H.C.P.): Therefore, substituting h/a = 1.633

Structure No. of Co- Atomic

The features of miller indices: 1. Point defects:

3. Surface or Grain boundaries defects (b) Screw Dislocation

4. Volume defects: Stacking faults Burgers Vector: 

 This reaction is reversible.

(b) Peritectic System: steel which contains Pearlite and Cementite

Cementite + Pearlite Pearlite+Ledeburite Cementite (primary) +

(Pearlite+Fe3C) Ledeburite (Pearlite+Fe3C)

Hypoeutectoid Hyper eutectoid Hypo eutectic Hyper eutectoid

Steels Cast irons

About –Fe (Austenite): (iii) The eutectoid (point S) reaction:

II. Annealing  Holding at this temperature for considerable

IV. TEMPERING: iv) Sub - zero treatment:

Types of strain Hardening Process (b) Re-crystallization:

Thermo plastics Thermosets

Recyclable Non Recyclable Non Recyclable

Types of Rubber:  U-V Stabilizer: Improve stability to the

(iii) Styrene butadiene rubber (SBR): very (i) Powder

Types of fiber reinforced plastics: Types of composites Materials:

a) Vacuum forming (for T.P only) Ceramic matrix composite posses

S.No Plastic Properties & Purpose Applications

(ii) Mechanical Method:

Advantages and Disadvantages of powder  Moderate corrosion resistant

L.C.S + Cr (10-25%) i.e,  = .000023mm/oC

2. White cast iron: Alloying elements and their effects:

9. Silicon 04. What properties need to be considered for

06. Mention two types of dislocation. 12. Whether individual components in

You might also like