ENGINEERING MATERIALS AND METALLURGY

UNIT I

PART A
1.

What is meant by alloying elements? It is a mixture of two or more metals or a metals and a non metals. The element which is present in the largest proportion is called the base metal, and other element present is called as alloying elements.

2.

State Hume rotherys rules? Size factor: The atoms must be of similar size, with less than 15% difference in atomic radius Crystal structure: The material must have the same crystal structure. Otherwise, there is some point at which the transition occurs from one phase to a second phase with different structure. Valence: The atoms must have the same valence. Other wise the valence electrons difference encourages the formation of compounds rather then solutions. Electro negativity: The atoms must have approximately the same electro negativity.

3. What is phase diagram? It is graphical representations of what phase are present in a materials system at various temperatures, pressures, and compositions. And the phase diagrams are also known as equilibrium diagram or constitutional diagrams.

4. What is meant by the term phase? A phase may be a portion of matter which is homogeneous. A phase is defined as any physically distinct, homogeneous, and mechanically separable portion of a substance. In laymans term, a phase requires a unique structure, uniform composition, and well-defined boundaries or interfaces.

5. State Gibbs phase rule? It is a simple equation that relates the number of phases presents (P) in a system at equilibrium with the number of degrees of freedom (F), the number of components (C),And the number of non-compositional variables. Gibbs phase rule: F = C-P+2

6. What are the types of cooling curves? Cooling curve for pure metal or compound Cooling curve of a binary solution Cooling curve of a binary eutectic system or a multiphase alloy.

7. What is cooling curves? Cooling curves are obtained by plotting the measured temperature at equal intervals during the cooling period of a melt to a solid. The data obtained from these cooling curves are useful in constructing the equilibrium.

8. What are the uses of phase rule?

 The phase rule predicts maximum number of phase presents in the alloy under equilibrium conditions at any point of diagram. If number of phases is known, one can determine the degrees of freedom using the phase rule. Thus the phase is useful to know whether the temperature or pressure or both variables can be changed without changing the structure of the alloy. 9. What are the types of equilibrium phase diagram? A phase diagram can be defined as a point as a plot of the composition of the phases as a function of temperature in any alloy system under equilibrium conditions. Phase diagram for complete solid solubility Phase diagram for partial solid solubility Phase diagrams containing three-phase reactions.
10.

What are the solid phases in the phase diagram? -Ferrite (): This phase is an interstitial solid solution of carbon in the BCC iron crystal lattice. Austenite (): The interstitial solid solution of carbon in iron is called austenite. Cementite (FeC): The intermetallic iron - carbon compound (FeC) is called as cementite. - Ferrite (): The interstitial solid solution of carbon in iron is called ferrite.

PART - B

11.

What are cooling curve? How does the time-temperature cooling curve of an alloy of eutectic composition differ from the pure metal?

12. Explain in detail about the types of equilibrium phase diagram? 13. Explain the micro-constituents of iron-carbon alloys? 14. Explain briefly about the iron-carbon carbide equilibrium diagram? 15. Explain the transformations which take place in the structure of cast- iron?

UNIT II PART A 1. Define heat treatment process? Heat treatment process may be defined as an operation or combination

Of operation involving heating and cooling of a metal/alloy in the solid state to obtain desirable properties.

2. What is the purpose of heat treatment process? To relieve internal stress. To improve machinability. To improve hardness of the metal surface. To increase resistance to wear, heat and corrosion.

3. Define principles of heat treatment? The rate of cooling is the controlling factor in developing hard or soft structure. Rapid cooling from the critical range results in hard structure, whereas very slow cooling produces the soft structure.

4. What are the types of heat treatment processes? The important heat treatment processes are Annealing Normalizing Hardening Tempering Aus tempering Mar tempering Case hardening

5. What is meant by annealing?

The term annealing refers to a heat treatment in which a material is exposed to an elevated temperature for an extended time period and then slowly cooled.

6. What is meant by recrystallisation? Recrystallisation is a process by which distorted grains of cold-worked metal are replaced by new, strain-free grains during heating above a specific minimum temperature.

7. What is meant by normalizing? Normalizing is similar to full annealing, but cooling is established in still air rather than in the furnace. Full annealing is an expensive and time consuming process. When a reasonably soft and ductile material is required and cost savings are desired. 8. What is quenching? Quenching refers accelerated cooling. The cooling can be accomplished by contact with a quenching medium which may be a gas, liquid or solid. Most of the times, liquid quenching media is widely used to achieve rapid cooling. 9. What is mar tempering? Mar tempering, also known as mar quenching, is a interrupted cooling procedure used for steels to minimize the stresses, distortion and cracking of steels the may be develop during rapid quenching.

10.

What is meant by carburizing process?

 Carburizing is the process in which carbon atoms are introduced onto the surface of the low carbon steel to produce a hard case of surface, while the interior or core remains soft. Steels for carburizing should have carbon from 0.10 to 0.20%

PART - B

11.

Compare the contrast the process of full annealing, process annealing, stress relief annealing, recrystallisation annealing, and spheroidise annealing?

12.(a) Describe the normalizing process of heat treatment. (b) Differentiate between normalizing and full annealing.
13. (a)

Explain the process of mar tempering. Compare and contrast it with aus tempering process? (b) Differentiate between hardness and hardenability?

14. (a) What are TTT diagrams? (b) How a TTT diagram is drawn? (c) Draw neat sketch of the TTT diagram for eutectoid steel?

15. Write short notes on the following surface heat treatment operation: A. Carburizing B. Cyaniding, and (b) Nitriding (d) carbonitriding.

UNIT III PART A 1. What are metals? Metals are elemental substance Metals are composed of elements which readily give up electrons to provide a metallic bond and electrical conductivity.

2. What are steels?

Steels are alloys of iron and carbon. However, steels contain other elements like silicon, manganese, sulphur, phosphorus, nickel, etc.

The alloying elements are either intentionally added or retained during the refining process.

3. What are plain carbon steels? Plain carbon steels are those in which carbon is the alloying element that essentially controls the properties of the alloys, and in which the amount of manganese cannot exceed 1.65% and the copper and silicon contents each must be less than 0.6%

4. What are the applications of plain carbon steels? Plain carbon steels are used for mass production products such as automobiles and applicance. They also find applications in the production of ball bearings, base plates, housings, chutes, structural members, etc.

5.

What are low carbon steels?

The low-carbon steels represent the largest tonnage of all the steels produced.

The low-carbon steels are those steels that contain less than about 0.25% carbon The low-carbon steels are also known as mild steels.

6.

What are the applications of high carbon steels?

Typical applications of plain high-carbon steels include cutting tools and dies, knives, razors, hacksaw blades, springs, and high-strength wires, etc. these are the application of high carbon steels.

7.

What are stainless steels? It is an alloy of iron, chromium, and other elements that resist corrosion from many environments. Three classes of stainless steels, Austenitic stainless steels,

Ferritic stainless steels and Martensitic stainless steels.

8.

What are the properties of copper? Copper possesses very high electrical conductivity. In fact is this respect it is second only to silver. It is also has very high thermal conductivity. It exhibits excellent resistance to corrosion It is very soft, ductile and malleable.

9.

What are the types of aluminium alloys? The alloys of aluminium may be subdivided into two groups as: Heat treatable aluminium alloys, and Non-heat treatable aluminium alloys.
10. 11.

What is precipitation hardening?

It is also known as age hardening. Is the most important method of strengthening the physical properties of some of the non-ferrous alloys by solid state reaction.

PART - B

12.

(a) Give the classification of steels. (b) Describe the properties and typical applications of low-medium and high carbon steels.

13. (a)

What are the main classifications of stainless steels?

(b) Discuss the different types of stainless steel, making reference to approximate compositions, structures, heat treatments.

14.

Write an engineering brief about the following steels: (a) Tool steels, (b) HSLA steels, and (c) maraging steels

15.

(a) Explain the principle characteristic of cast iron and explain the factor which affects the structure of cast iron.

(b) Describe the structures if the main types of cast irons and account for their continued use as engineering materials. 16.(a) What is meant by age hardening? Explain the process of precipitation strengthening treatment. (b) Explain the effects of ageing temperature and time on the properties of the alloys.

UNIT IV PART A
1.

What are polymers? The term polymer is derived from two Greek words poly and mers. The term poly means many, and the term mer means parts of units. Thus polymers are composed of a large number of repeating units of small molecules called monomers.

2.

What is polymerization and types of polymerization? It is the process of forming a polymer by linking together of monomers. Two polymerization mechanisms are Addition polymerization, and Condensation polymerization.

3.

What is addition polymerization?

It is also known as chain reaction polymerization is a process by which two or more chemically similar monomers are polymerized to form long chain molecules is called as addition polymerization.

4.

What is plastic? It is defined as the organic polymer, which cab be moulded into any desired shapes and size with the help of heat, pressure, or both thermoplastics and thermosetting plastics.

5.

What are thermoplastics? It is known as thermoplasts, are the plastics whose plasticity increases with the increase in temperature. Thermoplasts can be repeatedly moulded and remoulded to the desired shape and hence they have a good rescale and scrap value.

6.

What are thermosetting plastics? It is also known as thermosets, are plastics which becomes permanently hard when heat is applied and do not soften upon subsequent heating. They cannot be remoulded or reshaped again and again

7.

What are ceramics? It is a non-metallic and inorganic solid that are processed and or used at high temperature. Typical ceramics are electrical and thermal insulators with good chemical stability and good strength in compression.

8.

What are engineering ceramics? Engineering ceramics, are also known as technical/ industrial ceramics or advanced ceramics, are those ceramics that are specially used for

engineering application or in industries. It is mainly oxides, carbides, sulphides, and nitrides of metals.

9.

What are the three stages in addition polymerization? The addition polymerization occurs in three stages: Initiation, Propagation, and Termination

10.

What are phenolics? It is also known as Bakelite, are the oldest family of thermosetting plastics. The most important phenolic materials are the polyformaldehydes.

PART - B
11.What do you understand by polymerization? With the help of suitable examples, compare and contrast the process of addition polymerization and condensation polymerization.
12.

Define monomer and polymer. Write typical polymeric repeat unit structure for both addition and condensation polymerization.

13.(a) Describe the difference between thermoplastics and thermosetting plastics. (b) Explain the difference between commodity plastics and engineering plastics.

14.

List the properties and typical applications of the following thermoplastics:

(b) PMMA (c) PET, and (d) PEEK

15. (a)

What are ceramics? List and briefly explain five important properties of ceramics that makes them useful engineering materials.

(b) What are the main classifications of ceramics materials? UNIT V PART A
1.

What is meant by mechanical properties of material? Mechanical properties are those characteristics of material that describe its behavior under the action of external force is known as mechanical properties of material.

2.

Define the term elasticity and plasticity? Elasticity: It is the property of a material by virtue of which it is able to retain its original shape and size after the removal of the load. Plasticity: It is the property of a material by virtue of which permanent deformation takes place, whenever it is subjected to the action of external force.

3.

What are the factor affecting mechanical properties? The numbers of factor affect mechanical properties, the following factors are: Grain size Heat treatment Atmospheric exposure Low and high temperature

4.

What are the effects of heat treatment? Since the heat treatment changes are refines the grain size, therefore the mechanical properties are affected.

 It is also improve the workability, forge ability and machinability of the metals.

5. What are thermoplastics? It is known as thermoplasts, are the plastics whose plasticity increases with the increase in temperature. Thermoplasts can be repeatedly moulded and remoulded to the desired shape and hence they have a good rescale and scrap value.

6. What are thermosetting plastics? It is also known as thermosets, are plastics which becomes permanently hard when heat is applied and do not soften upon subsequent heating. They cannot be remoulded or reshaped again and again

7. What are ceramics? It is a non-metallic and inorganic solid that are processed and or used at high temperature. Typical ceramics are electrical and thermal insulators with good chemical stability and good strength in compression.

8. What are engineering ceramics? Engineering ceramics, are also known as technical/ industrial ceramics or advanced ceramics, are those ceramics that are specially used for engineering application or in industries. It is mainly oxides, carbides, sulphides, and nitrides of metals.

9. What are the three stages in addition polymerization? The addition polymerization occurs in three stages:

 Initiation, Propagation, and Termination

10.

What are phenolics? It is also known as Bakelite, are the oldest family of thermosetting plastics. The most important phenolic materials are the polyformaldehydes.

PART - B

Explain the two modes of Plasticdeformation.Decribe the working of universal testing machine with suitable diagram.
11.

12. With help of a neat sketch explain the charpy impact testing procedure and why impact specimens are notched.

With help of a neat sketch explain the Izod impact testing procedure and why impact specimens are notched.
13.