DepartmentofMechanicalEngineering

ME3392 – ENGINEERING MATERIALS AND METALLURGY

UNIT I- INTRODUCTION TO MATERIALS TESTING

Part A

1. Define the term solid solutions and its types.

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 thestructure should be similar to the base metal.
Example :Ag - Cu, Cu - Zn, Fe - C, etc.
2. Differentiate between substitution and interstitial solid solutions.
 Substitutional solid solution: Wherein the atoms of alloying elements occupy the
atomic sites of the base metal.
 Interstitial solid solution: Wherein the atoms of alloying elements occupy the
interstitial sites of the base metal.

3. What is Gibbs phase rule and state its importance.

Gibbs phase rule gives the relationship between the number of phases and the effect of
variables such as pressure, temperature and composition. Gibbs phase rule is derived for
equilibrium conditions and is given by,
P+F=C+2
Where, P = Number of phases in the system
F = Degrees of freedom
C = Number of elements

4. Define peritectic and eutectoiad reactions.

May-06, 16, Dec.- 14
Peritecticreaction :In peritectic transformation, a liquid and solid phase transforms
isothermally and forms a new solid having different composition. Peritecticreactions can be
expressed as :
Constant
Liquid1 + Solid1 Solid 2
Temperature

Example: Fe-C, Pt-Ag, Cu-Zn, etc.

 Eutectoid reaction :In eutectoid transformation, one solid transforms isothermally and forms
two new solids having different composition.

Constant
Solid 1 + Solid 2 Solid 3
Temperature
Example :Fe-C, Cu – Sn, Cu – Al, etc.

5. State Hume rothery’s 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.

6. Define peritectoid reaction. : May-07, Dec.-14

In peritectoid transformation, two different solid phases transform isothermally into a third
solid phase during cooling. Peritectoid reaction can be expressed as:

Constant
Solid1 + Solid 2 Solid 3
Temperature
Example :Ni - Zn, Cu - Sn, Ni - Mn, Fe - Nb, etc.
7. What do you mean by invariant reaction?
When a reaction occurs under equilibrium condition at a specific temperature and alloy
composition that cannot be varied it is said to be invariant.
8. What is an alloy?
A metal alloy is a mixture of two or more metals or non metals.
9. What is an equilibrium phase diagram?
It is defined as a plot of the composition of phases as a function of temperature in
any alloy system under equilibrium conditions.
 10. What is a lever-law calculation and what information can it provide?
Phase fraction = opposite arm of lever/ total length of tie line
Phase percentage = opposite arm of lever/ total length of tie line *100
Using the lever law calculation, one can compute the phase fraction and the phase
percentage.
11. Write a short note on:
 Pearlite: It is the mixture of ferrite and cementite formed by cooling of austenite. The
ferrite and cementite exist in the form of alternate lamellae.
 Ledeburite: It is the eutectic mixture of austenite and cementite. It consists of 4.3 %
carbon and falls under the group of cast irons.
 Cementite :Cementite is an inter-metallic compound of iron and carbon. It is also termed
asiron carbide. It’s crystal structure is complex orthorhombic and is the hardest structure
in the equilibrium diagram.
 Austenite :It is the interstitial solid solution of carbon in gamma (γ) iron which is a
[Link].

PART B & C
1. With the help of neat sketch explain the two types of solid solution.
2. Sketchneatly theiron-
carbideequilibriumdiagram,indicatingtemperatures,[Link]
soexplaintheperitecticreaction ofthissystem.
3. Explain:
Eutectic reaction (4)
Eutectoid reaction (4)
Peritectic reaction (4)
Peritectoid reaction (4)
4. Discusstheclassification,micro structureandapplicationofsteel .
5. Discussthecomposition,Propertiesandapplyofthefollowingcastiron.
FACULTY I/C HOD AC
 UNIT II- HEAT TREATMENT
PART A
1. Name any two shallow hardening processes.
 Martempering
 Austempering
2. What is the purpose of annealing?
i) To relieve internal stresses induced due to cold working.
ii) To make the steel suitable for further cold working.
iii) To reduce hardness and improve ductility.
iv) To ensure uniform phase distribution.
v) To refine the grain size.
3. Define hardness and hardenablity.
Hardness :It is measure of resistance offered by the steel to plastic deformation.
Hardenability :It is defined as the ease with which a desired depth of hardness can be attained in the
steel. It should be noted that hardenability is not an indication of the hardness of particular steel, rather
it is an index of the depth to which hardness
4. What is the significance of TTT diagram in heat treatment of steel?
 The relationship of temperature vs. time is thus established for specific composition of steel and
is represented as T.T.T. curve.
 The T.T.T. curve or diagram indicates the relationship between instantaneous temperature
[Link] for a particular composition of steel.
5. What is martempering and austempering?
 It is also known as marquenching, is a interrupted cooling procedure used for steels to minimize
the stresses, distortion and cracking of steels that may develop during rapid quenching.
 The Austempring is an isothermal heat treatment process, usually used to reduce quenching
distortion and to make tough and strong steel.

6. What is spheroididing?

 This type of annealing is used to improve machinability of steel.

 It is used for high carbon and air hardening alloy steels which are hard and difficult to be
machined.
7. When is the annealing process preferred?
 Annealing process is preferred where the metal is in distorted structural state or unstable or
having strain in the structure.
 Also for metals having residual stresses while manufacturing annealing is preferred.
8. Mention few applications of induction hardening.
Some of the applications of induction hardening are crank-shafts, camshafts, axles, gears, rolls
of rolling mills, brake drums, etc.

9. List any four principal methods of case hardening.

 Carburising
 Nitriding
 Cyaniding
 Carbonitriding
 Flame hardening
 Induction hardening.
10. Differentiate carburizing and nitriding.

Carburizing is the method of increasing Nitriding is the process of forcing diffusion

carbon on the surface of steel followed by of atomic
subsequent heat treatment. nitrogen in the steel.
The diffused carbon on the surface forms The diffused nitrogen on the surface forms
martensite structure after hardening respective nitrides which increase surface
treatment. hardness.

11. What is carbo-nitriding?

Carbonitriding is a combination of carburizing and nitriding surface hardening treatment.
Carbonitriding involves diffusion of atomic carbon and nitrogen on the surface of component. The
diffused carbon forms martensitic structure on heat treatment while diffused nitrogen forms hard
nitrides with the alloying elements such as Al, Mo, Cr, W, etc.
 PART B & C

1. Explain Jominy end quench test and its applications.

2. Explain Time-Temperature-Transformation (TTT) Curve in details?
3. What is annealing and explain the types the types of annealing?
4. Explain the types of hardening in detail?
5. Write a short note on
i) Normalizing
ii) Quenching
iii) Tempering
6. Explain continuous-cooling transformation (CCT) diagram in detail?

FACULTY I/C HODAC

 UNIT V – MECHANICAL PROPERTIES AND TESTING
PART A
1. Define the term Slip and twinning.
 Slip involves the sliding of blocks of crystal over one another along different
crystallographic planes known as slip planes.
 Twinning is the process in which the atoms in a part of a crystal subjected to
stress, rearrange themselves so that one part of the crystal becomes a mirror
image of the other part.
2. List the different types of fracture in a material.
 Brittle fracture
 Ductile fracture
 Fatigue fracture
 Creep fracture
3. What properties are determined from tension testing of metallic products?
 Limit of proportionality
 Yield strength
 Maximum tensile strength
 Breaking strength
 Percentage elongation
 Modulus of elasticity
4. What is meant by creep fracture and fatigue fracture?
 It is the property of a material by virtue of which it deforms continuously
under a steady load.
 It is defined fracture which takes place under repeatedly applied fatigue
stresses.
5. What is the significance of S-N curve?
 The S-N diagram is a graph obtained by plotting the number of cycles of stress
reversals (N) required to cause fracture against the applied stress level (S).
 Using the S-N diagram, the fatigue life of a material can be determined.

6. What are the factors affecting fatigue strength?

  Chemical composition
 Grain size
 Environmental effects such as corrosion
 The design of the product.
7. Define the term notch sensitivity.
The notch sensitivity refers to the tendency of some normal ductile materials to
behave like brittle materials in the presence of notches.
8. Define endurance limit in fatigue test.
Endurance limit is defined as the value of stress below which the material will not
fail even when it is loaded for infinite number of cycles.
9. Define fatigue.
The capacity of material to withstand for a repeatedly applied stresses is known as
fatigue.
10. What is the difference between HRB and HRC?
 There are many rock well Scales: B – Scale [1/16 inch diameter steel ball
indenter; 100kg load] Used to measure the hardness (HRB) of non – ferrous
metals.
 C – Scale [120o diamond core indenter, called a BRALE; 150kg load] Used to
measure hardness (HRC) of steels.
11. What is meant by plastic Deformation and elastic deformation?
 Plastic deformation is the deformation of a body which remains even after
removing the external load from the body.
 Elastic deformation is the deformation of a body which comes back to its
original position after removing the external load from the body.
 PART B & C

1. Explain in detail about the types of hardness test with its application, advantage and
disadvantages?

2. Explain in detail about the mechanism of plastic deformation by slip and twinning?

3. Explain in detail about the impact tests (Izod and Charpy) with its application, advantages

and disadvantages?

4. Discuss the characteristics of ductile fracture and brittle fracture with neat sketch?

5. Define fatigue and discuss briefly the steps involved in construction of an S-N curve.

6. Explain in detail about the procedure for tensile test and draw the typical stress strain curve for
a ductile material?

7. Write a short note on

i) Fatigue test
ii) Creep test
FACULTY I/C HODAC
 UNIT 3 – FERROUS AND NON FERROUS METALS

PART-A

1. Write the effects alloys adding on steels?

The effects of alloying elements on steel are:
 To increase strength
 To increase hardness
 To increase toughness
 To increase wear resistance

2. What is HSLA? Give its composition and applications

HSLA refers to high speed low alloy steels and also called as micro-alloyed steels. It consists of
low carbon content of about 0.07 to 0.13 % carbon with low alloying elements (< 0.5 %). The major
alloying elements include V, Ti, Nb and Al. HSLA steels are used in automotive and aircraft industry.

3. What is the composition of 18/4/1 type high speed steel

18/4/1 is the most widely used grade of tungsten high speed tool steel (T-series). It contains 0.7
% C, 18 % W, 4 % Cr and 1 % V. It retains high hardness upto a temperature of about 600 ºC. It has
very high wear resistance and cutting ability.

4. What are bearing alloys? Its types.

Bearing alloys are bearings that make use of metal alloy as its running surface, either lubricated
by fluids / greases or running on smooth surfaces. Examples: Bearings of I.C. engines, lathe machine,
milling machine, electric motors, etc.
 Tin based alloy
 Copper based alloy
 Aluminium based allow

5. What is precipitation hardening?

Precipitation or age hardening is a phenomenon whereby some alloys inhibit increased hardness
over a period of time at room temperature or after slight heating. This phenomenon produces hard
precipitates in the base metal matrix.
6. List any two types of cast iron and their application?
 Grey iron is capable of resisting wear, which is why it's used for producing engine blocks and
cylinder heads, manifolds, gas burner gear blanks, enclosures, and housings.

 White cast iron is a brittle material because of the chilling process used in its production.

7. Difference between composite and alloys?

 An alloy is a mixture of two or more components with at least of those two components being
a metal.
 A composite is, like an alloy a mixture of two or more components but does not include any
material.

8. What are supper alloy?

Super alloy is general term used to describe the nickel-base and cobalt-base alloys which have
been developed for use at elevated temperature.

9. What are three primary group of plain carbon steel?

 Low carbon steel
 Medium carbon steel
 High carbon steel

10. What is known as cupro nickel?

Cupro-nickels are alloys of copper and nickel. Copper and nickel are completely soluble in
each other in liquid and solid states. Copper provides the ductility, malleability and ability to be cold
worked to the cupro-nickels. Nickel provides the corrosion resistance, tensile strength, and proof
stress and fatigue strength.
11. Difference between brass and bronze
 Brasses are alloys of copper and zinc with small amount of other alloying elements.
 Bronzes are alloys of copper and any other major alloying element but not Zinc (such as Al,
Be, Sn, etc.)
12. What is the main strengthening mechanism in high strength aluminum alloys?
Precipitation strengthening treatment, also known as age hardening is the main strengthening
mechanism in high strength aluminum alloys.
13. What are the required good properties of a tool steel?
 Good toughness
 Good wear resistance
 Very good machinability
 Resistance to softening on heating

14. What is the difference between white cast iron and gray cast iron?
 In white cast iron, all the carbon is present in the combined form i.e. cementite and there is no
free carbon (graphite) because of which the fractured surface appears white, hence called
white cast iron.
 Gray cast iron consists of graphite in the form of flakes and appears gray, hence called gray
cast iron.

15. Define the term maraging.

Maraging steels are low carbon steels (< 0.03 % C) containing 18 to 25 % nickel and other
alloying elements in small proportion. The additional alloying elements include Mo - 3 to 5 %, Co - 3
to 8 %, Ti - 0.2 to 1.6 % and traces of Al. Maraging steels are subjected to air hardening followed by
aging, hence the name maraging steels.

PART-B & C

1. Discuss in detail, the age hardening of Al-Cu alloy with the help of phase diagram.
Or
Write short notes on the precipitation hardening and ageing treatment of Al-Cu alloy?
2. Explain the properties and the application of the following
i) Tool steels
ii) Maraging steel
3. Discuss the composition, properties of any four copper alloys.
4. Classify cast iron and state their properties and application in detail.
5. Discuss on the various aluminium and its alloys and their importance in engineering industries.
6. Discuss on the various bearing alloys and their application in detail.

FACULTY I/C HOD AC

 UNIT IV –NON-METALLIC MATERIALS
PART-A
1. Define polymerization. What are the methods?
Polymerization is defined as the process of forming large polymer by linking together monomers.
Eg.: Wood, resin, starch, nylon, etc. The general methods or mechanism of polymerization are:
i) Addition polymerization
ii) Copolymerization
iii) Condensation polymerization.
2. What is the difference between addition and condensation polymerization.
 Addition polymerization also known as chain reaction polymerization is a process by which
two or more chemically similar monomers are polymerized to form long chain molecules.
 The formation of polymers by stepwise intermolecular chemical reactions that normally
involve atleast two different monomers is termed as condensation polymerization. It is also
known as step-growth polymerization. Eg.: Polyamides, polyesters, etc.
3. What is Degree of polymerization?
It is the number of repetitive units present in one molecule of a polymer. i.e.
Degree of polymerization = Molecular weight of a polymer / Molecular weight of a single
monomer
4. What is mean by PSZ?
Partially stabilized Zirconia is a zirconium oxide that is blended and sintered with other oxides
such as Engineering Materials & Metallurgy 8 - 34 Non-Metallic Materials Technical PublicationsTM
– An up thrust for knowledge those of magnesium, calcium and yttrium, to control the crystal structure
transformations.
5. What are sialons? State their applications
 The word sialon is derived from the ingredients involved such as silicon, aluminium oxygen
and nitrogen.
 it is formed by blending silicon nitride with different proportions of aluminium oxide,
aluminium nitride and yttrium oxide.
Application: i) They are used for cutting tool materials, wire and tube drawing dies, rock and coal
cutting equipment’s.
6. Define metal matrix composite.
It contains continuous or discontinuous fibers or whiskers in a ductile metal matrix.

 The most commonly used matrices in ductile metals are aluminium, magnesium, copper,
titanium, nickel and super alloys.
 The continuous fibers may be graphite, alumina, boron or silicon carbide
7. Define Elastomers
These polymers are known for their high elongations, which are reversible upon release of
applied [Link] consist of coil-like molecular chains, which straighten up on application of load.
E.g.: natural and synthetic rubber.
8. Differentiate thermosetting and thermoplastic polymers.
Thermoplastics
 They are formed by addition polymerization.
 They are linear polymers composed of chain molecules
Thermosetting
 They are formed by condensation polymerization.
 They are composed of three dimensional networks of crosslinked molecules.
9. Define FRP.
Fibre-reinforced plastic or fibre-reinforced polymer is a composite material made of a polymer
matrix reinforced with fibres.

10. How will the crystallinity of a polymer be affected by the addition of a plasticizer?
Because the plasticizer is a molecule that fits between the main polymer chains, it should
reduce the crystallinity.

11. List the applications of engineering ceramics.

 They are used for cutting tool materials, wire and tube drawing dies, rock and coal
cutting equipments. But, due to its chemical affinity to iron, it is not suitable for
machining of steels.
 Because of good mechanical properties, ceramics are used in engine components and
structural applications.
12. What are the important uses of aluminium and silicon carbide?
 Alumina or aluminium oxide is used as a refractory material for high temperature
applications. It is also used as an abrasive material for grinding wheels.
 Silicon carbide are used as resistant and heating elements, for electric type of furnaces.
Also, they are used for high temperature applications like turbine blades, automobile
and heat engines, etc.
13. Give few important characteristics of polymers
i) Polymers are light in weight.
ii) They have high corrosion resistance
iii) Low density.
 iv) Low thermal and electrical properties.
v) Easy to fabricate.
vi) Low cost.

14. Classify ceramics on the basis of application.

Ceramics are classified as,
i) Abrasives
ii) Fired-clay products
iii) Glasses
iv) Cements
v) Rocks
vi) Refectories

PART-B & C

1. Write down the types and applications of composites in detail.

2. Write down the types and application of ceramics in detail.
3. List the properties and application of any six types of polymers.
4. Explain the strengthening mechanism of fiber-reinforced composite in detail.
5. Compare thermosetting plastic and thermo plastic.
6. Explain the different types of thermo-plastic and thermo setting plastic in detail.

FACULTY I/C HOD AC