VALLIAMMAI ENGINEERING COLLEGE

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1 VALLIAMMAI ENGINEERING COLLEGE SRM Nagar, Kattankulathur DEPARTMENT OF MECHANICAL ENGINEERING QUESTION BANK IV SEMESTER ME ENGINEERING MATERIALS AND METALLURGY Regulation 2013 Academic Year Prepared by Dr. S.THIRUGNANAM, Professor Dr. P.MATHIVANAN, Professor Mr. G.ANBUCHEZHIYAN, Assistant Professor Mr.S. SIVALINGAM, Assistant Professor

2 VALLIAMMAI ENGINEERING COLLEGE SRM Nagar, Kattankulathur DEPARTMENT OF MECHANICAL ENGINEERING QUESTION BANK SUBJECT: ME ENGINEERING MATERIALS AND METALLURGY SEM / YEAR : IV/ II UNIT-I/ ALLOYS AND PHASE DIAGRAMS Constitution of alloys Solid solutions, substitutional and interstitial phase diagrams, Isomorphous,eutectic, eutectoid, peritectic, and peritectoid reactions, Iron carbon equilibrium diagram.classification of steel and cast Iron microstructure, properties and application. Q.No. PART-A BT 1. What is peritectic Reaction? Write an example for that reaction. 2. What is Eutectoid Reactions? Write an example of the eutectoid reaction occuring in the Iron Carbon System. 3. Define alloy. 4. Define alloying elements? 5. How will you explain peretectic reaction? 6. What is steel? 7. State the condition for Gibb s phase rule. 8. Differentiate between substitution and interstitial solid solutions. 9. What Is Invariant Reaction 10. Define the term solid solution 11. Define the term ferrite and Austenite in iron carbon alloy system. 12. Explain allotropy of iron 13. Why carbon solubility is more in Austenite? 14. State Gibb s phase rule. 15. How do cast irons differ from steels in terms of carbon content? 16. Write the different types of cast iron 17. Define isomorphous. 18. Define Eutectic Reaction. Give an example. 19. Write the Classification of steel. 20. Write the constitution of austenite. Q.No. PART-B: BT 1. i)explain briefly Isomorphous phase diagram for Cu-Ni system and Ideal phase diagram (soluble and insoluble) i)how are solid solutions classified? Give example for each. 2. Explain the types of cast iron? Draw the microstructure of any four types of cast iron? 3. How will you plot binary phase diagram for two metals which are completely soluble in liquid and solid states?

3 4. Explain the following invariant reactions with reference to a phase diagram (a) Eutectic reaction (b) Eutectoid reaction (c) Peretectic reaction (d) Peretectoid reaction. 5. i)what are the micro constituent of iron carbon alloys? Explain the general characteristics of each? ii)draw the typical microstructure of 1.2%C steel at 920 C 780 C and 200 C 6. Draw Iron-iron carbide equilibrium diagram and mark on it all salient temperatures and composition fields. 7. Name the phase reactions occurring in Fe-Fe3C system. What are the temperatures and compositions at which they occur? 8. Explain the primary crystallization of eutectoid steels, hypoeutectoid steels and hypereutectoid steels. 9. E x p l a i n the primary crystallization of eutectic cast irons, hypoeutectic cast irons and hypereutectic cast iron with the help of neat sketch. 10. Explain in brief the properties and applications of cast Iron types. 11. Draw Fe-C diagram and mark all the phases and explain the reactions? 12. i)draw the phase diagram between A and B, if the two metals are completely soluble in solid and liquid state. ii)discuss the similarities and differences between substitutional and interstitial solid solution? 13. (i)elements A and B melt at 700 C and 1000 C respectively. Draw a typical isomorphous phase diagram between the elements A and B. (ii)elements A and B melt at 700 C and 1000 C respectively. They form an eutectic at 35% A at temperature 500 C. Draw a typical phase diagram between A and B. 14. Draw a hypothetical phase diagram A-B with the help of following data: (a) Melting point of A = 1100 C (b) Melting point of B = 1300 C (c) Eutectic reaction occurs at 1000 C at 40% B composition. (d) maximum solubility of B in A and A in B at eutectic temperature in 10% and 5% respectively which drops down to zero at 0 C. Mark each line and area. How the structure of alloy will change if alloy containing 10% B composition is cooled from liquid state? Q.No. PART C BT 1. Draw Iron -Carbide equilibrium diagram and mark on it all salient temperature and composition fields. 2. Enumurate the properties and application of GrayC.I, NodularC.I, WhiteC.I, Malleable C.I 3. Two elements A and B have melting points 800 C and 600 C respectively (i) Draw a phase diagram between A and B if they exhibit unlimited solid solubility. Draw a phase diagram between A and B if they exhibit unlimited (ii) Draw a phase diagram between A and B if a eutectic reaction occurs at composition 40%B and at temperature 400 C. Assume that the maximum solid solubility in either case is 5% and the room temperature solubility in either case is 1% 4. Draw a typical isomorphs phase diagram and explain the structural changes of alloys ( say 50% A and 50% B). the lever rule at some temperature in alpha + liquid portion for this alloy UNIT- II / HEAT TREATMENT Definition Full annealing, stress relief, recrystallisation and spheroidising normalising, hardening and Tempering of

4 steel. Isothermal transformation diagrams cooling curves superimposed on I.T. diagram CCR Hardenability, Jominy end quench test - Austempering, martempering case hardening, carburizing, Nitriding, cyaniding, carbonitriding Flame and Induction hardening Vacuum and Plasma hardening.. Q.No. PART-A BT 1. Define Normalizing and Hardening process. 2. Define recrystallisation 3. What is the use of the isothermal transformation diagram? 4. Name the various method of heat treatment of steel. 5. Explain the term Stress relief annealing and Spheroidizing. 6. Define Hardenablity 7. Define the term heat treatment. 8. What are the purposes of processing heat treatments? 9. Explain the purpose of annealing. 10. Define CCR. 11. What is T-T-T diagram? 12. Enumerate Martempering? 13. Define Quenching. 14. Define tempering. 15. What do you mean by the term case hardening? 16. What is Austempering? 17. Explain carburizing and nitriding. 18. What is laser surface hardening? 19. What is Flame hardening? 20. Mention few applications of induction hardening Q.No. PART-B: BT 1. Draw a neat sketch of the TTT diagram for eutectoid steel and label the regions. Mark the different products formed on this diagram. 2. What is a CCT diagram? Describe various cooling curves on CCT diagrams. How such curves are drawn? Write short notes on critical cooling rate 3. Explain how Jominy end quench test is used for determining the hardenability of steels. 4. i) What is meant by hardenability? Describe a method of measuring hardenability of alloy steel. (ii) Distinguish between diffusion and thermal surface hardening treatments. 5. Brief about tempering process and explain CCT diagram. 6. Define the types of annealing Process and explain them? 7. Write short notes on: 1.Annealing 2.spheroidising 3.Normalising 4. Hardening 8. Explain the process of nitriding. List and discuss the advantages of nitriding over carburizing 9. What is meant by carburizing of steels? Briefly explain the various types of carburizing. 10. Write short notes on :1. Carburizing 2.Cyaniding 2. Nitriding 3.Carbonitriding 11. Write short notes on: 1.Age hardening (ii) 12. Explain the following case hardening process: i) Induction hardening ii) Flame hardening 13. Enumerate Martempering and Austempering. 14. With a schematic layout explain the following : Vacuum and Plasma hardening

5 Q.No. PART C BT 1. Explain the difference between TTT diagram and iron carbon equilibrium diagram. 2. Describe why are TTT diagrams usually not applicable to industrial engineering practices? 3. Outline the principle of high frequency induction hardening. How induction hardening is carried out. Mention its advantages, disadvantages and applications. 4. Explain different types of tempering process UNIT- III / FERROUS AND NON-FERROUS METALS Effect of alloying additions on steel- α and β stabilisers stainless and tool steels HSLA, Maraging steels Cast Iron - Grey, white, malleable, spheroidal alloy cast irons, Copper and copper alloys Brass, Bronze and Cupronickel Aluminium and Al-Cu precipitation strengthening treatment Bearing alloys, Mg-alloys, Ni-based super alloys and Titanium alloys. Q.No. PART-A BT 1. Explain stainless steels. 2. What is meant by maraging steel? 3. Define tool steel. 4. Name some of the Tool steel. 5. What are bearing materials? 6. Enumerate the important types of copper alloys. 7. Describe precipitation hardening. 8. State three reasons why ferrous alloys are used extensively. 9. Write the constitution of Stainless steel. 10. State three characteristics of ferrous alloys that limit their utilization 11. Briefly explain cupronickel. 12. List four important alloying elements added in alloy steels. 13. What are the required good properties of a tool steel? 14. Define high speed steel. 15. Define chilled cast iron. 16. Define the process precipitation hardening. 17. Describe HSLA? Where it is used? 18. What is the main strengthening mechanism in high strength aluminum alloys? 19. Explain the effect of chromium and molybdenum in low alloy steels. 20. Explain super alloys. Q.No. PART-B: BT 1. Discuss the influence of various alloying element addition in steels 2. Discuss the composition, properties, application- Maraging steels, Tool steel,hsla 3. Discuss the composition, properties, application of different types of cast irons 4. What are stainless steels?what are the main characteristics of stainless steels? Name different types of stainless steels and their main application? 5. Discuss the composition, properties and typical application of any four copper alloys. 6. Explain the composition properties and typical application of some aluminium alloy?

6 7. Enumerate the composition and applications of following alloys (i) Cupronickel (ii) Bronze (iii) Bearing Alloy (iii)mg alloy 8. Write short notes about the following materials in terms of composition properties and application (i) Maraging Steel (ii) Austenitic Stainless Steel (iii)alpha Beta Brass 9. Explain Ni based super alloys and Ti alloys. 10. What is an alloy steel? How are alloy steels classified? Explain them. 11. Explain the steps involved in precipitation hardening? 12. What are the properties of Aluminum? What are the different types of alloying element such as copper, iron manganese, magnesium used with aluminum and its application? 13. With part of phase diagram and relevant graphs, Explain precipitation hadening treatment of AL-CU alloy. 14. Classify stainless steel and tool steel and explain following (i) Maraging steel(ii) Spheroidal cast iron (ii) HSS Steel in terms of composition property and use. Q.No. PART C BT 1. (i)assess suitable non ferrous material for the following articles 1. bush 2.furnace heating element 3. type writer parts 4.big end bearing 5. filament of electric lamp 6. turbine blade (ii) Write short notes on: 1. Bearing metals 2. Brasses 2. Formulate the influence of alloying Al, Cr, Ni, Mo, Si, Mn, V & Cu in steel Explain in brief. 3. Explain about a. Gray C.I b. White C.I c. Malleable C.I d. Spheroidal Graphite C.I 4. (i)why copper is a suitable material for automobile radiators? Explain. (ii)what are the outstanding properties of cupronickel alloys? UNIT- IV / NON-METALLIC MATERIALS Polymers types of polymer, commodity and engineering polymers Properties and applications of various thermosetting and thermoplastic polymers (PP, PS, PVC, PMMA, PET,PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE, Polymers Urea and Phenol formaldehydes)- Engineering Ceramics Properties and applications of Al2O3, SiC, Si3N4, PSZ and SIALON Composites-Classifications- Metal Matrix and FRP - Applications of Composites. Q.No. PART-A BT 1. Define the term polymer? 2. What are synthetic polymers? 3. Explain condensation polymerization.

7 4. How are polymers classified? 5. Explain the application of types of thermoplastics. 6. Explain ABS. 7. Define PET. 8. Define plastics. 9. Differentiate Thermoplastic And Thermosetting Plastics 10. What is composite.write an example for composite materials 11. Name any four engineering polymers. 12. Differentiate commodity plastics with engineering plastics. 13. Name any four commodity plastics and engineering plastics. 14. What are the sources of raw materials for plastics? 15. Write short notes on nylons. 16. Define engineering ceramics. Write any four engineering ceramics materials 17. Write the general mechanical properties of ceramics. 18. What do you mean by copolymers? 19. List two examples of particulate reinforced metal matrix composites. 20. What are the uses Alumina Q.No. PART-B: BT 1. What is polymerization? Describe addition polymerization and condensation polymerization. 2. Explain about the flowing thermoplastics; [1] polyethylene[2] Polyvinyl chloride [3] Acetyl [4] polyamides 3. List the properties and assess the typical applications of the following thermoplastics [1] PTFE [2] PMMA[3] PET [4] PEEK [5] PE 4. Explain in the following : PET,PC, PA, ABS 5. What are the special properties of plastics that make them suitable for engineering applications? Describe the concept of Co-polymerization 6. Explain the properties and applications of the following poymers and discuss anyone fabrication methods of polymers. (i) PMMA (ii) PP (iii) ABS and (iv) Glass 7. Write short notes on: (i) Ceramics (ii) Urea Formaldehyde (iii) Phenol Formaldehyde 8. Discuss the properties and applications of the following four ceramics. (1) Silica (2) Zirconia (3) SiC (4) Cubic boron nitride. 9. Name suitable alloys, polymers and ceramics for manufacturing the following items. 1.Bush 2.furnace heating element 3.lathe bed 4.coins 5.girders for airship 6.Big end bearing 7.Turbine blade 8. knobs

8 9. Conduit pipes 10.Windshield 10. Describe the properties and applications of following structural ceramics a. Alumina and Partially stabilized zirconia(psz) b. Silicon carbide and Silicon nitride c. Sialon 11. (i)describe the difference between thermoplastics and thermosetting plastics (ii) Explain the difference between commodity plastics and engineering plastics. 12. (i)classify the composite materials and list two properties and application of them. ii) What are the FRP and its application 13. With the schematic diagram illustrate the processing of reinforced composites. 14. Write short notes on particle reinforced composites and fibre reinforced composites. Q.No. PART C BT 1. What are the engineering ceramics and formulate the characteristic and classification of engineering ceramics. 2. Write short notes (i) PTEE (ii) Phenol formaldehyde (iii) Engineering ceramics (iv) FRFP 3. (i)enumerate the properties of the following. (a) Thermoplastics (b) Thermosetting Plastics (c) Elastomers (ii) Describe the concept of Co-polymerization create 4. (i)how the plastics materials are classified? Explain each classification? (ii)describe the major properties of thermosetting plastics. Formulate the application of phenolic and melamine. UNIT- V / MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS Mechanisms of plastic deformation, slip and twinning Types of fracture Testing of materials under tension, compression and shear loads Hardness tests (Brinell, Vickers and Rockwell), hardness tests, Impact test lzod and charpy, fatigue and creep failure mechanisms. Q.No. PART-A BT 1. Define fracture. 2. What is brittle fracture? 3. Define ductile fracture. 4. Explain the fatigue fracture. 5. Define creep fracture. 6. What is the use of tensile test? 7. Explain the use of Izod test. 8. Write the difference between Slip and Twinning. 9. Define endurance limit in fatigue test.

9 10. Differentiate between Fatigue and Creep tests. 11. Distinguish between elasticity and plasticity. 12. What are the factors affecting mechanical properties? 13. How can you prevent the brittle fracture 14. Differentiate between ductility and malleability. 15. Define the terms brittleness and hardness. 16. What do you mean by toughness and stiffness? 17. What are the factors affecting the creep? 18. Define the term notch sensitivity. 19. Define endurance limit(sn). 20. Differentiate between Brittle fracture and ductile fracture Q.No. PART-B: BT 1. Critically compare the deformation by slip and twinning? 2. Explain the mechanism of plastic deformation of metals by slip and twinning? 3. Write an engineering brief about the creep test? 4. What are the different types of fractures in metallic materials? Formulate the important features of these fractured surfaces. What is the use of this study? 5. Draw a typical creep curve and explain the various stages of creep. 6. Describe with neat sketch fatigue test. 7. Draw the engineering stress strain curve for mild steel, aluminium and cast iron. Discuss the tensile test and different mechanical properties obtained in tensile testing. 8. With the help of neat sketches explain the difference between brittle and ductile fracture. 9. Describe Brinell hardness test to determine the hardness of a metal. 10. Explain the procedure for performing the Rockwell test. 11. Explain the testing procedure for Vickers hardness test and mention the advantages and limitations. 12. (i)describe the procedure of Charpy impact testing and the properties obtained from it. (ii) List application of impact test (iii) Compare charpy and izod impact test 13. A steel specimen is tested to evaluate several mechanical properties. The dimension of the specimen and observation during the test are given below: Diameter of the specimen =15mm Gauge length = 65mm load at yield point =44KN Maximum Load =78KN Facture load =53KN Gauge length at fracture =83mm Diameter of fracture section =10mm Strain at a load 20KN =8.764X10-4 mm/mm Determine : 1.The yield strength 2. Ultimate Strength 3. % of Elongation 4. Modulus of Elasticity

10 5.% Reduction in Area 6.Fracture Stress 7.Modulus of Toughness 14. Describe how the torsion test is conducted and what are the properties from this test? Q.No. PART C BT 1. (i).draw the S.N curve for mild steel and aluminum and explain the features. Formulate the procedure used to obtain S.N diagram? (ii) Explain briefly about charpy impact test? 2. (i)formulate the difference between properties like hardness, yield strength, ultimate strength, fracture strength, creep strength,fatigue strength, impact toughness. (ii)discuss the role of slip and twinning in plastic deformation of materials. 3. The following data were obtained in a tensile test on a specimen of 16mm diameter with a 55mm gauge length : Load (kn) Elongation(mm) The specimen diameter after fracture was 12.75mm Determine : 1.Tensile strength 2.Young's modulus 3.0.2% Proof stress 4.%Elongation 5.% Reduction in area 4. A steel specimen is tested to evaluate several mechanical properties.the dimension of the specimen and observation during the test are given below: Diameter of the specimen =20mm Gauge length = 75mm Load at yield point = 44KN Maximum Load =80KN Facture load =56KN Gauge length at fracture =82mm Diameter of fracture section =09mm Strain at a load 20KN =7.764X10-4mm/mm Determine : 1.The yield strength 2. Ultimate Strength 3. % of Elongation 4. Modulus of Elasticity 5.% Reduction in Area