UNIVERSITI MALAYSIA PERLIS. ENT 145 Materials Engineering [Kejuruteraan Bahan]
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1 UNIVERSITI MALAYSIA PERLIS Peperiksaan Semester Satu Sidang Akademik 2012/2013 Januari 2013 ENT 145 Materials Engineering [Kejuruteraan Bahan] Masa : 3 jam Please make sure that this question paper has TWELVE (12) printed pages including this front page before you start the examination. [Sila pastikan kertas soalan ini mengandungi DUA BELAS (12) muka surat yang bercetak termasuk muka hadapan sebelum anda memulakan peperiksaan ini.] This question paper has SIX (6) questions. Answer ALL questions in Section A and THREE (3) questions in section B. Each question contributes 20 marks. [Kertas soalan ini mengandungi ENAM (6) soalan. Jawab SEMUA soalan Bahagian A dan TIGA (3) soalan Bahagian B. Setiap soalan menyumbang 20 markah.] Note : Some formulas and tables are given in the Appendices [Nota: Beberapa rumus dan jadual diberikan dalam lampiran]
2 Part A Answer ALL questions [Bahagian A Jawab semua soalan] Question 1 [Soalan 1] (a) (b) Bohr atomic model has some significant limitations that explain several phenomena involving electrons. Therefore, a resolution was reached with a wavemechanical atomic model. Describe the importance of additional refinements that resulted from the wave-mechanical atomic model. [Model atom Bohr telah didapati mempunyai beberapa batasan untuk menjelaskan beberapa fenomena mengenai electron. Oleh itu, satu kebezajelasan telah dicapai dengan model atom gelombang-mekanikal.terangkan mengenai maklumat tambahan yang penting yang didapati daripada model atom gelombang ] (3 Marks / Markah) Sketch and explain the main differences between ionic, covalent and metallic bonding. [Lakar dan jelaskan perbezaan utama antara ikatan ion, ikatan kovalen dan ikatan logam] (c) Atom X has an atomic radius of nm and density of g/cm 3. [Atom X mempunyai jejari atom nm dan ketumpatan g/cm 3.] (i) Determine the crystal structure for atom X. Justify you answer. [Nilai struktur kristal bagi atom X. Justifikasikan jawapan anda.] (ii) Determine the atomic packing factor (APF) for crystal structure in (i). [Tentukan faktor pemadatan atom bagi struktur Kristal pada (i).] (5 Marks / Markah)
3 Question 2 [Soalan 2] (a) Low-alloy steel can be categorized into low-carbon steel, medium-carbon steel and high carbon steel. For each of the low-alloy steel, describe the properties and its typical applications. [Keluli beraloi rendah dibahagikan kepada keluli berkarbon renda, keluliberkarbon sederhana dan keluli berkarbon tinggi. Untuk setiap keluli beraloi rendah, terangkan sifat dan penggunaannya.] (4 Marks / Markah) (b) A portion of the iron iron carbide (Fe-FeC) phase diagram is shown in Figure 1. Consider 3.0 kg of austenite containing 1.15 wt% C, cooled to below 725 o C. [Satu bahagian bagi gambarajah fasa besi-besi karbida ditunjukkan dalam Gambarajah 1. Pertimbangkan 2.0 kg austenite yang mengandungi 1.15 wt% C, di sejukkan ke bawah 725 o C.] (i) Determine the proeutectoid phase. [Tentukan fasa proeutektoid.] (ii) Calculate the mass of total ferrite and cementite form. [Kira jisim bagi jumlah ferit dan cementit yang terbentuk.] (2 Marks / Markah) (3 Marks / Markah) (iii) Calculate the mass of the pearlite and proeutectoid phase form. [Kira jisim bagi pearlite dan fasa proeutektoid yang terbentuk.] (3 Marks / Markah) (c) A FCC iron-carbon alloy initially contains 0.2 wt% C is carburized at an elevated temperature and in an atmosphere where the surface carbon concentration is at 1.0 wt%. If after 49.5 h the concentration of carbon is 0.35 wt% at a position 3.5 mm below the surface of the alloy, analyze the temperature at which the treatment was carried out. Refer to table in Appendices. [Satu besi-karbon aloi pada awalnya mengandungi 0.2 wt% C disusukkarbonan pada suhu ternaik dan atmosfera dimana kepekatan permukaan pada 1.0wt%. Jika selepas 49.5 jam kepekatan karbon menjadi 0.35wt% pada kedudukan 3.5mm dibawah permukaan aloi itu, nilai suhu dimana rawatan dilakukan. Sila rujuk jadual pada lampiran.] (8 Marks / Markah) 4/
4 - 4 - Figure 1 [Gambarajah 1]
5 - 5 - Part B Answer any THREE (3) questions. [Bahagian B Jawab mana-mana TIGA (3) soalan] Question 3 [Soalan 3] (a) (b) (c) Discuss the differences between brittle and ductile metals with respect to its tensile stress-strain behaviour. [Bincangkan perbezaan antara logam rapuh dan logam mulur berdasarkan kepada sifat tegangan tegasan-terikan.] (4 Marks / Markah) A cylindrical specimen of hypothetical metal alloy has a diameter of 8.0 mm. A tensile force of 1000 N produces an elastic reduction in diameter of 2.8 x 10-4 mm. Compute the modulus of elasticity for this alloy, given that the Poisson s ratio is [Satu spesimen bagi logam aloi hipotesis berbentuk silinder mempunyai diameter 8.0 mm. Daya tegangan sebanyak 1000N menghasilkan pengurangan anjal bagi diameter sebanyak 2.8 x 10-4 mm. Kira modulus anjal bagi aloi ini, diberi nisbah Poisson s ialah 0.30.] Table 1 shows a list of materials and their mechanical properties. Each of the material will be tested as a cylindrical rod specimen with 100 mm long and having a diameter of 10 mm. If the tensile load is 27.5 kn, answer the following questions. [Jadual 1 menunjukkan senarai bagi bahan dan sifat mekanikalnya. Setiap bahan tersebut akan diuji sebagai satu specimen rod silinder dengan panjang 100 mm dan diameter 10 mm. jika beban tegangan ialah 27.5 kn, jawab soalan-soalan berikut.] (i) (ii) From Table 2, choose the material(s) that will not experience plastic deformation. Justify your choice(s). [Daripada Jadual 2, pilih bahan yang tidak akan mengalami ubah bentuk plastik. Justifikasi pinlihan anda.] By referring answer in (i), select the material(s) that will not experience a diameter reduction of more than 7.5 x 10-3 mm. [Dengan merujuk kepada jawapan di (i), pilih bahan yang tidak akan mengalami pengurangan diameter tidak lebih daripada 7.5 x 10-3 mm.] (4 Marks / Markah) Table 1 [Jadual 1] Material Modulus of Yield Strength Poisson s Elasticity (GPa) (MPa) Ratio Aluminum alloy Brass alloy Steel alloy Titanium alloy
6 Question 4 [Soalan 4] (a) (b) Discuss pearlite, spheroidite and martensite with respect to microstructures and mechanical properties. [Bincang pearlit, spherodit dan martensit berdarkan kepada mikrostruktur dan sifat mekanikal.] The complete isothermal transformation diagram of 0.76 wt% C steel alloy is shown in Figure 2. [Gambarajah lengkap penjelmaan suhu untuk bagi keluli aloi 0.76 wt % C ditunjukkan dalam Gambarajah 2.] (i) Develop the heat treatment process for producing a microstructure of 100 % martensite structure. [Bangunkan proses rawatan haba untuk menghasilkan mikrostruktur bagi 100% struktur martensit.] (5 Marks / Markah) (ii) Develop the heat treatment process for producing a microstructure of 50% bainite and 50% martensite structure. [Bangunkan proses rawatan haba untuk menghasilkan mikrostruktur bagi 50% struktur bainit dan 50% struktur martensit.] (5 Marks / Markah) (iii) Alloy in question (i) is tested for bending fatigue test. It has experienced a fracture which occurs in brittle manner. Propose a suitable solution to improve mechanical properties of the alloy. Justify your answer. [Aloi pada (i) diuji bagi ujian lenturan lesu. Daripada ujian tersebut, aloi mengalami patah di mana patah berlaku dalam betuk rapuh. Cadangkan satu penyelesaian yang bersesuaian untuk memperbaiki sifat mekanikal aloi tersebut. Justifikasikan jawapan anda.] (4 Marks / Markah) 7/
7 - 7 - Figure 1 [Gambarajah 1] Figure 2 [Gambarajah 2]
8 Question 5 [Soalan 5] (a) Pitting, intergranular corrosion and stress corrosion are example of metallic corrosion. [Bopeng, kakisan antara butir, kakisan tegasan adalah contoh bagi kakisan logam.] (i) Describe conditions under which these corrosions occur. [Jelaskan dibawah keadaan apa berlakunya kakisan.] (3 Marks / Markah) (ii) Discuss the measures that may be taken to prevent and control these corrosions. [Bincangkan pengukuran yang akan diambil untuk mencegah dan mengawasinya kakisan tersebut] (b) An aircraft component is fabricated from an aluminium alloy that has plane strain fracture toughness of 35 MPa m. Fracture occurred at a stress of 250 MPa when the maximum internal crack length is 2.0mm. [Satu komponen kapal terbang telah difabrikasi daripada aloi aluminum yang mempunyai keliatan patah terikan satah 35MPa m. Patah terjadi pada tegasan 250 MPa bila panjang retak dalaman maksimum ialah 2.0mm.] (i) Determine the value of dimensionless correction factor, Y. [Tentukan nilai bagi faktor pembetulan tak berdimensi, Y.] (5 Marks / Markah) (ii) If a stress level is increased to 325 MPa and the maximum internal crack length is reduced to 1.1 mm, predict whether any fracture will occur. Compare your answer with existing data. Justify your answer. [Jika aras tegasan ditingkatkan kepada 325MPa dan panjang retak dalaman maksimum dikurangkan kepada 1.1mm, anggarkan sama ada patah akan terjadi. Bandingkan jawapan anda dengan data yang tersedia.justifikasi jawapan anda.]
9 Question 6 [Soalan 6] (a) A specimen 760 mm long of an S-590 alloy is to be exposed to a tensile stress of 80 MPa at 815 o C. Figure 3 shows stress versus steady-state creep rate for S-590 alloy at four temperatures. Determine its elongation after 5,000 hour. Assume that the total of both instantaneous and primary creep elongations is 1.5 mm. [Satu spesimen panjang 760 mm bagi aloi S-590 akan didedahkan kepada tegasan tegangan sebanyak 80MPa pada suhu 815 o C. Gambarajah 3 menunjukkan tegasan berlawanan keadaan-mantap kadar rayapan aloi S-590 pada empat suhu. Tentukan pemanjangannya selepas 5,000 jam. Anggap bahawa jumlah bagi pemanjangan rayapan ketika dan pemanjangan rayapan utama ialah 1.5 mm. ] (7 Marks / Markah) Figure 3 [Gambarajah 3] 10/
10 (b) Figure 4 shows stress amplitude versus logarithm cycles to failure for a cast iron. [Gambarajah 4 menunjukkan amplitud tegasan berlawanan logaritma kitar untuk patah bagi besi tuang.] (i) Determine the fatigue limit for this alloy. [Tentukan had lesu bagi aloi tersebut.] (3 Marks / Markah) (ii) Estimate the fatigue lifetimes at stress amplitudes of 250 MPa and 175 MPa. [Anggarkan masa hayat lesu pada amplitud tegasan untuk 250 MPa dan175 MPa.] (4 Marks / Markah) (iii) Data from Figure 4 is to be used for bending rotating test. This material will be used as an automobile axle rotates at average rotational velocity of 750 rpm. Predict the maximum lifetimes of continuous driving that are allowed for stress levels of 250 MPa and 150 MPa. [Data dari Gambarajah 4 akan digunakan untuk ujian lenturan berputar. Bahan ini akan digunakan sebagai satu gandar kenderaan yang berputar pada purata halaju putaran sebanyak 750 rpm. Anggarkan masa hayat maksimum panduan berterusan yang dibenarkan untuk aras tegasan 250 MPa dan 150 MPa. ] Figure 4 [Gambarajah 4] -oooooo-
11 Appendices [Lampiran] Table A1 Tabulation of Error Function Value Table A2 Tabulation of Diffusion Data
12 Appendices [Lampiran] ρ = na V C N A K Ic = Yσ πa APF = V S V c a = 2R 2 a = 4R 3 ln D = ln D 0 Q d R (1 T ) J = D dc dx C x C 0 = 1 erf ( x C s C 0 2 Dt ) v = x z
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