UNIVERSITI MALAYSIA PERLIS. ENT 145 Material Engineering [Kejuruteraan Bahan]
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1 - 1 - UNIVERSITI MALAYSIA PERLIS Peperiksaan Akhir Semester Pertama Sidang Akademik 2015/2016 Januari 2016 ENT 145 Material Engineering [Kejuruteraan Bahan] Masa: 3 jam Please make sure that this question paper has NINE (9) printed pages including this front page before you start the examination. [Sila pastikan kertas soalan ini mengandungi SEMBILAN (9) muka surat yang bercetak termasuk muka hadapan sebelum anda memulakan peperiksaan ini.] This question paper has SIX (6) questions. Answer ALL questions in PART A, and ONE (1) question in PART B. Each question contributes 20 marks. [Kertas soalan ini mengandungi ENAM (6) soalan. Jawab SEMUA soalan dalam BAHAGIAN A, dan SATU (1) soalan dalam BAHAGIAN B. Markah bagi tiap-tiap soalan adalah 20 markah.]
2 - 2 - PART A Answer ALL questions [BAHAGIAN A Jawab SEMUA soalan] Question 1 [Soalan 1] Identify four components and its specific class of materials used in a computer. [Tentukan empat komponen dan kelas terperinci bagi bahan-bahan digunakan dalam sebuah komputer.] (2 Marks / Markah) Compare the three primary bonds in detail. Draw a schematic for each. Explain the driving force in the formation of such bonds. [Bandingkan tiga ikatan utama secara terperinci. Lukis skematik bagi tiap-tiap satu. Jelaskan daya pacuan bagi pembentukan ikatan-ikatan tersebut.] (8 Marks / Markah) Gold has a body centered cubic (BCC) crystal structure with lattice constant of nm and density of g/cm 3. Given its atomic weight is g/mol. [Emas mempunyai struktur kristal kiub berpusat badan dengan pemalar kekisi nm dan ketumpatan g/cm 3. Diberikan berat atomnya ialah g/mol.] (i) Determine the atomic radius of gold. [Tentukan jejari atom emas.] (ii) Determine the atomic packing factor (APF) for gold. [Tentukan faktor pemadatan atom (APF) bagi emas.]
3 - 3 - Question 2 [Soalan 2] Briefly explain conditions of atomic motion in diffusion. [Terangkan secara ringkas syarat-syarat pergerakan atom dalam resapan.] (2 Marks / Markah) Discuss the concept of steady and non-steady state as it applies to diffusion. Give an example in your answer. [Bincangkan konsep keadaan stabil dan tidak stabil apabila ianya digunapakai dalam resapan. Berikan satu contoh pada jawapan anda.] Differentiate between plain carbon steel, alloy steel and stainless steel. [Bezakan di antara keluli berkarbon biasa, keluli beraloi dan keluli tahan karat.] 4/
4 - 4 - (d) A portion of the iron iron carbide (Fe-FeC) phase diagram is shown in Figure 1. Consider 1.0 kg of austenite containing 1.15 wt % C, cooled to below 725 C. [Satu bahagian bagi rajah fasa besi-besi karbida ditunjukkan dalam Gambarajah 1. Pertimbangkan 1.0 kg austenit yang mengandungi 1.15 wt % C, disejukkan 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) Figure 1 [Gambarajah 1]
5 - 5 - Question 3 [Soalan 3] 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 kelakuan tegangan tegasan-terikan.] 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 garis pusat 8.0 mm. Daya tegangan sebanyak 1000 N menghasilkan pengurangan anjal bagi garis pusat 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 garis pusat 10 mm. Jika beban tegangan ialah 27.5 kn, jawab soalan-soalan berikut.] (i) From Table 1, choose the material(s) that will not experience plastic deformation. Justify your choice(s). [Daripada Jadual 1, pilih bahan yang tidak akan mengalami ubah bentuk plastik. Justifikasi pilihan anda.] (ii) By referring to answer in (i), select the material(s) that will not experience a diameter reduction of more than 7.5 x 10-3 mm. Justify your choice(s). [Dengan merujuk kepada jawapan di (i), pilih bahan yang tidak akan mengalami pengurangan garis pusat tidak lebih daripada 7.5 x 10-3 mm.] Table 1 [Jadual 1] Material Modulus of Yield Strength Elasticity (GPa) (MPa) Poisson s Ratio Stainless steel alloy 302 (annealed) Ductile cast iron Aluminum alloy 7075-T6 (tempered) Titanium alloy (as-rolled)
6 - 6 - Question 4 [Soalan 4] For a plain carbon steel has carbon content of 1 wt % at 900 C. On average, how many carbon atoms can you find in 100 unit cells? If at room temperature, the carbon content of ferrite drops to wt %, on average, how many unit cells would you have to search to find one carbon atom? Compare the differences in these two cases. [Bagi keluli karbon biasa dengan 1 % berat kandungan karbon pada 900 C. Pada purata, berapa banyak atom karbon boleh anda dapati dalam 100 unit sel? Jika pada suhu bilik, kandungan karbon ferit jatuh kepada % berat, secara purata, berapa banyak sel unit anda perlukan untuk mencari satu atom karbon? Terangkan secara ringkas perbezaan di dalam kedua-dua kes.] Cast irons are very important engineering materials. Briefly explain cast irons and their basic range of composition. Give their applications and three basic types of cast irons. [Besi tuang adalah bahan kejuruteraan yang sangat penting. Terangkan secara ringkas besi tuang dan julat asas komposisi. Beri kegunaan-kegunaan mereka dan tiga jenis asas besi tuang.] Plain carbon and alloy steels are extensively used in manufacturing of bolts and screws. Give four reasons for this. [Keluli karbon biasa dan keluli aloi digunakan dengan meluas dalam pembuatan bolt dan skru. Berikan empat sebab untuk ini.] (8 Marks / Markah)
7 - 7 - PART B Answer ONE (1) question only [BAHAGIAN B Jawab SATU (1) soalan sahaja] Question 5 [Soalan 5] Describe ductile, brittle and fatigue failures. Explain in terms of their failure surfaces. [Terangkan kegagalan mulur, rapuh dan kelesuan. Terangkan dari segi permukaan kegagalannya] A fatigue test is made with a median stress of 120 MPa and a stress amplitude of 165 MPa. Calculate the maximum and minimum stresses, the stress ratio and the stress range. [Ujian kelesuan dibuat dengan tegasan median 120 MPa dan amplitud tegasan 165 MPa. Kirakan tegasan maksima dan minima, nisbah tegasan dan julat tegasan.] A structural plate of an engineering design must support 207 MPa in tension. If aluminum alloy 2024-T851 is used for this application; [Satu plat struktur bagi rekabentuk kejuruteraan harus menampung 207 MPa dalam tegangan. Jika aloi aluminum 2024-T851 digunakan untuk aplikasi ini;] (i) Determine the largest internal flaw size that this material can support. Use plain strain fracture toughness, K IC = 26.4 MPa m and the value of dimensionless correction factor, Y = 1. [Tentukan nilai bagi saiz rekah dalaman terbesar yang boleh ditampung oleh bahan ini. Guna keliatan patah terikan satah, K IC = 26.4 MPa m dan faktor pembetulan tak berdimensi, Y = 1.] (ii) If a stress level is increased to 500 MPa and the maximum internal crack length is reduced to 1.0 mm, predict whether any fracture will occur. Compare your answer with existing data. Justify your answer. [Jika aras tegasan ditingkatkan kepada 500 MPa dan panjang retak dalaman maksimum dikurangkan kepada 1.0 mm, anggarkan sama ada patah akan terjadi. Bandingkan jawapan anda dengan data yang tersedia. Justifikasi jawapan anda.]
8 - 8 - Question 6 [Soalan 6] Pit, intergranular and stress corrosions are example of metallic form corrosion. [Kakisan bopeng, kakisan antara butir, kakisan tegasan adalah contoh bagi kakisan bentuk logam.] (i) Describe under which conditions these corrosions occur. [Jelaskan di bawah keadaan apa berlakunya kakisan ini.] (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.] (3 Marks / Markah) Figure 2 shows the circumferential stress σ, (also called hoop stress) in a pressurized cylindrical vessel and is calculated by the equation of σ = Pr/t, where P is the internal pressure, r is the radius of the vessel and t is thickness. The vessel has mm diameter, 6.35 mm thickness and an internal pressure of 34.5 MPa. Assume the crack occurred at the center of the vessel and Y = For the fracture toughness, K IC and yield strength, σ Y values of each vessel material, refer to Table A1 in Appendix. [Gambarajah 2 menunjukkan tegasan lilitan σ (juga dipanggil tegasan gegelang) di dalam sebuah tangki silinder bertekanan dikirakan dengan menggunakan persamaan σ = Pr/t, di mana P adalah tekanan dalaman, r adalah jejari tangki, dan t adalah ketebalan. Tangki tersebut mempunyai garis tengah cm, ketebalan 6.35 mm dan tekanan dalaman 34.5 MPa. Anggap geometri retakan berlaku di bahagian tengah tangki tersebut dan Y =1.12. Bagi nilai-nilai kekerasan patah, K IC dan kekuatan alah, σ Y bagi setiap bahan-bahan tangki tersebut, rujuk Jadual A1 di Lampiran.] (i) Compute the critical crack length (2a) if the vessel is made of Al 7075-T651. [Kira panjang retakan kritikal (2a) sekiranya tangki tersebut diperbuat oleh Al 7075-T651.] (8 Marks / Markah) (ii) If the material of 350 maraging steel alloy is to be used, compare the difference of the critical crack length (2a) with your answer in (i). Justify your answer. [Sekiranya bahan keluli maraging 350 digunakan, bandingkan perbezaan retakan kritikal (2a) dengan jawapan anda di (i). Justifikasi jawapan anda.] crack σ σ 2a P r t Figure 2 [Gambarajah 2]
9 - 9 - Appendices [Lampiran] Table A1 Typical Fracture Toughness Values for Selected Engineering Alloys m = ρv ρ = na V C N A J = D dc dx C t = D 2 C x 2 C x C 0 = 1 erf ( x C s C 0 2 Dt ) ln D = ln D 0 Q d R (1 T ) σ = F A o ε = l i l o l o σ = Eε v = x z = l l o σ = (Pr t) K IC = Yσ πa APF = V S V c
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