REG.NO.

NETTUR TECHNICAL TRAINING FOUNDATION

(DTC, TTC, BTC, VTC, GTC, RNTC, ONTC, GNTC, MNTC, HNTC)
DIPLOMA IN TOOL AND DIE MAKING
II SEMESTER COMMON EXAMINATION- JUNE 2012
SUBJECT: MATERIAL TECHNOLOGY
SUBJECT CODE: CP 01 02 08

TOTAL MARKS: 70
TOTAL TIME: 2H 15MIN
MARKS: 15
TIME: 15MIN
5X1=5

PART-A
1.0

FILL IN THE BLANKS

1.1

Porosity is an example for ___________ property.

1.2

The raw material for all iron and steel products are __________.

1.3

____________ is fundamentally an alloy of iron and carbon.

1.4

The main alloying element present in magnet is _________.

1.5

The polymer, which is obtained by adding different types of monomers is called _______.

2.0

CHOOSE THE CORRECT ANSWER

2.1

The electrons occupying the outermost orbit or shell of an atom is called _______. (

5X1=5
)

a. conduction electron b. valence electron c. semi conductors d. energy electrons

2.2

_________ is an example for synthetic polymers

a. cotton

2.3

b. wool

c. lignin d. nylon

_____________ is a destructive test.

a. hardness test b. radiography testing c. visual inspection d. liquid penetrant test

2.4

Brass is an alloy of

a. copper and tin b. zinc and tin c. copper and zinc d. zinc and lead
2.5

Punches for the press tool are made up of

a. high speed steel b. stainless steel c. HCHCr steel d. heat resisting steel

3.0

MATCH THE FOLLOWING

5X1=5

3.1

cast iron

a.

medium carbon steel

3.2

machinery steel

b.

fibers

3.3

stiffness

c.

shock loading steel

3.4

non metal

d.

resistance of a material to deflection

3.5

organic polymers

e.

cupola furnace

f.

ceramics

A
B

3.1

3.2

3.3

3.4

3.5

NETTUR TECHNICAL TRAINING FOUNDATION

(DTC, TTC, BTC, VTC, GTC, RNTC, ONTC, GNTC, MNTC, HNTC)
DIPLOMA IN TOOL AND DIE MAKING
II SEMESTER COMMON EXAMINATION- JUNE 2012
SUBJECT:MATERIAL TECHNOLOGY
SUBJECT CODE: CP 01 02 08
PART B
1.0 ANSWER ANY TEN OF THE FOLLOWING
1.1

Mention any four advantages of using alloy steel.

1.2

Name any four physical properties of materials.

1.3

What do you mean by smelting?

1.4

State the properties of semiconducting materials.

1.5

What do you mean by white ware?

1.6

What do you mean by a catalyst? Give examples.

1.7

What is monel? Mention any two properties of monel metal.

1.8

What do you mean by heat capacity?

1.9

Explain the brinell hardness testing.

1.10

Name any four properties of ceramic materials.

1.11

Explain about the effect of nickel in steel.

1.12

What is the purpose of using non ferrous metals and alloys?

2.0

ANSWER ANY SIX OF THE FOLLOWING

2.1

Distinguish between hardness and hardenability?

2.2

Differentiate between elasticity and plasticity?

2.3

What do you mean by alloy steel? Name any 4 alloy steels.

2.4

What do you mean by powder metallurgy?

2.5

What do you mean by super conductivity?

2.6

Mention the name of the steel used for following elements.

TOTAL MARKS: 70
TOTAL TIME: 2H 15 MIN
MARKS: 55
TIME: 2H
2X10=20

3X6=18

a. punch and die b. shank c. hacksaw blades d. spanners e. files f. bottom plate.
2.7

Which are the zones of a cupola furnace? Explain.

2.8

Explain the classification of polymer structure?

3.0 ANSWER ANY THREE OF THE FOLLOWING

3.1

Explain the manufacture of pig iron with a neat sketch.

3.2

What are the advantages and disadvantages of casting?

3.3

Explain about any two types of copper alloys.

3.4

Explain how steels can be classified?

4.0
4.1

ANSWER THE FOLLOWING

Explain the radiography testing of materials with neat sketches.

4X3=12

5X1=5

Answer Key
Part A
1.0

FILL IN THE BL ANKS

1.1
1.2
1.3
1.4
1.5

2.0

CHOOSE THE CORRECT ANSWER

2.1
2.2
2.3
2.4
2.5

3.0

Physi cal Propert y

Pig Iron
Steel
Cobalt
Co-pol ymer

b
d
a
c
c

M ATCH THE FOLLO WING

3.1
3.2
3.3
3.4
3.5

e
a
d
f
b

Part B
1.0

ANSWER ANY 10
1.1

Greater hardenabilit y, better w ear resistanc e and corrosi on

resistance, oxidation resistance, great er ductilit y at higher
strength, less distortion and cracking etc
1.2
Dimension, appearance, densit y, specific gravit y, melting
point, porosit y etc
1.3
Reduction of iron ore in to pig iron
1.4
Semiconduct ors are materials that essentiall y can be
conditioned to act as good conductors, or good insulators, or
anything in betw een.
Common elements such as carbon, sili con, and germanium are
semiconductors.
Silicon is the best and most w idel y used semiconductor.
1.5
White w are - any of a broad class of ceramic products that
are w hite to off -w hite in appearance and frequentl y cont ain a
significant vitreous, or glassy, component. Including products
as di verse as fine china dinnerw are, lavatory sinks and toilets,
dental implants, and spark- plug insulators.
1.6
Catal yst are added to expedite (fasten) and complet e the
pol ymerization reaction. Eg. Boron tri fluride, peroxide, Zi egler
catal yst .
1.7
The major nickel base alloy w ith copper is monel. Nickel i s
present up to 67%. Properties - bright appearance, stronger than
mild steel, excellent corrosion resistance etc.

1.8

Heat capacit y, is the measurable physi cal quantit y that

characterizes the amount of heat requi red to change a
substance's temperature by a gi ven amount. In the International
System of Units (SI ), heat capacit y is expr essed in units of
joul e(s) (J) per kel vin (K)
1.9
Brinell hardness testing -Uses ball shaped indentor
Cannot be used for thin materials.
Surface area of indentation is measured.
1.10
Extreme hardness , high w ear resistance, can reduce w ear
caused by friction, coorrosion resistance , Heat resistance , Low
electrical conducti vit y, Low thermal conducti vit y , Low thermal
expansion, Poor thermal shock resistance .
1.11
Nickel is added to i ncrease tensile strength w ithout
reducing ductilit y; in high concentrations, to improve corrosion
resistance.
1.12
Non ferrous metal do not corrode (al uminum for example) ).
Non ferrous metals are usuall y light w eigh t. They have special
electric and magnet ic properties, soft nature, east to cast and
form.
2.1
Hardness The abi lit y of a material to resist scrat ching,
w ear and tear & indentation. Hardenabilit y - This is dependent
upon the chemical composition of the steel alloy. The addition of
Nickel, Chromium and Mol ybdenum w ill slow the transformation to
other phases and allow more martensit e to form.
Most heat treatable steels are allo ys rather than plai n car bon
steels.
2.2
Elasticit y - The abilit y of a material to absorb force and
flex in different directions, returning t o its original positi on.
Plasticit y- The abilit y of a materi al to be change in shape
permanentl y.
2.3
Al lo y steel is steel that is alloyed w ith a variet y of
elements in total amounts betw een 1.0% and 50% b y w eight to
improve its mechanical properties. Alloy steels are broken dow n
into tw o groups: low -alloy steels and high -alloy st eels. Eg: nickel
alloy steel, chromium steel, vanadium steel etc.
2.4
Pow der metallurgy is the process of bl ending fine
pow dered materials, pressing them into a desired shape or form
(compacting), and t hen heating the compressed material in a
controlled atmosphere to bond the mat erial (sintering). The
pow der metallurgy process generall y consist s of four basi c steps:
(1) pow der manufacture, (2) pow der blending,(3) compacti ng, (4)
sintering. Compacti ng is generall y perf ormed at room temperature,
and the el evated -temperature process of sintering is usuall y
conducted at atmospheric pressure. Optiona l secondary
processing often follow s to obtain special properties or enhanced
precision.
2.5
Superconducti vit y i s a phenomenon of exactl y zero
electrical resist ance and expulsion of magnetic fields occurring in
certain materials w hen cooled below a charact eristic critical
temperature .
2.6
a. D2
Carbon Steel

b. MS
c. High Carbon Steel
e. High Carbon Steel
f. MS

d.Medium

2.6
2.8

Preheat zone, reduction zone, oxidation zone, metal/slag zone

According to the shape of the macromolecules, pol ymer structure may
be broadl y classified as Linear and frame w ork structure , Branchedchain structure, Cross linked chai n structure, Cr ystalline structure.
Linear and frame w ork structure: Linear pol ymer structure consi sts of
long chains in w hich indi vidual long chain molecules are quite
separate from one anotherPol ymers may be s ynthesized i n w hich side
branch chai ns are connected to the main ones. The number branches
and the ratio of the length of main chain to that of the side chain ma y
vary.
The importance lies to branchi ng is ext ensi ve; the pol ymer w ill
become stronger and less plastic due to the simple interl ocking
actions of the branched chains w ith each other. The cont rolling of
branching w ith in pol ymers is of great industrial importance.
In cross-linked pol ymers, adjacent linear chai ns are joined one to
another at various positions by covalent bonds. The process of cross linking is either during synthesis or b y a nonreversible chemical
reaction that is usuall y carried out at an elevated temperature.In
rubber cross-linking is called vul canization.

3.1

A bl ast furnace is a t ype of metallurgical furnace used for smelting to

produce industrial metals, generall y pi g iron.In a blast furnace, fuel,
ore, and flux (limestone) are continuousl y supplied through the top of
the furnace, w hile air (sometimes w ith oxygen enri chment) is blow n
into the bottom of t he chamber, so that the chemical react ions take
place throughout the furnace as the material moves dow nward. The
end product s are usuall y molten metal and slag phases tapped from
the bottom, and flue gases exiting from the top of the furnace. The
dow nw ard flow of the ore and flux in contact w ith an upflow of hot,
carbon monoxide-ri ch combustion gases is a countercurrent exchange
process.
Blast furnaces are t o be contrasted w ith air furnaces (such as
reverberatory furnaces ), w hich w ere naturall y a spirat ed, usuall y by the
convection of hot gases in a chimney f lue. According to t his broad
definition, bloomeri es for iron, blow ing houses for tin, and smelt mills
for lead w ould be classified as blast furnaces. How ever, the term has
usuall y been limited to those used for smelting iron ore to produce pig
iron, an intermediat e material used in the production of commercial
iron and st eel.

3.2

Advantages of Cast ing :1. On Basis of Size of Object to be

Manufactured:Size of cast objects var y over large range. An object
from 5gm to 200tonn, anything can be cast.2. On Basis of
Complexit y: Casting can be effecti vel y used for complex shaped
objects. It can w ork w here general machining processes can not be
used, as in complicat ed inner and outer shapes of object.3. Weight
Saving:Component made w ith casting process is lighter t han the
component made w ith other machi ning processes .4. Control Over The
Process:Casting provides versatilit y. Wide range of properties can be
attained b y adjusting percentage of al loyi ng elements.5.
Accuracy: Casting can be made w ith hair like precision provided proper
molding and casting technique is empl oyed.6. Fibrous Structure:Onl y
casting have this advantage. Casting l eaves component w ith its solid
fibrous structure w hich inherit great compressi ve strengt h. So,
component subject ed to compressi ve strength are made w ith casting
ex. IC engi ne cylinder .

7. Control O ver Grain Size:Grain size of cast component can be easil y

controlled by controlling coolin g rate w hich in turn can be used to
modif y the properti es.
Disadvantages of Casting:
Though casting is cheapest for MASS Production, it becomes non
economical in case of JOB production. Sand casting leaves rough
surface w hich needs machining in most of cases. It adds up the cost in
production. Again i n sand casting, poor dimensional accuracy is
achieved.Cast products are superi or for compressi ve loads but they
are very poor in tensile or shock loads. (They are brittle).
3.3

Copper alloys are metal alloys that have copper as their principal
component. They have high resistance against corrosion. The best
know n traditional types are bronze, w here tin is a signifi cant addition,
and brass, using zi nc instead.Brass is a n alloy of copper and zinc; the
proportions of zinc and copper can be varied to create a range of
brasses w ith varying properties. In comparison, bronze i s principall y
an alloy of copper and tin. Bronze d oes not necessaril y contain tin,
and a variet y of all oys of copper, incl uding allo ys w ith arsenic,
phosphorus, alumi nium, manganese, and silicon, are commonl y termed
"bronze". The term is applied to a vari et y of brasses and the
distinction is largely hi storical. Brass i s a substitutional alloy. It is
used for decoration for its br ight gold- like appearance; for
applications w here low friction is required such as locks, gears,
bearings, doorknobs, ammunition, and val ves; for pl umbing and
electrical applicati ons; and extensi vel y in musical instruments such as
horns and bells for its acoustic properties. It is also used i n zippers.
Because it is softer than most other metals in general use, brass is
often used in situat ions w here it is important that sparks not be
struck, as in fittings and tool s around explosi ve gases.
Bronze is a metal al loy consisting primaril y of copper, usuall y w ith tin
as the main additi ve. It is hard and bri ttle, and it w as particularl y
significant in antiquit y, so much so that the Bronze Age w as named
after the metal. How ever, since "bronze" is a somew hat imprecise
term, and historical pieces have variable compositions, in particular
w ith an unclear boundary w ith brass, modern museum and scholarl y
descriptions of older objects increasingl y use the more cautious and
inclusi ve term " copper alloy" instead.

3.4

According to carbon content -low carbon steel, medium carbon and

high carbon st eel. According to purpose and use tool steels,structural
steels, boiler steels, electric steels. Ac cording to met hod of
manufact ure open hearth steel, Bessemer steel, LD steel. According to
amount of deoxidization rimmed, killed and semi killed stee l.
According to amount of alloy cont ent low alloy and high alloy st eel.

4.1

Radiographic Testing is a nondestruct ive testing (NDT) method of

inspecting material s for hidden flaw s by using the abilit y of short
w avelengt h electromagnetic radiation (high energy photons) to
penetrat e various materials.Either an X -ray machine or a radioacti ve
source (Ir-192, Co- 60, or in rare cases Cs-137) can be used as a source
of photons. Neutron radiographic testing (NR) is a variant of
radiographic testing w hich uses neutrons instead of phot ons to
penetrat e materials. This can see ver y different things from X -rays,
because neutrons can pass w ith ease through lead and st eel but are
stopped by pl astics, w ater and oils.