ME6403 Engineering Materials and Metallurgy Mechanical Engineering 2017-18

ME6403 ENGINEERING MATERIALS AND METALLURGY

UNIT – I - ALLOYS AND PHASE DIAGRAMS
PART A
1. What is an alloy?
A metal alloy, or simply an alloy, is a mixture of two or more metals or a metal (metals) and
a non- metal (non-metals).
2. Define solid solution. [Nov/Dec 2011]
A solid solution is formed when two metals are completely soluble in liquid state and also
completely soluble in solid state. In other words, when homogeneous mixtures of two or more
kinds of atoms (of metals) occur in the solid state, they are known as solid solutions.
3. Differentiate between substitutional and interstitial solid solution.[May/Jun 2009]
[April/May 2015] [Nov/Dec 2014] [Nov/Dec 2007]
In substitutional solid solution, the solute atoms (impurities) substitute for parent solvent
atoms in a crystal lattice. E.g.,Cu-Ni system,Cu-Zn system and Au-Cu system
In interstitial solid solution, the solute atoms fit into the space between the solvent or
parent atoms.
4. State Hume Rothery’s rules for formation of substitutional solid solutions. (Or) State
the conditions under which two metallic elements will exhibit solid solubility
[April/May 2015][May/Jun 2014] [May/Jun 2009]
1. Size factor: The atoms must be of similar size, with less than a 15% difference in
atomic radius (in order to minimize the lattice strain).
2. Crystal structure: The materials must have the same crystal structure.
3. Valence: The atoms must have the same valence.
4. Electro negativity: The atoms must have approximately the same electro negativity.
5. What are intermediate phases?
If an alloying element is added in excess of the limit of solid solubility, a second phase
appears along with the primary solution. If the second phase differs in both crystal
structure and properties from primary solid solution, then it is known as an
‘intermediate’ phase..
6. Define ‘phase’. What different kinds of phases are possible?
A phase is defined as any physically distinct, homogeneous and mechanically separable
portion of a substance. Three different kinds of phases are solid, liquid and vapour..
7. What are the advantages of the equilibrium diagrams?
1.To show what phases are present at different compositions and temperature under
equilibrium conditions.
2.To indicate the equilibrium solid solubility of one element in other element.
3.To indicate the temperature range over which solidification of a material occurs.
4.To indicate the temperature at which different phases start to melt.
8. State Gibb’s phase rule. [May/Jun 2014]
Gibb’s phase rule is given by F=C-P+2 where,
F=degrees of freedom of system or number of variables (such as temperature, pressure or
composition) that may be changed independently without altering the equilibrium;
C=number of components (usually elements or compounds) forming the system; and
P=no of phases present in the system.
The constant 2 in the equation implies that both temperatures and pressure are allowed to
change.
9. What is a liquidus line, a solidus line and a solvus line?
In a phase diagram, liquidus line is the line or boundary that separates liquid and
liquid+solid phase regions.
A Solidus line is a line or boundary that separates solid and solid+liquid phase regions.
A Solvus line separates single-phase solid regions from two-phase solid regions.
10. What is the information that can be obtained from each point in a phase diagram?
Using a phase diagram, one can obtain at least the following three informations.1. The
phases that are present, 2. The composition of each phase, and 3. The amount of each phase
present.
11. What is tie-line?
A tie line is simply an isothermal line drawn through point of consideration, extending
across the two-phase region and terminating at the phase boundary lines on either side.
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12. Explain the lever-law calculation and what information does it provide?
Phase fraction = (Opposite arm of lever / Total Length of Tie line)
Phase percentage = ( Opposite arm of lever /Total length of Tie line) X 100
Using the lever law calculations, one can compute the phase fraction and the phase
percentage.
13. What is meant by invariant reaction? [Nov/Dec 2013]
The eutectic reaction is also called an invariant reaction since it occurs under equilibrium
conditions at a specific temperature and alloy composition that cannot be varied.
14. Define the Eutectoid reaction. Give examples. [Nov/Dec 2014] [May/Jun 2012]
In the eutectoid reaction a solid phase decompose into two other solid phases
upon isothermal cooling. Austenite a solid solution of carbon and gamma iron, decomposes
in to pearlite a mixture of two solids alpha iron and iron carbide

In the Fe-Fe3C equilibrium diagram the eutectoid reaction takes place at the temperature of
727°C, at the cmposition of 0.8% of C, Austenite is converted into Pearlite mixture during
cooling.
15. What is eutectic reaction? [Nov/Dec 2013] [Nov/Dec 2011]
Upon cooling a liquid phase is transformed into the two solid phases at eutectic temperature.
The opposite reaction occurs upon heating. This is called eutectic reaction. In general the
eutectic mixture with in a simple binary alloy system is the lowest melting point mixture
within that alloy system.

16. Distinguish between peritectic and peritectoid reactions. [Nov/Dec 2014]

The peritectic reaction can be written as
Solid 1 +Liquid = Solid 2

The peritectoid reaction can be written as

Solid 1 + Solid 2 = Solid 3

17. Define: ferrite and austenite. [May/Jun 2013]

Ferrite is a primary solid solution based on iron having BCC structure. Maximum solubility
of carbon in iron is 0.025% carbon at 723°C, while its solubility at room temperature is only
about 0.008%.
Austenite is a primary solid solution based oniron having FCC structure. The maximum
solubility of carbon in FCC iron is about 2% at 1140°C.
18. Define: Cementite and Pearlite.
Cementite is the name given to the carbide of iron (Fe3C). It is the hard,brittle, intermetallic
compound of iron with 6.69% of carbon.
Pearlite is the eutectoid mixture of ferrite (87.5%) and cementite (12.5%). It is formed when
austenite decomposes during cooling. It contains 0.8% of carbon.
19. Define: martensite, and bainite.
Martensite is the super saturated solid solution of carbon in iron. It is formed when a steel
is very rapidly cooled from the austenitic state.
Bainite is a decomposition product of austenite, consisting of an aggregate of ferrite and
carbide. Bainite has hardness in between the hardness of pearlite and martensite.
20. Why is the iron-carbon equilibrium diagram usually not shown beyond 6.67% carbon?
Because in practice, all steels and cast irons have carbon contents less than 6.67 wt % C.
21. What is meant by eutectoid, hypoeutectoid, hypereutectoid steels? .[May/Jun 2007]
[Nov/Dec 2013]
Steels that contain 0.8% C (the eutectoid amount of carbon) are called eutectoid steels.
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Steels having less than 0.8% C are known as hypoeutectoid steels.

Steels having more than 0.8% C are known as hypereutectoid steels.
22. How do cast irons differ from steels in terms of carbon content?
Composition from 0.008% to 2% carbon represent steel and those above 2% carbon
represent cast iron.
23. Distinguish between hypoeutectic and hypereutectic cast irons.
Cast irons that contain less than 4.3% C are termed as hypoeutectic whereas cast irons
that contains more than 4.3% C termed as hypereutectic.
24. Define polymorphism and Allotropy.
Polymorphism is a physical phenomenon where a material may have more than
one crystal structure. A material that shows polymorphism exists in more than one type of
space lattice in the solid state. If the change in structure is reversible, then the polymorphic
change is known as allotropy. The best known example for allotropy is iron.
25. Name the various micro structures of Fe-Fe3C phase diagram.
Various micro sturctures of Iron carbon equilibrium diagram areFerrite, Austenite,
Pearlite, Cementite, Ledeburite, Martensite, Troostite, Sorbite and Bainite.

PART –B
1. What are cooling curves ? Explain the time-temperature cooling curve of an pure metal,
binary solid solution and binary eutectic system?
2. Plot and explain with examples (a) a binary phase diagram for two metals which are
completely soluble in liquid and solid states. [May/Jun 2014]
(b) a phase diagram for binary eutectic alloy system ? [May/Jun 2013][April/May 2015]
3. What are the micro-constituents of iron-carbon alloys ? Explain the general characteristics
of each.
4. Draw iron-iron carbide equilibrium diagram and mark all salient temperatures and
composition fields and phase reactions involved in it ? [Nov/Dec 2014][April/May 2015]
5. Describe the phase changes that occur when a molten 0.35% C steel solidifies and cools
slowly from 1700° C to room temperature. Also draw the probable microstructure of steel at
about 800°C and 25 °C. [May/Jun 2014]
6. Name the phase reactions occurring in Fe –Fe3C system.What are the temperatures and
compositions at which they occur? [Nov/Dec2013][May/Jun 2012] [Nov/Dec 2014]
7. Explain the primary crystallization of eutectoid steels, hypoeutectoid steels and
hypereutectoid steels.
8. Explain the primary crystallization of eutectoid cast irons, hypoeutectoid cast irons and
hypereutectoid cast irons.
9. Two metals A and B have melting points at 900 °C and 800°C .The alloy pair forms an
eutectic at 600°C of composition 60% B and and 40%A. A and B have unlimited mutual
solubilities.Their solid solubilities are as follows: 10%B in A at 600°C and 5%B in A at 0°C.
12% A in B at 600°C and 4% A in B at 0°C. Assume liquidous, solidous and solvus lines to
be straight, no solid state reactions other than solubility changes occur in the series.(i) Draw
the phase diagram for series and label all the temperatures,compositions and fields (ii) Find
the number, type, extent and composition of the phases present in an alloy of composition
60%A and 40%B at 200 °C ?
10. Two metals A and B have 100% mutual solubilities in the liquid and solid states. The melting
point of pure metals A and B are 800°C and 600 °C respectively. Details of start and end of
solidifications of various alloys in the series as follows:
Alloy Compositions Temperature at the Temperature at the end
start of solidification of solidification
90% A +10% B 798°C 750°C
70% A +30% B 785°C 705°C
50% A +50% B 757°C 675°C
30% A +700% B 715°C 645°C
10% A +90% B 650°C 615°C

(i) Draw the phase diagram of the series if there are no solid state reactions and label all the
regions. (ii) Determine the number, relative amount and concentration of phases present in
an alloy of 40%A and 60% B at 700°C and 400°C ?
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UNIT – II HEAT TREATMENT

PART A
1. What are the purposes of the processing heat treatments?
1. To relieve internal stresses. 2. To improve machinability. 3. To refine grain size.
4. To soften the metal. 5. To improve hardness of the metal surface.
6. To improve mechanical properties (like tensile strength, hardness, ductilit y, etc.)
2. Draw the cooling curve for a pure metal and an alloy.

3. List the various stages of a heat treatment process.

Stage 1: Heating a metal/alloy beyond the critical temperature.
Stage 2: Holding at that temperature for a sufficient period of time to allow necessary
changes to occur.
Stage 3: Cooling the metal/alloy (i.e., quenching) at a rate necessary to obtain the
desired properties. That is, cooling at a rate necessary to obtain the desired
changes in the nature form, size and distribution of micro-constituents.
4. What is meant by annealing? List the different types of annealing.
Annealing is defined as a softening process consisting of heating the steal to a
temperature at or near the critical point, holding there for a proper time and then allowing
it to cool slowly in the furnace itself.Types: a) Full annealing. b) Process annealing. c)
Stress relief annealing. d)Recrystallisation annealing, and e) Spheroidise annealing.
5. What are the purposes of annealing?
1. To relieve or remove stresses. 2. To induce softness. 3. To refine grain structure, 4. To
alter ductility, toughness, electrical, magnetic or other properties. 5. To remove gases.
6. To produce a definite microstructure.
6. What is meant by full annealing? [May/Jun 2012]
Full annealing consists of heating the steels 15 degrees to 40 degrees centigrade above A3
temperature in case of hypoeutectoid steels and above A1 temperature in case of
hypereutectoid steels and cooling very slowly in the furnace itself. Austenitic steel is the
most ductile of the steels and has a very high relative strength. It is held at this temperature
until all the material transforms and then slowly cools in a furnace to about 50 degrees
Celsius when it can be then cooled through convection in the room. In this process hardness
and strength are restored by additional heat treatments after machining
7. What is meant by process annealing? [May/Jun 2013]
Process annealing is applied to cold worked materials to negate effects of cold work.
Commonly sandwiched between two cold work operations, it improves ductility. This is used
to treat worked metals, such as two pieces of metal that have been welded together. This
makes it possible for the metal to undergo further work without fracturing. The metal is heated
to just below the A1 temperature line (see blue arrow); it is held there long enough for the
metal to change the size and distribution of its grain structure and then cooled naturally in air.
This process is cheaper than Full Annealing or Normalizing because the metal is not heated
to high temperatures
8. What is meant by stress relief annealing and spheroidizing ? State its importance.
[Nov/Dec 2013] [Nov/Dec 2014]
Stress relief – purpose of it is to remove stresses. Temperatures are low such that cold work
effects are not affected. Reduces the residual stresses in large castings and welded parts.

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These stresses are caused by thermal cycling or work hardening. The metal is heated to 600
degrees Celsius (see green line), held at that temperature level for over an hour and then
cooled in air.
Spheroidizing: Medium and high carbon steels are too hard to machined. Prolonged
cycling between temperatures just below and above A1 line will develop spheroidite structure.
This results in maximum softness and ductility.
9. Differentiate between normalizing and full annealing. [April/May 2015]
S. Normalising Full Annealing
No.
Normalizing is similar to full annealing, Heating above UCT cooling very
1 but cooling is established in still air slowly in the furnace itself
i n s t ea d in the furnace
Normalising is more economical than full
annealing (since no furnace is required to Full annealing is costly
2
control the cooling rate).
3 Normalising is less time consuming. Full annealing is more time
Normalising temperature is higher than full consuming.
Annealing temperature is lower
4 annealing. than normalising.
5 It provides a fine grain structure. It provides coarse grain structure.
10. What is quenching? List some of the quenching medium generally used in industries.
[May/Jun2014]
Quenching refers to accelerated cooling.
Some of the quenching medium that are used generally in industries are: 5-10% caustic
soda, 5-20% brine (NaCl), cold water, warm water, mineral oil (obtained during the
refining of crude petroleum), animal oil, vegetable oil (such as linseed, cottonseed, and
rapeseed).
11. What are the factors should be considered while selecting a quenching medium?
1.Desired rate of heat removal. 2. Required temperature interval.3. Boiling point. 4.Viscosity.
5. Flash point (if combustible).6. Stability under repeated use. 7. Possible reactions
with the material being quenched. 8. Cost.
12. What are the three stages for quenching?
Stage 1: Vapour-jacket stage. Stage 2: Vapour-transport cooling stage. Stage 3: Liquid
Cooling stage.
13. What does the term hardening refer to? What are the factors that affect the hardness?
Hardening refers to the heat treatment of steel which increases its hardness b y
quenching.
The hardness obtained from the hardening process depends upon the following
factors: 1. Carbon content, 2. Quenching medium, 3. Specimen size, and 4. Other factors
14. Distinguish the work hardening process with the age hardening process.
Work hardening also known as strain hardening, is the process of hardening a metal,
while working on it (under cold-working conditions).
Age hardening also known precipitation hardening, is the process of hardening a
metal when allowed to remain or age after heat treatment.
15. The tempering process usually follows hardening process. Justify. [Nov/Dec 2013]
The martensite which is formed during hardening process is too brittle and lacks good
ductility and toughness. Hence, it cannot be used for more applications. Also the
internal residual stresses that are introduced during hardening have a weakening effect.
The ductility and toughness of martensite can be enhanced and these internal stresses are
relieved by a heat treatment process known as tempering.
16. What is the significance of TTT diagram in the heat treatment of steel?[May/Jun2014]
The TTT diagram is most useful in giving an overall picture of the
transformation behaviour of austenite. This enables the metallurgist to interpret the
response of a steel to any specified heat treatment. Using a TTT diagram, one can plan
practical heat treatment operations to get desirable microconstituents, to control limited
hardening or softening, and the time of soaking.
17. What is CCT diagram?
The CCT diagram is a plot of temperature versus the logarithm of time for a steel alloy
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of definite composition. It is used to indicate when transformations occur as the initially

austenitised material is continuously cooled at a specified rate. In addition, it is also used
to predict the final microstructure and mechanical characteristics.
18. Define the term critical cooling rate(CCR).What are the factors affecting it?
[Nov/Dec 2014]
The slowest rate of cooling of austenite that will result in 100% martensite transformation is
known as the critical cooling rate.
Factors affecting the critical rate are: 1. Chemical composition of steel, 2. Hardening
temperature, and 3. Metallurgical nature (i.e, Purity) of steel.
19. What is the difference between hardness and hardenability? [May/Jun 2014]
[April/May 2015] [Nov/Dec 2014] [May/Jun 2012]
The term hardness is the property of a material by virtue of which it is able to resist
abrasion, indentation and scratching. It is a mechanical property related to strength and is a
strong function of the carbon content of a metal.
On the other hand, hardenability is the susceptibility of a material to get hardened. It
is affected by the alloying elements in the material and grain size.
20. What is martempering and austempering? [April/May 2015]
Martempering, also known as marquenching, is a interrupted cooling procedure
used for steels to minimize stresses, distortion and cracking of steels that may develop
during rapid quenching.
Austempering is an isothermal heat treatment process, usually used to reduce quenching
distortion and to make tough and strong steels.
21. List some of the surface-hardening techniques employed for altering surface chemistry?
[May/Jun 2013]
1. Diffusion methods:a) Carburizing, b) Nitriding, c) Cyaniding, and d) Carbonitriding.
2. Thermal methods: a) Flame hardening, and b) Induction hardening.
22. Explain briefly about carbonitriding.
Heat steel at 700–800 °C (1300–1600 °F) in an atmosphere of carbonaceous gas and
ammonia. Then quench in oil. Surface hardness 55 to 62 HRC. Case depth 0.07 to 0.5 mm
(0.003 to 0.020 in.). Less distortion than in carburizing. This process can be applied to bolts,
nuts, and gears.
23. What is flame hardening?
This involves heating the surface of a steel with an oxyacetylene flame (transforming the
structure of the surface layers to austenite), and then immediately quenching the surface
with cold water (changing the austenite to martensite). The depth of hardening depends on
the heat supplied per unit surface area per unit time. Thus, the faster the burner is moved over
the surface, the less the depth of hardening. The temperatures used in this method are typically
of the order of 850°C or more, i.e. above the ‘A’ temperature
24. What is temper embrittlement?
The tempering of some steels may result in a reduction of toughness as measured by impact tests.
This is termed as temper embrittlement.
25. Define Recrystallisation ? [Nov/Dec 2014]
Recrystallisation is a process accomplished by heating whereby deformed grains are replaced by a
new set of grains that nucleate and grow until the original grains have been entirely consumed.
PART B
1. Compare and contrast the different process of Annealing ? [M/J-2013],[M/J- 2014] [ May/June 2012]
2. Explain briefly the various tempering processes. Compare and contrast Austempering and
Martempeirng processes? [Nov/Dec 2012] [April/May 2015] .[Nov/Dec 2014]
3. (a)Describe the normalising process of heat treatment?
(b)Differentiate between normalising and full annealing? [Nov/Dec 2014]
4. Explain the Jominy end-quench method of determining hardenability. List the factors affecting
hardenability? [May/Jun2013][May/June 2012] [April/May 2015]
5. What do you understand by Isothermal transformation ? Draw a neat sketch of the TTT diagram for a
eutectoid steel and label the regions. Mark the different products formed on this diagram?
[Nov /Dec 2013] [April/May 2015 ][Nov/Dec 2012]
6. (a) What is a CCT diagram? (b) Describe various cooling curves on TTT diagrams.How such curves
drawn? (c) Write short notes on critical cooling rate?

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7. What is meant by Case hardening of steels ? Briefly explain the various types of Carburising?
8. Explain the process of nitriding and Cyaniding .List and discuss the advantages of nitriding over
carburising? [Nov/Dec 2013]
9. Describe the flame hardening process with the aid of neat sketch .Also brief the advantages,
disadvantages and applications of flame hardening? [Nov/Dec 2013]
10. Explain the principle of Induction hardening and compare with flame hardening process?
[May/Jun 2014] [May/Jun 2013]

UNIT – III FERROUS AND NON-FERROUS METALS

PART – A
1. What are three primary groups of plain carbon steels? [May/Jun 2013]
1. Low-carbon steels: Those contain less than 0.25% carbon.
2. Medium-carbon steels: Those containing between 0.25 and 0.60% carbon.
3. High-carbon steels: Those containing more than 0.60% carbon.
2. What are the primary effects of chromium, and copper as alloying elements in steel?
[April/May 2015] [May/Jun2013] [May/Jun2014]
Effects of alloying chromium: Increases corrosion and oxidation resistance, increases
hardenability, increases high-temperature strength, and resists abrasion and wear (with
high carbon).
Effects of alloying copper: Increases strength, and increases corrosion resistance.
3. What is the effect of alloying Silicon and Cobalt in steels? [Nov/Dec 2014]
Silicon improves oxidation resistance, strengthens low alloy steels and acts as a deoxitizer.
Cobalt contributes to red hardness by hardening ferrite, improves mechanical properties such
as tensile strengths, fatigue strength and hardness, refines the graphite and pearlite, a mild
stabilizer of carbides, improves heat resistance and retards the transformation of austenite
and thus increases hardenability and freedom from cracking and distortion.
4. Which alloy elements are basically a) carbide(stabilizers) formers, and b) graphite
(stabilizers)promoters? [April/May 2015]

a) Carbide formers: Cr, W, Ti, Mo, Nb, V, and Mn.

b) Graphite promoter: Si, Co, Al, and Ni.
5. What makes a stainless steel “stainless”? [Nov/Dec 2013]
The chromium oxide (extremely dense-thin) protective layer acts as a barrier to retard
further oxidation, rust or corrosion. As this steel cannot be stained easily, it is called
stainless steel.
6. What are the required properties of a tool steel? [Nov/Dec 2013]
Tool steels should have the following properties:
1. Good toughness, 2. Good wear resistance, 3. Very good machinability,
4. Slight change of form during hardening, 5. Little risk of cracking during hardening.
5. Resistance to softening on heating.
7. What is meant by 18-4-1 high speed steel?
A widely used high-speed tool steel is 18-4-1 high speed steel. This steel contains
18% tungsten, 4% chromium, and 1% vanadium. It is considered to be one of the best of
all purpose tool steels.
8. What are HSLA steels? Where are they used? [Nov/Dec 2014] [April/May 2015]
HSLA steels are nothing but high-strength low-alloy steels. HSLA steels, also known
as micro alloyed steels, are low-carbon steels containing small amounts of alloying
elements.These HSLA steels are widely used as structural or constructional alloy
steels.
9. What are Maraging steels? Give its composition. [Nov/Dec 2013]
Maraging steels are low-carbon, highly alloyed steels. These are very high- strength
materials that an be hardened to obtain tensile strengths of up to1900 Mpa.
Composition: Maraging steels contain 18% nickel, 7% cobalt, and small amounts of
other elements such as titanium. The carbon content is low, generally less than 0.05%.
10. What are the features that make cast iron an important material?
1. It is a cheap metallurgical substance,2. Good castability,3. Good mechanical rigidity and
good strength under compression.4. Good machinability can achieved when a suitable
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composition is selected.
11. What is the difference between malleable cast iron and ductile cast iron? [Nov/Dec 2014]
Malleable cast iron is produced by heat treating unalloyed white iron. The ductile (or
SG or nodular) cast iron is produced by adding magnesium and/or cerium to molten cast
iron.Both malleable and ductile cast irons have the nodules, also called spheroids. But the
nodules of ductile cast irons are more perfect spheres.
12. What are the primary effects of adding Ni, and Mo in cast irons? [May/Jun 2012]
S.No. Alloying General effects
element It has graphitizing effect on cementite. So ittends to produce a
grey iron.
1. Nickel (Ni) It has a grain-refining effect, which helps to prevent the
formation of coarse grain.
It also toughens thin sections.
It increases the hardness of thick sections. It also
2. Molybdenum improves toughness.
13. (Mo)
List the outstanding properties of copper and some typical applications.
The copper possesses the following properties:1. Very high electrical conductivity.
2. Very high thermal conductivity.3. Exhibits excellent resistance to corrosion.
4. Very soft, ductile and malleable.
Copper is extensively used for manufacturing power cables, telephone cables, cables for
computer networks, printed circuit boards, connectors, etc.
14. What is the main difference between a brass and a bronze? [May/Jun-2013]
Brass is an alloy of copper and zinc whereas bronze is an alloy of copper and tin.
15. List at least four types of brasses used.
Gliding metal (or commercial bronze), cartridge brass, standard brass (or cold
working brass), Muntz metal (or yellow metal), Naval brass, Admiralty brass.
16 List some bronze alloys.? [May/Jun 2013]
Bell bronze, phosphor bronze, aluminium bronze, silicon bronze, coinage bronze and
leaded bronze.
17. How do you classify Cast irons?
Cast iron types : 1.Grey C.I 2. White C.I 3.Maleable C.I 4. Spheroidal graphite C.I.

18. What are gun metals? Give its composition.?

Gun metals are alloys of copper, tin, and zinc.
Composition of admiralty gun metal: 88 Cu, 10 Sn, 2 Zn, 2 (max) Ni.
19. State the composition, properties and applications of cupronickel and Monel metal.
[Nov/Dec 2014]
The composition of the alloys can vary from 90% Cu–10% Ni to 70% Cu–30% Ni.
Uses: As heat exchanger or condenser tubes in evaporators of desalination plants, process
industry plants, air cooling zones of thermal power plants, high-pressure feed water heaters
and Cupronickels are alloys of copper and nickel.
Monel consists of ( in %) Ni - 66 , Cu- 31.5, Fe- 1.35, Mn- 0.9 plus residuals.
Uses of monel metal: For making propellers, pump fittings, condenser tubes, steam
turbine blades, sea water exposed parts, tanks, and chemical and food handling plants.
20. What is Duralumin and mention its applications?
Duralumin is an alloy of aluminium and copper.
Composition: 94 Al, 4Cu, 0.5 Mg, 0.5 Mn, 0.5 Si, 0.5 Fe.
Typical applications: For aircraft and automobile industries; for making electric
cables, in surgical and orthopaedic implements or gadgets, etc.
21. What is meant by precipitation hardening? [ May/Jun 2012] [Nov/Dec 2013] [Nov/Dec 2014]
Precipitation hardening, also known as age hardening, is the most important method of
improving the physical properties of some of the non-ferrous alloys by solid state reaction.
22. Differentiate between natural ageing and artificial ageing.
The ageing process done at room temperature is often called natural ageing. Natural
ageing takes a prolonged period of time in terms of several days to reach maximum
strength.Ageing at high temperature of 190° C to 260° C accelerates the precipitation
process and the time required is reduced considerably. This process is called artificial

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ageing.
23. What are the required characteristics of a bearing material?
1. Bearing material should possess sufficient hardness and wear resistance.2. It hould have a
low coefficient of friction.3. It should be tough, shock-resistant, and sufficiently ductile.
4. It should have a sufficient melting point, and high thermal conductivity.5. It hould have
good casting qualities, and good resistance to corrosion.
24. What are super alloys? [May/Jun 2014]
Super alloy is a general term used to describe the nickel-base and cobalt-base alloys which
have been developed for use at elevated temperatures.
Super alloys produce a combination of high strength as elevated temperature,resistance to
creep at temperatures up to 1000° C, and resistance to corrosion.
25. What is meant by Babbit metal ? Give its composition and applications.[Nov/Dec 2011]
Also called as white metal, it is an alloy used to provide the best bearing surface in a plain
bearing. It has properties that help reduce friction which make it a good material to use in a
plain bearing. The structure of the alloy is made up of small hard crystals dispersed in a
matrix of softer alloy.
Common compositions for Babbitt alloys:
1) 90% tin 10% copper, 2) 89% tin 7% antimony 4% copper , 3) 80% lead 15% antimony
5% tin
Applications: Internal combustion engines use Babbitt metal which is primarily tin-based
because it can withstand cyclic loading. Lead-based Babbitt tends to work-harden and
develop cracks but it is suitable for constant-turning tools such as sawblades.

PART B
1. Describe the properties and typical applications of Low, Medium and high carbon steels?
2. Summarise the effect of the following elements as alloying additions to steels: Mn, Si, Cr, Mo, V,
Ti, Al, Si, Cu, W ? [Nov/Dec 2013]
3. Describe the different types of stainless steels, making reference to approximate compositions,
structures, heat treatments and applications ? [May/Jun 2012]
4. Write an engineering brief about (a)Tool steels (b) HSLA steels (c)Maraging steels (d)High speed
steels? [April/May 2015] [May/Jun 2014] [Nov/Dec 2014]
5. Describe the structures of main types of Cast iron and explain the factors which affect the structure
of Cast iron?
6. Discuss the composition, properties and typical applications of Copper alloys?
[ Nov/Dec 2014] [May/Jun 2012]
7. Explain the composition, properties and typical applications of Aluminium alloys?
8. Explain the process of Precipitation strengthening treatment for the Al-4%Cu system?
[MAY/JUN- 2014] [April/May 2015]
9. a.What are the necessary metallurgical characteristics required in a good bearing metal?
b.Compare and contrast lead- base, tin-base, copper-base and aluminium-base bearing
alloys. [Nov/Dec 2014] [MAY/JUN- 2014]
10. What is an alloy steel ? How are alloy steels classified. Explain them?

UNIT – IV NON-METALLIC MATERIALS

PART – A
1. What are polymers? [May/Jun 2013] [Nov/Dec 2014]
Polymers are composed of a large number of repeating units of small molecules
called manometers.
Polymers may be defined as giant organic, chain-like molecules having molecular
weight from 10000 to more than 1,000,000 g.mol-1.
2. What is meant by the term ‘unsaturated molecule’? State its significance in plastics.
[May/Jun 2014]
A compound in which the valence bonds of the carbon atoms are not satisfied is said to
be unsaturated. Such unsaturated molecules are important in the polymerization i.e.,
joining together of small molecules into large one having the same constituents.

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3. What is polymerization?
Mechanism where smaller molecules combine to form larger molecules. Types: Addition
polymerization and Condensation polymerization.
4. Define the term ‘degree of polymerization’? [May/Jun-2012]
Degree of polymerization is the number of repetitive units (or mers) present in one
molecule of a polymer. Mathematically,
Degree of polymerisation = ( Molecular weight of a polymer/ Molecular weight of a single
monomer.)
5. What is the difference between addition polymerization and condensation
polymerization?
Addition polymerization, also known as chain reaction polymerization, is a process by
which two r more chemically similar monomers are polymerized to form long chain
molecules.
Condensation polymerization, also known as step-growth polymerization, is the
formation of polymers by stepwise intermolecular chemical reactions that normally involve
at least two different monomers.
6. Why are additives added to polymers?
The various polymer additives include:
1. Filler materials, 2. Plasticizers, 3. Stabilizers, 4. Colorants, 5. Flame retardants,
6. Reinforcements, and 7. Lubricants.
7. Name any four commodity plastics and engineering plastics?. [May/Jun 2012]
Commodity plastics: i) Polyethylene (PE), ii) Polypropylene (PP), iii) Polystyrene
(PS), iv) Polyvinyl chloride (PVC).
Enginering Plastics: i) Ethenic, ii) Polyamides, iii) Cellulosics, iv) Acetals.
8. Distinguish between thermoplastics and thermosetting plastics. [April/May 2015]
S.
No. Thermoplastics Thermosetting
They are formed by addition They are plastics
formed by
1. polymerisation. condensation polymerisation.
They are linear polymers, so they are They are composed of three
2. composed of chain molecules. dimensional networks of cross-
Softening is possible on reheating Softening linked molecules.
is not possible on
3. (because of the weak secondary forces). reheating
They can be easily moulded on They (because
cannotof bestrong covalent
remoulded into
4. remoulded into any shape. bonds).
any new shape.
5. They can be recycled again. They cannot be recycled.
9. Name any four thermoplastics and thermosetting plastics.
Thermoplastics: Polythenes, Polypropylene, Polystyrenes, PVC.
Thermosetting plastics: Polyesters, phenolics, epoxides, melamine formaldehyde.
10. What are the following ‘acronyms’ refer to: PE, PP, PS, PVC, PTFE, PMMA.?
[May/Jun 2012]
PE: Polyethylene; PP: Polypropylene; PS: Polystyrene; PVC; Polyvinyl chloride;
PTFE: Polytetrafluro ethylene; PMMA: Polymethyl methacrylate.
11. List the properties and typical applications of PVC.
Properties: Good low-cost, general purpose materials; ordinary rigid, but can be made
flexible with plasticizers; susceptible to heat distortion.
Typical applications: Pipes, valves, fittings, floor tiles, wire insulations, toys, phonograph
records, safety glass interlayers.
12. What are acrylic materials? Name any two. [Nov/Dec 2013]
Acrylic materials are thermoplastic polymers based on the polymerization of esters of
acrylic acid and/or methacrylic acid.
The most commonly used acrylic polymers are:
1. PMMA (Polymethyl methacrylate), 2. PAN (Polyacrylonitrile).
13. Write short notes on nylons.
Polyamides (PA), also known as nylons, are the products of condensation reactions
between an amine and an organic acid.
There are number of common polyamides. They are usually designated as nylon 6,
nylon 6/6, nylon 6/10, nylon 6/12, nylon 11, and nylon 12. These suffixes refer to the
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number of carbon atoms in each of the reacting substances involved in the condensation
polymerization process.
14. What are bakelites? Also state their applications.
Phenolics, also known as Bakelites, are the oldest family of thermosetting plastics. The
most important phenolic materials is the polyformaldehydes. Typical applications include
electrical plugs, sockets, switches, telephones, door knobs and handles, adhesives,
coatings, and laminates.
15. List the characteristics of urea-formaldehyde.
1. They are similar to the phenolics. 2. They are hard and rigid thermosets.
3. They have good electrical insulation properties. 4. They are light in colour.
5. They exhibit good resistance to most chemicals.
16. List some of the distinct characteristics of engineering ceramics.
1. High resistance to abrasion and wear. 2. High strength at high temperature.
3. Good chemical stability. 4. Good electrical insulation characteristics.
17. Name any four engineering ceramics.
1. Alumina (Al2O3). 2. Selicon carbide (SiC). 3. Silicon nitride (Si3N 4).
4. Partially stabilized zirconia (PSZ), and 5. Sialons.
18. What is meant by PSZ?
Partially stabilized zirconia (PSZ) is nothing but a zirconium oxide (ZrO2) that has
been blended and sintered with some other oxide such as magnesium oxide (MgO),
calcium oxide (CaO), and yttria (Y2O3), to control crystal structure transformations.
19. What are sialons? State their applications. [May/Jun-2014]
The name sialon is an acronym derived from the ingredients involved, namely Si formed
when aluminium and oxygen partially substitute for silicon and nitrogen in silicon
nitride.Sialons are used for cutting tool materials, dies for drawing wire and tubes, rock-
cutting and coal-cutting equipment, nozzles and welding shields.
20. What is the role of matrix material in a composite?
The matrix usually provides the major control over electrical properties, chemical
behaviour, and elevated-temperature use of the composite.
21. List the various matrix materials used.
1. Polymers: Kevlar,nylon, polyethylene. 2. Metals: Be, Boron, W.
3. Glass: E-glass, S-glass. 4. Carbon: HS (high strength), HM (high modulus).
5. Ceramics: Al2O3, B4C, SiC, ZrO2. 6. Whiskers: Al2O3, Cr, graphite, SiC, Si3N4.
22. What are cermets? What are two common uses of cermets?
The term ‘cermet’ refers to ceramic-metal composite containing between 80 and 90 % of
ceramic. Cermets are composed of ceramic particles in metallic matrix.
Typical applications: Cutting tools, slip gauge, wire-drawing dies, rocket motor and
jet-engine parts.
23. What is ABS and state any two of its applications. [Nov/Dec 2013]
Acrylonitrile-butadiene-styrene graft copolymer
(ABS). TECARAN ABS is an amorphous
thermoplastic, which has high impact strength even at
low temperatures. The moisture absorption of ABS is
low.
Special types of this material are suitable for electroplating. It has high impact strength, even
at low temperatures, low moisture absorption, poor resistance to weathering and suitable
for electroplating.
24. What is meant by metal matrix composites? Give one example each to matrix material
and reinforcement used? [April/May 2015]
A metal matrix composite (MMC) is composite material with at least two constituent parts, one being
a metal necessarily, the other material may be a different metal or another material, such as a ceramic
or organic compound. Material: AlMg1SiCu + 20 vol. % Al2O3P used for Drive shaft for people and
light load motor vehicles

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25. What is Fibre reinforced Plastics? [NOV/DEC 2014]

Fibre-reinforced plastic (FRP) (also fibre-reinforced polymer) is a composite material made of
a polymer matrix reinforced with fibers. The fibres are usually glass, carbon,aramid, or basalt. Rarely,
other fibres such as paper or wood or asbestos have been used. The polymer is usually
an epoxy, vinylester or polyester thermosetting plastic, and phenol formaldehyde resins
PART- B
1. What is polymerization? Describe addition polymerization and condensation polymerization.
. [May/Jun 2014] [May/Jun 2013]
2. (a).Describe the difference between thermoplastics and thermosetting plastics? [Nov/Dec 2012]
(b).Explain the differences between commodity plastics and Engineering Plastics?
3. What are the properties and application of thermo plastics PVC, PET, PP , PC PMMA,
ABS,PEEK PTFE ? [Nov/Dec 2014] [May/Jun 2012] [Nov/Dec 2013] [April/May 2015]
4. What are the properties and application of thermosetting plastics PF,UF,Polyesters,Epoxides,
Polyurethanes ? [Nov/Dec 2012] [May/Jun 2013]
5. Discuss the properties and typical applications of the following engineering Ceramics (i) Al 2
O, (ii)SiC, (iii) Si3 N4 , (iv) PSZ (v) Sialons [May/Jun 2014] [April/May 2015]
6. Describe the following terms a) Linear polymer b) Branched polymer c) chain stiffening
d) Cross linked polymer. [Nov/Dec 2012]
7. Explain the difference in strengthening mechanism between dispersion-strengthened and
large-particle reinforced composites?
8. Write short note about the different types of matrix materials and reinforcement materials
used to make polymer matrix composites. [May/Jun 2014]
9. (i) Explain the strengthening mechanism of fibre-reinforced composites? [Nov/Dec 2014]
(ii)List the advantages, Limitations and applications of composite materials ?
10. What are the properties and application of thermo plastics PE, PS, PAN, PA, POM,PC, PPO,
PPS, PI, PAI ?

UNIT – V MECHANICAL PROPERTIES AND DEFORMATION

PART – A
1. Distinguish between elasticity and plasticity.
Elasticity is the property of a material by virtue of which it is able to retain its original
shape and size after the removal of the load.
Plasticity is the property of a material by virtue of which a permanent
deformation (without fracture) takes place, whenever it is subjected to the action of
external forces.
2. Differentiate between ductility and malleability.
Ductility is the property of a material by virtue of which it can be drawn into wires before
rupture takes place.
Malleability is the property of a material by virtue of which it can withstand deformation
under compression without rupture.
3. What do you mean by toughness and stiffness?
Toughness is the property of a material by virtue of which it can absorb maximum
energy before fracture takes place.
Stiffness is the property of a material by virtue of which it resists deformation.
4. What is the effect of the grain size on the mechanical properties of the materials?
[May/Jun 2014]
The materials having smaller grains (i.e., fine grained structure) have high yield
strength, high tensile strength, and more hardness. Also fine grain results in better
resistance to cracking and better surface finish.
The materials having grains (i.e., coarse grained structure), exhibit better
workability, hardenability, forgeability and creep resistance. But coarse grains result in
poor surface finish, less tough and have greater tendency to cause distortion.

5. Distinguish between elastic and plastic deformation of solid. [May/Jun 2013]

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S.
No. Elastic deformation Plastic deformation
It is the deformation of a body It is the deformation of a body
1. with completely disappears as Soon as which remains even after
the external load is removed from the Removing the external load from the
body. body.
2. It obeys Hook’s law. It does not obey Hook’s law.
The elastic deformation is the beginning The plastic deformation takes
3. of the progress of deformation. place after the elastic deformation
has stopped.
6. Define the terms slip and twinning. [Nov/Dec 2013] [Nov/Dec 2014]
Slip may be defined as the sliding of blocks of the crystal over one another along
definite a mirror image of the other part.
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.
7. State the Schmid’s law and write the equation for critically resolved shear stress.
The stress required at a given temperature to initiate slip in a pure and perfect single
crystal, for a material is constant. This is known as Schmid’s law.

8. What are the causes of twins?

1. Mechanical twins: Twins that are produced by mechanical deformation are called
mechanical twins.
2. Annealing twins: Twins that are produced by annealing are called annealing twins.
9. List the different types of fracture in a material.
1. Brittle fracture, 2. Ductile fracture, 3. Fatigue fracture, and 4. Creep fracture.
10. State the Griffith’s criteria.
A crack will propagate when the decrease in elastic energy is at least equal to the energy
required to create the new crack surface.

11. Distinguish between brittle fracture and ductile fracture.

S.
No. Brittle fracture Ductile fracture
It occurs with negligible plastic
1. deformation. It occurs with large plastic
It occurs at the point where micro deformation.
It occurs in some localised region
2. crack is more. where the deformation is very large.
The rate of crack propagation is
3. rapid. The rate of crack propagation is slow.
4. Failure is due to the direct stress. Failure is due to the shear stress.

12. What is meant by fatigue fracture?

A fatigue fracture is defined as the fracture which takes place under repeatedly
applied fatigue stresses.
13. What is S-N diagram? What is the significance of it? [May/Jun 2012][May/Jun 2014]
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 S-N

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diagram, the fatigue life of a material can be determined.

14. What is meant by super plasticity?
The ability of some metals to deform plastically by 1000 – 2000 % at high temperature and
low loading rates.
15. What is creep? Draw a typical creep curve and show different creep stages on it.
[May/Jun 2013] [April/May 2015]
Creep fracture is the fracture that takes place due to
excessive creeping of metals under steady loading.
Deformation that occurs under constant load/stress and
elevated temperatures which is time-dependent is
known as creep. Creep deformation (constant stress) is
possible at all temperatures above absolute zero.
However, it is extremely sensitive to temperature.
Hence, creep in usually considered important at
elevated temperatures (temperatures greater than 0.4
Tm, Tm is absolute melting temperature).
16. Define endurance limit in a fatigue test. [Nov/Dec 2014]
It is also known as fatigue limit, The fatigue limit is a maximum stress amplitude below
which the material never fails, no matter how large the number of cycles is. Fatigue life:
Number of cycles to fail at specified stress level. Fatigue strength: stress at which fracture
occurs after specified number of cycles (e.g. 107 )

17. Draw the stress – strain diagram for

ductile material. [April/May 2015]

18. What is meant by fracture toughness?

Fracture toughness is a property which describes the ability of a material containing a crack
to resist fracture, and is one of the most important properties of any material for many design
applications.
19. What is meant by Slip plane, Slip direction and Slip system?
Dislocations move on a certain crystallographic plane and the plane of greatest atomic
density : slip plane. Dislocations move in a certain crystallographic direction and the close
packed direction within the slip plane : slip direction. The Feasible combination of a slip
plane together with a slip direction is considered as a slip system is called a slip system
20. Define Fatigue. What are the factors affecting fatigue strength?
Fatigue fracture is the fracture that occurs under repeatedly applied fatigue stresses. This
fracture occurs at a stress well below the tensile strength of the materials
1. Fatigue strength is influenced by many factors such as chemical composition, grain size,
and amount of cold working.
2. Fatigue strength is high at low temperatures and gradually decreases with rise in
temperature.
3. Environmental effects such as corrosion of the product by moisture decreases the
fatigue strength.
4. The design of the product also influences the fatigue strength.
21. How can you prevent fatigue fracture?
The following methods can be adopted to prevent the fatigue failure.
1. Use of good design to avoid stress concentration by eliminating sharp recesses and
severe stress raisers.
2. Control of the surface finish by avoiding damage to surface machining, punching,

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stamping, shearing, etc.

3. Reduction of corrosion environmental effects by surface heat treatments like
polishings, coatings, carburizing, nitriding, etc.
4. The material should have fine grain structure and also it should be free from
residual stresses and dislocations.
22. What is meant by creep fracture?
The creep is defined as the property of a material by virtue of which it deforms
continuously under a steady load.
23. What are the factors affecting creep?
1. Grain, 2. Thermal stability of the micro-structure,3. Chemical reactions, 4. Prior strain.
24. How can you prevent the creep fractures?
The following methods can be adopted to prevent the creep failure.
1. Use of coarse grained materials will avoid creep fracture.
2. Strain hardening can be done to avoid creep fracture.
3. The material should be free from any residual stresses and dislocations.
4. Precipitation-hardened alloys can be used to avoid creep fracture.
25. What is the difference between Izod and Charpy impact testing methods?
[May/Jun 2012] [Nov/Dec 2014]
Based on the types of specimen used on impact testing machine, the impact tests can be
classified into: 1. Izod test, and 2. Charpy test. Izod test uses a cantilever specimen of
size 75 mm×10mm×10mm. Charpy test uses a simply-supported test specimen of size
5mm×10mm×10mm.

PART B
1. Explain the different types of mechanical properties and mechanism of plastic deformation by
slip and twinning. [May/Jun 2014] [Nov/Dec 2012]
2. What is brittle fracture? Explain the Griffth’s theory on brittle fracture and deduce an
expression for the critical stress required to propagate a crack simultaneously in a brittle
material?
3. What is meant by ductile fracture? Explain the mechanism of it?
4. Explain the mechanism of fatique fracture. How can we prevent ?
5. (i) Describe a tensile test to determine various tensile properties [April/May 2015]
(ii)Explain the procedure of (i)a compression test (ii) a shear test?
[May/Jun2012] [Nov/Dec 2014]
6. a) List the various types of hardness testing. Write a short note on Rockwell, brinell and
Vickers hardness and their significance. [May/Jun2012] [April/May 2015]
7. Explain and distinguish Izod test and Charpy test to determine the impact strength of a
material? [Nov/Dec 2012 ] [Nov/Dec 2013] [April/May 2015]
8. Write an engineering brief about the creep test . [Nov/Dec 2014]
9. Sketch and describe the fatigue test .Draw the S-N curve for mild steel and aluminium and
explain its features. Explain the procedure used to obtain S-N diagram.?
[Nov/Dec 2014][May/Jun-2013] [May /Jun-2014]
10. Derive an expression for critical resolved shear stress in a material subjected to uniaxial
tensile loading ?

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