1.

Define the terms below :

i. Atom
An atom is the basic unit of an element formed for all materials whether in solid,
gas or liquid.

i. Compound
Various kinds of atoms are combined chemically with proportion, which is
expressed by a chemistry formula. Compound are homogeneous forms of matter.
Their constituent elements are always present in fixed proportions. The
components of a compound do not retain their individual properties. It takes large
inputs of energy to separate the components of a compound.

ii. Phase
Phase is a portion of a system that has uniform physical and chemical
characteristics. Two distinct phase in a system have distinct physical or chemical
characteristics and are separated from each other by definite phase boundaries.

iii. Phase Equilibrium Diagram

Equilibrium Phase Diagram is graphical representations of what phases are
present in a materials system at various temperatures, pressures and compositions.

2. Sketch and state the total number of atoms per unit cell for the following crystal
structure:

i. Simple Cubic
ii. Body Centered Cubic

iii. Hexagonal Closed-Packed

3. Explain the following mechanical behaviour of materials.

i. Creep
When a metal or an alloy is under a constant load or stress, it may undergo
progressive plastic deformation (permanent elongation) over a period of time.

ii. Fatigue
In many types of service applications metal parts subjected to repetitive or
cyclic stresses will fail due to fatigue loading at a much lower stress than that
which the part can withstand under the application of a single static stress.

iii. Fracture
Fractures can be classified as ductile or brittle, but a fracture can be a mixture of the
Fracture is separation of a solid under stress into two or more parts.

4. Distinguish between Substitution Solid Solution and Interstitial Solid Solution by

using appropriate diagram.

Substitutional – Solute atoms occupy the regular lattice sites of the parent metal
(solvent). Substitutional solid solutions can be random (Cu-Ni) or ordered (Cu-Au).
Substitutional solid solutions are those in which the solute atoms (minor component)
substituted for the solvent atoms (major component or parent element) on the lattice
positions normally occupied by the solvent atoms. The crystal structure of the solvent
is unchanged, but the lattice may be distorted by the presence of the solute atoms if
there is a difference in the atomic size of these 2 atoms.

Interstitial – Solute atoms occupy the interstitial positions (Steel – C solute atoms in
Fe) . Interstitial solid solutions are those in which the solute atoms fit into spaces
between the solvent or parent atoms in the crystal lattice. This spaces or voids are
called interstices.It can form when solute atoms are much smaller than solvent atoms.
Example of solute atoms which have a small size are hydrogen, carbon, nitrogen and
oxygen.
5. Explain how recrystallization process works by using appropriate diagram.

- Crystallisation occurs around small nuclei, which may be impurity particles. The
first crystals have the crystal shape into which the metal would naturally solidify,
for example face-centred cubic in the case of copper. However, as the crystal
grows, it tends to develop spikes and its shape changes into a tree-like form called
a dendrite

6. Define non-ferrous metal and state FOUR(4) types of non-ferrous metal.

Non-ferrous naturally means a metal or alloy which contains little or no iron. Non-
ferrous metals are the metal that exclude iron and steel.
Types:
- Aluminium
- Copper
- Steel
- Titanium
7. Why ship propeller is made from bronze and why body made from steel in preventing
corrosion.

- Steel is an anode and bronze is a cathode and both are in a sea-water which act as
electrolyte.

- The steel (hulls) will be corroded because of its anodic, so a more anodic material than steel
and bronze is used as corrosion sacrificial which it is zinc.

- Zinc blocks are fitted to hulls so that the electrochemical corrosion process will occur only
to the zinc.

- The zinc blocks must be replaced time to time because its worn out of corrosion as shown in
this picture.

8. List FOUR(4) properties and ONE(1) application of copper and aluminium.

1. Aluminium properties
- High strength-to-weight ratio
- High thermal and electrical conductivity
- Good corrosion resistance
- Good manufacturing properties.

Aluminium application

- Buildings and other types of construction

 2. Cooper properties
- Reddish brown metal
- High electrical and thermal conductivity
- Low strength with high ductility
- Corrosion resistance.

Cooper application

- Containers and packaging

9. List THREE(3) advantages of hot work process.

- Metal are in plasticity condition. Energy and forces needed are small. Can be
worked for bigger size metals.

- Blow holes in ingots can be disappeared by compression. Doesn’t produce internal

stress in metal.

- The deformation and recovery takes place simultaneously.

-Improve toughness, impact strength and ductility.

10. Explain the principle of tube drawing procedure in cold work process.

The ‘drawing’ process can also be used for tube drawing.

Tube drawing does not mean manufacturing a tube from solid raw material.
It means lengthening a tube reducing its diameter.
Various arrangements used for tube drawing.
11. With the aid of diagram. Explain process of investment casting.

- The first step in investment casting is to manufacture the wax pattern for the
process. The pattern for this process may also be made from plastic; however it is
often made of wax since it will melt out easily and wax can be reused
- Since the mold does not need to be opened castings of very complex geometry can
be manufactured. Several wax patterns may be combined for a single casting. Or
as often the case, many wax patterns may be connected and poured together
producing many castings in a single process. This is done by attaching the wax
patterns to a wax bar, the bar serves as a central sprue. A ceramic pouring cup is
attached to the end of the bar. This arrangement is called a tree, denoting the
similarity of casting patterns on the central runner beam to branches on a tree.
- The casting pattern is then dipped in a refractory slurry whose composition
includes extremely fine grained silica, water, and binders. A ceramic layer is
obtained over the surface of the pattern. The pattern is then repeatedly dipped into
the slurry to increase the thickness of the ceramic coat. In some cases the pattern
may be placed in a flask and the ceramic slurry poured over it.
- Once the refractory coat over the pattern is thick enough it is allowed to dry in air
in order to harden
- The next step in this manufacturing process is the key to investment casting. The
hardened ceramic mold is turned upside down and heated to a temperature of
around 200F-375F (90C-175C). This causes the wax to flow out of the mold
leaving the cavity for the casting.
- The ceramic mold is then heated to around 1000F-2000F (550C-1100C). This will
further strengthen the mold, eliminate any leftover wax or contaminants, and drive
out water from the mold material. The casting is then poured while the mold is
still hot. Pouring the casting while the mold is hot allows the liquid metal to flow
easily through the mold cavity filling detailed and thin sections. Pouring the
casting in a hot mold also gives better dimensional accuracy since the mold and
casting will shrink together as they cool.
- After pouring of the molten metal into the mold, the casting is allowed to set as
the solidification process takes place.
- The final step in this manufacturing process involves breaking the ceramic mold
from the casting and cutting the parts from the tree.
 12. Explain the process of normalizing and quench hardening.

Normalizing :

- Normalization is a kind of heat treatment that relieves stress on steel; this

improves ductility and toughness in steels that may harden after the cold
working process.
- For normalization to occur, steel is warmed to a temperature just above its
upper critical point.
- This is generally more than 50 ºC of that temperature. The steel is then held
long enough for smaller metal grains to form and high energy grain shapes
to come together.
- This transformation is called grain refinement and leads to the formation of
a more uniform piece of metal. After steel is heated to a temperature above
its critical point, it is air-cooled until it drops to room temperature.
- Normalizing temperatures are said to range from 810 ºC to 930 ºC. The
thickness of the metal determines how long a piece of metal is held at what
is known as the soaking temperature, or the temperature that transforms the
microstructure. The thickness and composition of the metal also determines
how high the work piece is heated.
Hardening :

- Quenching is a rapid way of bringing a metal back to room temperature after heat
treatment (such as annealing, normalizing or stress relieving) to prevent the
cooling process from dramatically changing the metal's microstructure.
- Quenching results in the hardening of steel at the same temperature that full
annealing does.
- Special purpose polymers, forced air convection, fresh water, salt water and
oil can all be used to carry out the quenching process. Water is an effective
medium when the goal is to have steel to reach maximum hardness. However,
using water can lead metal to crack or become distorted. If extreme hardness isn't
necessary, then other media such as mineral oil, whale oil or cotton seed oil may
be used in the quenching process instead.

13. Impact test is used to determine the toughness of a material.

i. State THREE(3) forms of notch that is used in the impact test.

-V notch
-U notch
-Key hole notch

ii. Name TWO(2) types of impact test.

-Izod Test
-Charpy Test

ii. Explain the procedure of the impact test mentioned in Question b(ii) and
sketch a schematic diagram.

1. Charpy Impact Test

 The Charpy test involves striking a suitable test piece with a striker, mounted at the
end of a pendulum. The test piece is fixed in place at both ends and the striker impacts the
test piece immediately behind a a machined notch.

2. Izod Impact Test

The Izod impact test fixes one end of a notched specimen in a cantilever position by
means of a vice. A striker on the arm of a pendulum or similar energy carrier then strikes the
specimen. The energy absorbed by the specimen in the breaking process is known as the
breaking energy. The breaking energy can be converted into an indication of a materials
impact resistance using such units as foot-pounds or joules.

3. Tensile Impact Test

The thickness and width of the test specimen is recorded. The specimen
is then clamped to the crosshead and placed into the pendulum. The
pendulum is released and allowed to strike the anvil breaking the
specimen. The tensile impact energy is recorded and then corrected
impact energy is calculated.