ME 2820: MATERIALS PROCESSING

EXAM 1 B-2021

QUESTION 1 (35 Points)

(a) A 0.505 inch diameter cylindrical specimen with a 2.000 inch gauge length is pulled in tension
to generate the load vs. elongation data presented in Table I. Use this data to do the following:
(i) Plot the engineering stress versus engineering strain (3 points)
(ii) Determine the engineering yield strength of the material (4 points)
(iii) Determine the engineering ultimate tensile strength of the material (4 points)
(iv) Determine the fracture strength of the material (4 points)
(v) Determine the modulus of stiffness of the material (4 points)
(vi) Determine the modulus of resilience of the material (4 points)
(b) Using the data in Table I, and Equations (1) and (2), do the following:
(i) Plot the true stress vs. true strain curve (3 points)
(ii) Determine the strength coefficient (3 points)
(iii) Determine the strain hardening coefficient (3 points)
(iv) Write the true stress vs. true strain equation for this material (3 points)

𝜎"#$% = 𝜎%'( × *1 + 𝜀%'( . (1)

𝜀"#$% = 𝑙𝑛*1 + 𝜀%'( . (2)

Table I
Note that the Equations become invalid past the point
lbf in. at which necking begins; therefore, measured
0 2.000 diameters are given in Table II for these data points,
1,650 2.002 and they should be used in the true stress – true strain
3,400 2.004 computations.
5,200 2.006
6,850 2.008
7,750 2.01
8,650 2.02 Table II
9,300 2.04
10,100 2.08 lbf Length (in.) Diameter (in.)
10,400 2.12 10,400 2.240 0.461
10,650 2.16
10,700 2.2
10,100 2.270 0.431
10,400 2.24 9,600 2.300 0.418
10,100 2.27 8,200 2.330 0.370
9,600 2.3
8,200 2.33
QUESTION 2 (30 Points)
(a) A cylindrical connecting rod in a machine is subjected to cyclic uniaxial tension-
compression stress loading over a long period of time. If the load amplitude is
10,000 N, given the data in Table III, calculate the minimum allowable rod
diameter that ensures fatigue failure will not occur at 107 cycles. (15 points)

Table III

Stress Amplitude (MPa) Number of Cycles to Failure

310 2 × 105
223 1 × 106
191 3 × 106
168 1 × 107
153 3 × 107
143 1 × 108
134 3 × 108
127 1 × 109

(b) A bar 975 mm long made from an aluminum alloy is exposed to a tensile stress of
2.75 MPa at 480°C. The data in Table VI was obtained from the alloy at this
temperature and stress magnitude.
(i) Plot the data as strain vs. time (2.5 points)
(ii) Determine the steady-state creep rate (2.5 points)
(iii) Determine the elongation of the bar after exposure to these conditions for 4
minutes. (10 points)
Table VI
QUESTION 3 (35 Points)
(a) Label the diagram shown as Figure 1. (1 point each)

Figure 1

(b) Identify the casting process that is most suited for making each of the following: (1 point each)
(i) Thirty-pound brass bell
(ii) Zinc zipper
(iii) Aluminum automobile piston
(iv) One-foot tall bronze figurine
(v) Six-feet long steel pipe
(c) The flow rate of liquid metal into the cylindrical down sprue of a mold is 1 liter/second. If the
cross-sectional area at the top of the sprue is 800 mm2 and the sprue’s length is 180 mm, what
should be the area at the bottom of the sprue in order to avoid air aspiration. (8 points)
(d) Calculate the depth of the pouring basin for the sprue in (b). (7 points)
(e) Calculate the diameter of the runner that prevents turbulent flow if the density and viscosity of
the metal being cast are 2,700 kg/m3 and 10-3 Pa.s, respectively. (7 point)