UNIVERSITY OF JOHANNESBURG

Exam
6 June 2012
APK D RING 105
08h30 – 11h30

COURSE : ENGINEERING TIME : 3 hours

SUBJECT : SCIENCE OF MATERIAL 3A MARKS : 130
SUBJECT CODE : MTK3A11

Examiner : N Janse van Rensburg

Moderator/: : Prof. RF Laubscher

Hierdie vraestel bestaan uit 10 bladsye / This paper consists of 10 pages

• Requirements : Calculator
• This examination is closed book.
• Answer all questions in Section A and answer one question in section B.

Page 1 of 10
Section A [110]

Answer all questions in Section A

QUESTION 1 [26]

1.1. Steel has probably the widest range of applications of any material. Literally
thousands of different steel products are produced by steel mills from a cast
shape, either ingots or the shape that exits the concast process.

1.1.1. Explain how hot and cold finishing alters steel properties;
1.1.2. Discuss the effect of hot and cold finishing on the hardenability of steels
1.1.3. Discuss the difference between hot and cold finished steel products;.
(12)

Figure 1.1—Iron–iron carbide phase diagram

1.2. For the iron–iron carbide phase diagram above:

1.2.1. Discuss and illustrate the development of a hypoeutectoid composition

C0, as it is slowly cooled from within the austenite phase region to
below the eutectoid temperature. (10)

1.2.2. For the same hypoeutectoid composition C0, how does the
microstructure develop under non-equilibrium conditions? (4)

Page 2 of 10
QUESTION 2 [30]

Perhaps one of the most important tasks that an engineer may be called upon to
perform is that of materials selection with regard to component design. The choice of
material for an engineering application – or its substitution for another material with
better engineering, economic, or environmental properties - is fundamental in most
manufacturing industries. Inappropriate or improper decisions can be disastrous from
both safety and economic perspectives.

2.1. Name three families in the engineering material kingdom and list two attributes
of each family. (9)

2.2. Discuss a material selection strategy that you can employ in the design
process. (8)

2.3. Consider a thin-walled spherical tank of radius r and thickness t as shown in

figure 2.1 below. The tank is subjected to an internal pressure p and has a
radial crack of length 2a.

Figure 2.1—Schematic diagram showing the cross section of a

spherical tank that is subjected to an internal pressure 𝑝

A design often utilised with pressure vessels is termed leak-before-break.

Using the principles of fracture mechanics, allowances is made for the growth
of a crack through the thickness of the vessel wall prior to the occurrence of
rapid crack propagation. Thus, the crack will completely penetrate the wall
without catastrophic failure, allowing for its detection by leaking of pressurised
fluid.

Assume that the circumferential wall stress 𝜎 is a function of the pressure 𝑝 in

𝑝𝑟
the vessel and the radius 𝑟 and the wall thickness 𝑡 according to 𝜎 = 2𝑡

2.3.1. Define the term plain strain fracture toughness, K Ic (4)

2.3.2. What assumption can be made regarding the critical crack length in order to
meet the leak-before-break criterion? (2)
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2.3.3. Using the leak-before-break criterion and principals of fracture mechanics,
derive the appropriate material index by which one can rank the materials
listed in table 5.1 (7)

Table 5.1—Material properties of various engineering materials

Material Yield strength Fracture toughness
(𝑀𝑃𝑎) (𝑀𝑃𝑎√𝑚)
1040 290 54.0
4140 tempered at 315°C 1570 65.0
17-7PH 1210 76.0

QUESTION 3 [54]

Read the following case study of a failure analysis that was performed on a sheared
shaft of a brine recycle pump and answer the questions that follow:

Al-Jubail plants Phase 2 A&B consist of 40 desal units. Each unit operated with two brine recycle pumps.
Pump columns and elbows are fabricated by Ni-resist D2 construction material in all four areas. In C-2
and C-3 the brine recycle pump columns and elbow were failed by stress corrosion cracking (SCC), while
C4 and C-5 brine recycle pumps were free from damage. The results of investigation had clearly shown
that the cause of failure was originated from poor material selection. Therefore, the columns and elbows
were replaced by 2205 duplex stainless steel, which has better corrosion resistance properties.

The upper and lower columns and elbow of brine recycle pump (A) of desal # 15 were replaced in 1997.
At this time, the pump was overhauled. During the period between last overhauled and failure, two new
rewind motors were installed.

The following information was gathered during the visual inspection:

1. Pump was sheared at two locations.
2. Many cracks were found in key area.
3. The failure appeared to be fatigue fracture.
4. Sleeve was broken in several pieces.

The following information was gathered from the operations data sheet:
1. Unit was tripped or shutdown on 30/10/2004 between 12:00 and 16:00 hours.
2. Unit was restarted between 16:00 and 20:00 hours with one pump only (Pump B) on the same
day.
3. On 31/ 10/2004, between 16:00 and 20:00 hours, the pump B trip again.
4. No information about the reason of second trip was available.
5. Pump A was running without any indication of problems as per plant staff.
6. Pump was not returned to service after the first trip due to the failure.

The following information was gathered from the vibrations records:

1. On Aug 19, 2000 new rewound motor was installed.
2. The vibrations of new motor were considered to be high.
3. The vibration of coupled motor and pump was slightly high but in acceptable range.
4. The pump was kept in operation.
5. On 8/9/2002, abnormal sound from water cooling line was recorded.
6. On 1/11/2003 abnormal sound was heard at discharge.
7. Vibrations were in the same range (104 μ at 1x).
8. On 26/1/2004 new rewound motor was installed.
9. Solo ran vibrations were high.
10. Balancing of motor was carried out.
11. After coupling vibrations of pump was kept as they were before motor replacement (slightly higher
than 102 μ).
Page 4 of 10
 12. Last vibration reading recorded before incident was on 8/8/2004.
13. Startup with present of T&I was carried out on 31/10/2004, one day after unit trip. Pump was
found noisy and not taken load during test run.
14. Motor was transferred to desal 19 (P-3B), solo run was carried out on 6/11/04 as per T&I vibration
records.
15. A metal piece was found inside motor.
16. T&I recommended internal inspection of the pump by WR#1888619 dated 18/12/2004.

Non-destructive testing revealed cracks visible on the shaft in the key position. These cracks were
concentrated in one edge area as shown in Figure 3.1. (A) and (B). Two other brine recycle pump shafts
were tested by Dye Penetrant Testing (D-1 P3-B & D-33 P3-B) and no cracks were found.

Figure 3.1 ― Concentration of cracks on the key edge cut into the shaft.

Table 3.1 shows the chemical analysis of the broken shaft material. The results of analysis show the shaft
material is Austenitic 316 SS. From the closer visual inspection of the failed parts, many cracks were
found in different locations especially in key area. Also, some pitting was found on the shaft surface which
indicates corrosion activities on the shaft. From the operation data sheet, it appeared that the final stage
of failure was occurred during the start-up of the unit after the trip.

Page 5 of 10
Table 3. 1 ― Shaft Material Analysis

Figure 3.2 shows the location of shearing in bearing area. The accumulation of corrosion product could be
clearly seen in the sheared area. This corrosion initiated in sheared area due to the non-availability of
protective film due to the shearing. Figure 3.3 shows the failed shaft after removal from its location.

Figure 3.2 ― Shearing in the bearing area

Figure 3.3 ― Closer view of first rupture in the shaft

The material was evaluated for any change in general specifications. The chemical analysis of shaft
shows typical Austenitic 316 SS material which is as per the design requirements and the composition is
listed in Table 3.1. The microstructure did not show any abnormality. Also, the hardness of material does
not show any deterioration of material as shown in Table 3.2. From the visual inspection, some pitting was
observed on the shaft surface. Figure 3.4 shows these pits. EDX analysis indicated the presence of
chloride ions in the pits. This indicates the initiation of corrosion process in the shaft area. The corrosion
would have initiated during the operation and/or during long or short shut down.

Page 6 of 10
Table 3. 2 ― Hardness Values of Broken Shaft

Figure 3.4 ― Pitting corrosion on the shaft surface

Figure 3.5 shows the fracture surface of the shaft. The crack initiation was located in key area.

Figure 3.5 ― Closer view of one face of the shaft fracture surface

3.1. Stainless steels are categorised according to microstructure. List 3 types of

stainless steels, their general application (according to their general properties),
hardenability characteristics, and an example of each type. (12)

3.2. Name one the major effect of the following alloying elements found during
chemical analysis:

3.2.1. Chromium
3.2.2. Nickel
3.2.3. Manganese
3.2.4. Molybdenum (4)

Page 7 of 10
3.3. Taking into account the events leading to the failure of the shaft, give an
possible explanation of the failure mechanisms that played a role in his failure
(4)

3.4. Define fatigue and discuss 3 factors that affect the fatigue life of a component.
(8)

3.5. Pitting and possible crevice corrosion was observed. Define these types of
corrosion and comment on the mechanisms responsible for causing these types
of corrosion. (4)

3.6. Many factors can control the tendency for a material to corrode. Discuss the
effect of material properties and the environment when considering corrosion.
(12)

3.7. Non-Destructive Testing is defined as a family of techniques used to identify

surface or internal flaws that could affect the serviceability of a raw material or
component without damaging or destroying it. Which N.D.T. technique would
you use to detect the following flaws. Briefly describe each technique:

3.7.1. Flaws beneath the surface of 20mm wide stainless steel bloom?
3.7.2. Surface and near-surface flaws of a C-steel component?
3.7.3. Flaws in weldments? (6)

3.8. If you where the engineer investigating this failure, what recommendations
would you make. (4)

Page 8 of 10
Section B [20]

Select and answer only one 20 mark question in section B.

QUESTION 4 [20]

Tool steels evolved from alloy development aimed at hardening heavy sections and
using less severe quenching media.

4.1. Identify 4 categories of tool steels and identify two typical applications for each
category. (12)

4.2. Discuss the hardening characteristics of tool steels in terms of safety in

hardening, depth of hardening, size change in hardening and resistance to
decarburization. (8)

QUESTION 5 [20]

Tribology is the science of the mechanisms of friction, lubrication, and wear of

interacting surfaces that are in relative motion. Many manifestations of tribology are
beneficial and make modern life possible. Many others are serious nuisances, and
careful design is necessary to overcome problems caused by excessive friction or
wear.

5.1. Characterise each of the following types of wear as either (a) erosion, (b)
adhesive wear, (c) abrasion wear or (d) surface fatigue: (10)

5.1.1. Spalling
5.1.2. Galling
5.1.3. Pitting
5.1.4. Fretting
5.1.5. Gouging
5.1.6. Scuffing
5.1.7. Impact wear
5.1.8. Polishing
5.1.9. Berneling
5.1.10. Cavitation

5.2. What preventative measures can be taken to avoid low stress abrasion wear?
(10)

Page 9 of 10
QUESTION 6 [20]

Given the data in Table 6.1, select the appropriate material for the following
applications. Motivate your answer (20)

6.1. Shaft for a gear train

6.2. Plastic injection moulding cavity
6.3. Short-run punch-press tooling, shear blades and cutting tools
6.4. Bushings and aircraft tubing
6.5. High temperature moulding
6.6. Corrosion resisting cutting tools
6.7. Wear plates in mining applications
6.8. Drawing dies, cutlery
6.9. Surgical instruments, cutlery
6.10. Cutting tools
Table 6.1—Comparison of properties of various materials

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