Material Science and Metallurgy

Sub. Code: ME3T3 LTPC

3003

Unit – I: Structure of Metal and alloys

Part- A
1. Define metallic bonding.
2. Define space lattice
3. State the use of miller indices.
4. List the common crystal defects.
5. State Ficks first law of diffusion
6. Define diffusion.
7. List out the application of diffusion.
8. What is kirkendall effect?
9. What is the role of diffusion in metals and alloys
10. Draw a). BCC, b). FCC and c). HCP crystals
11. What are the seven crystal systems in metals?
12. Define bravias lattices.
13. Define coordination number
14. Define atomic packing factor
15. Define atimic radius
16. What are the factors affecting structure of solids?
17. List out the various imperfections in solids.
18. What do mean by edge dislocation?
19. State two types of solid solutions.
20. Define polymorphism and allotrophy.
21. Draw the following planes in a FCC structures, (200), (220), and (112)

Part – B
1. Explain different types of crystal imperfections in metallic materials.
2. Describe the factors which affect the formation of solid solutions between two metals.
3. Discuss the role of dislocations in metallic materials. List the differences between the
edge dislocation and screw dislocation.
4. Define coordination number and atomic packing factor. Determine coordination number
and atomic packing factor for the following, (i). BCC, (ii). FCC, (iii). HCP.
5. With the aid of neat sketch explain edge dislocation and screw dislocation.
6. Explain the phenomenon diffusion and factors affecting the diffusion.
7. Explain different types of surface imperfection in detail.
8. Draw a neat sketch of a BCC unit cell. Derive the relation between lattice parameter and
atomic radius for a BCC unit cell. Calculate its atomic packing factor.
9. Explain the terms a). Space lattice, b). Coordination number, c). Atomic packing factor.
10. What is strengthening mechanism? Explain various strengthening mechanism in the
metallic materials.
11. Discuss the various types of bonds occurring in a crystal. Discuss any two of them in
detail.

Unit – II: Mechanical Properties

Part - A
1. What is meant by mechanical properties of materials?
2. Distinguish between elasticity and plasticity.
3. Differentiate between ductility and malleability.
4. Define the terms brittleness and hardness.
5. What do you mean by toughness and stiffness?
6. What is the effect of the grain size on the mechanical properties of the
7. materials?
8. Distinguish between elastic and plastic deformation of solid.
9. Define the terms slip and twinning.
10. List the different types of fracture in a material.
11. What is brittle fracture?
12. What is ductile fracture?
13. Distinguish between brittle fracture and ductile fracture.
14. What is meant by fatigue fracture?
15. What is S-N diagram? What is the significance of it?
16. What are the factors affecting creep?
17. How can you prevent the creep fractures?
18. What is the difference between Izod and Charpy impact testing methods?
19. Define the term elasticity and plasticity.
20. Classify the different hardness testing methods.
21. Define creep.
22. Distinguish between slip and twinning

Part - B

1. Explain the two modes of plastic deformation. describe the working of universal testing
machine with suitable diagram.
2. Write down the procedure for preparing Charpy and Izod specimens for impact testing
and also explain how testing is performed?
3. Explain the mechanism of plastic deformation by slip and twinning with neat sketch.
4. Explain the testing procedure for determining the following properties. a). Rockwell
hardness test, b). Brinell hardness number, c). Vickers hardness test
5. Sketch and describe the fatigue test.
6. Differentiate between ductile fracture and brittle fracture
7. Draw creep curve and explain the different stages of creep damage.
8. Explain the term machinability and weldability of metals.
9. Describe the following, a). Slip and Twinning, b). Intermetallic compounds in metals, c).
Determination of hardenability.
10. Describe the following, a). Toughness, b). Hardness, c). Tensile strength, d). Ductility

Unit – III: Phase Diagrams

 Part – A

1. What is an alloy?
2. How many components are found in an alloy?
3. What is meant by base metal?
4. What are alloying elements?
5. Differentiate between substitutional and interstitial solid solution.
6. What are intermetallic compounds?
7. Define ‘phase’. What different kinds of phases are possible?
8. What is an equilibrium phase diagram?
9. What are the advantages of the equilibrium diagrams?
10. State Gibb’s phase rule?
11. What are cooling curves?
12. What is liquidus line? and Solidus line? and A solvus line?
13. What pieces of information can be obtained for each point in a phase diagram?
14. Differentiate between eutectic and eutectoid reactions.
15. Distinguish between peritectic and peritectoid reactions.
16. What do you understand by ‘allotropy of iron’?
17. Define: ferrite and austenite.
18. Define: Cementite and Pearlite?
19. Define: martensite, and bainite?
20. What is meant by eutectoid, hypoeutectoid, hypereutectoid steels?
21. What is phase diagram?
22. State Gibbs phase rule?
23. What is the significance of lever rule?
24. Define the term solid solutions.
25. What is TTT diagram?
26. What is the significance of TTT diagram in the heat treatment of steel?
27. What is CCT diagram?

Part - B

1. With the help of neat sketch explain the two types of solid solution. Types of solid
solution:
2. Sketch neatly the ideal iron- carbide binary equilibrium diagram, indicating temperatures,
composition and different phases present. Also explain the peritectic reaction of this
system.
3. Discuss the classification, micro structure properties and application of steel
4. Discuss the composition, Properties and apply of the following cast iron.
5. Explain:
i. Eutectic reaction
ii. Eutectoid reaction
iii. Peritectic reaction
iv. Peritectoid reaction
6. Explain the procedural steps for constructing the binary phase diagram where the
components show complete liquid and solid solubility. Draw the labelled diagram and
 name the system. Give one example for the alloy system showing above mentioned
behavior.
7. Explain TTT curve of for steel.
8. Give an account of how an isothermal transformation diagram for a steel may be
compiled. Describe the structures to be expected when a austenite transforms at
temperatures below the critical point.
9. Explain the process of powder metallurgy. State its advantages, limitations and
applications of powder metallurgy.
10. State the essential stages involved in the process of manufacture by powder metallurgy
technique. Using examples of typical components, explain the advantages and practical
limitations of the process.

Unit – IV: Heat treatment

Part - A

1. Define the term ‘heat treatment’.

2. What are the purposes of the processing heat treatments?
3. List the various stages of a heat treatment process.
4. List some of the important heat treatment operations widely used.
5. What is meant by annealing?
6. What are the purposes of annealing?
7. List the different types of annealing.
8. What is meant by normalizing?
9. Differentiate between normalizing and full annealing.
10. What is quenching? List some of the quenching medium generally used in industries.
11. What are the factors should be considered while selecting a quenching medium?
12. Distinguish the work hardening with the age hardening process.
13. What is significance of the critical cooling rate?
14. What is meant by hardenability? What are the factors affecting it?
15. What is the benefit of the Jominy end-quench test?
16. What is martempering and austempering?
17. What do you mean by the term case hardening?
18. Differentiate between pack carburizing and gas carburizing.

Part - B
1. Explain the short notes on Annealing
2. Write short notes stress relief annealing, recrystallisation annealing.
3. Discuss the method of constructing isothermal diagrams.
4. Explain the procedure of Jominy end quench test.
5. Explain Case hardening Classified as carburizing, nitriding, cyaniding, carbonitriding
6. Explain Vacuum Hardening and plasma Hardening
7. Explain the following terms, a). Flame hardening, b). Induction hardening.
8. Describe the following, a). Quench cracks, b). Quenching media.
9. a). Distinguish carefully between “hardness and hardenability”
b). Name and briefly describe a test which gives some identification of hardenability
10. Explain briefly the theory of tempering of alloy steels in the heat treatment process.
11. Distinguish between Austempering and Martempering. What are the effects of tempering
temperature on the mechanical properties of steel.

Unit – V: Alloys and other materials

Part – A

1. What are metals? Classify engineering materials.

2. What are ferrous metals? Classify ferrous materials.
3. State three reasons why ferrous alloys are used extensively.
4. State three characteristics of ferrous alloys that limit their utilization.
5. How can you specify a steel? What is the difference between 4140 steel and 4340
steel?
6. What are three primary groups of plain carbon steels?
7. What are alloy steels? How are alloy steels classified?
8. List four important alloying elements added in alloy steels.
9. What are the primary effects of adding Ni, and Mo in cast irons?
10. What properties do non-ferrous alloys have that usually are not associated with
ferrous alloys?
11. Write some characteristics of non-ferrous alloys that limit their utilization.
12. List the outstanding properties of copper and some typical applications.
13. What is the main difference between a brass and a bronze?
14. List at least four types of brasses used.
15. List some bronze alloys.
16. What properties have made aluminium and its alloys the most important non-
ferrous metal?
17. What are the two types of aluminium alloys?
18. What are the required characteristics of a bearing material?
19. List the bearing materials that are commonly used.
20. What are super alloys?
21. What are polymers?
22. List any four attractive characteristics of polymers.
23. Classify polymers.
24. Define the following terms: i) Monometer, ii) Homopolymer, and iii) Copolymer.
25. What is polymerisation?
26. Define the term ‘degree of polymerisation’?
27. What are the types of aluminium alloys?
28. What are bronzes? List some use of bronzes.
29. What are the effect chromium and molybdenum in low alloy steel ?
30. What is bearing alloy?
31. Distinguish between thermoplastics and thermosetting plastics.
32. Name any four thermoplastics and thermosetting plastics.
33. What advantages do thermoplastic polymers have over thermosetting polymers, and
vice versa?
34. What are the sources of raw materials for plastics?
35. What do the following ‘acronyms’ refer: PE, PP, PS, PVC, PTFE, PMMA
36. List the properties and typical applications of PVC.
37. List some of the distinct characteristics of engineering ceramics
38. What are the main classifications of ceramic materials?
39. Name any four engineering ceramics.
40. Compare the fracture toughness of alumina, silicon carbide, and silicon nitride.
41. What are composites?
42. What are the constituents of composites?
43. How are composite materials classified?
44. What is the role of matrix material in a composite?
45. List the various matrix materials used.
46. What are bronzes? List some use of bronzes.
47. What is bearing alloy?
48. Define: FRP
49. Give few important characteristic of polymer.
50. What is hybrid composite?
51. How are refractories classified?
52. What are PEEK and PMMA?
53. Name any four Commodity plastics and Engineering plastics?
54. Distinguish between Thermo Plastics and Thermosetting Plastics?
55. State the advantages of fibre reinforced composites.

Part – B

1. a. Enumerate the composition and applications of following alloys.

(1) Cupronickel, (2) Bronze
b. State the effects of the following alloying elements in steel bearing alloy.
2. State the effects of following alloying elements: Chromium, Molybedenum,
3. Discuss different types of copper alloys and their properties and applications.
4. What are the types of titanium alloy, their composition properties and applications?
5. Describe the molecular structure, properties and application of the following polymers.
a. Polyvinyl chloride (PVC) (4)
b. Polystyrene (PS) (4)
c. Polyethylene terephthalate (PET) (4)
d. Poly carbonate (4)
6. Describe the molecular structure, properties and application of the following
polymeric materials.
1. Poly methyl methacrylate (PMMA) (4)
2. Poly tetra f1uoro ethylene (PTFE) (4)
3. Polyethylene terephthalate (PET) (4)
4. Acryl nitride butadiene styrene. (4)
7. Explain the following Engineering Ceramics: a) AL2O3, b) SiC, c) Si3N4
8. Describe the difference between thermoplastics and thermosetting plastics.
9. What do you understand by polymerization? With the help of suitable examples, compare
and contrast the process of addition polymerization and condensation polymerization.
10. Difference between addition polymerization and condensation polymerization
11. Name the suitable alloys, polymers and ceramics for manufacturing the following items.
(i) Bush, (ii) Furnace heating element,(iii) Lathe bed,(iv) Coins (v)Girders for airship (vi)
Big end bearing (vii)Knobs (viii) Windshields (ix)Conduit pipes (xi)Touch screen (xi)
Turbine blade, (xii) Furnace linings (xiii) Grinding(abrasive) wheels
(xiv)Coating on cutting inserts (xv) Cutting inserts for ferrous alloys