B.ENG. (HONS.

) COURSE
MECHANICAL ENGINEERING STREAM
YEAR ll – SEMESTER I
JANUARY 2020 SESSION OF EXAMINATIONS

MME 2203-Ferrous and Non-Ferrous Materials 1st February 2020

08:30am-10:35am

This paper contains FIVE questions. You are to attempt FOUR.

Stationery: Use of calculators is allowed

1. (a) Boron steels are amongst the strongest metallic materials used on European
vehicles. Write shorts notes on boron as a hardenability agent in steel.
(4 marks)

(b) Maraging steels comprise a special class of ultra-high-strength steels.

(i) Write notes to describe the main characteristics of Maraging steels which sets
them apart from conventional high-strength steels.
(5 marks)

(ii) List two application areas where Maraging steels are used extensively and
explain why.
(6 marks)

(c) Tool steels represent an important category of steels and are used extensively in the
forming and machining of metals. They have evolved to attain different
combinations of strength, impact toughness and wear resistance at a range of
operating temperatures enabling them to perform specific functions including hot
forming, cold working and high-speed machining.

Suggest a tool steel for each of the following applications and explain its main
characteristics (microstructure, composition, properties) that makes it a suitable
choice.

(i) High speed lathe cutting tools;

(ii) Jackhammer flat chisel bits.

(5, 5 marks)

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2. (a) What are the three main types of plain carbon steels?

(3 marks)

(b) List four elements other than iron and carbon which are commonly present in plain
carbon steels.
(4 marks)

(c) Depending on the type of plain carbon steel and its delivery condition (such as cold
formed; hot forged etc) the steels can benefit from different types of heat
treatments. List three main types of heat treatment used for plain carbon steels.
(3 marks)

(d) For any two of the three types of steel listed in your answer to question 2 (a), give a
typical application and the most appropriate heat treatment or work condition of the
steel. Give reasons for your choice of application and steel condition.
(6 marks)

(e) List and briefly explain three main purposes for which alloying elements are added to
steel.
(3, 3, 3 marks)

3. (a) Sketch the Fe-Cr phase diagram.

(4 marks)

(b) Explain the importance of alloy chemistry in the production of austenitic, ferritic and
martensitic stainless steels. In your answer refer to the Fe-Cr phase diagram.
(4, 4, 4 marks)

(c) Name a cast iron that contains graphite with the following morphologies:

(i) Flake; (ii) Rosette; and (iii) Spherical.

(3 marks)

(d) A ‘Ni-hard’ alloy cast iron comprise 88Fe-2.8C-1.2Si-4Ni-2Cr (in wt%).

(i) Which of the elements C, Si, Ni and Cr would promote the formation of graphite
in the microstructure of cast irons?
(2 marks)
(ii) What is a typical microstructure of ‘Ni-hard’ cast iron?
(2 marks)

(iii) Give one typical application for ‘Ni-hard’ alloy cast iron and one main reason
why.
(1, 1 marks)

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4. (a) List five most commonly alloying elements present in commercial aluminum alloys to
provide increased strength.
(5 marks)

(b) List three main strengthening mechanisms of wrought aluminum alloys. For each,
assign two wrought aluminum alloy families that may undergo significant
strengthening by such mechanism.
(6 marks)

(c) Assign a wrought aluminium alloy suitable for each of the following applications.
Give reasons for your choice.

(i) Extruded sections of a balcony door frame;

(ii) The superstructure of a cargo ship; and

(iii) The upper wing skin of a jetliner.

(3, 3, 3 marks)

(d) State whether the following statements are true or false:

(i) Quenching of wrought Al-Cu aluminium (2xxx series) alloys will result in
martensite formation.

(ii) Wrought Al-Zn-Mg/Cu (7xxx series) alloys with a Zn + Mg content in excess of 6

wt% generally exhibit good weldability.

(iii) Copper is added to Al-Mg-Si (6xxx) aluminium alloys to enhance their corrosion
resistance.

(iv) Cast Aluminium-magnesium (5xx.x) series alloys display poor castability.

(v) As a general rule, Al-Cu (2xxx) series alloys display good weldability.
(5 marks)

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5. (a) Copper and its alloys make one of the major groups of commercial metals.

(i) List six primary selection criteria for this group of metals.

(3 marks)

(ii) Brass alloys display a range of characteristics depending on their composition.

Write short notes to contrast α and α+β' brasses.

(8 marks)

(iii) Suggest an application for each of the following copper based materials and give
reasons for your choice of answer.

- A high copper content alloy consisting of Cu alloyed with 1.7wt% Beryllium;

- Electrolytic tough pitch copper (Cu-ETP).

(3, 3 marks)

(b) State whether the following statements are true or false:

(i) Chromium-copper, high copper content alloys are not responsive to age
hardening heat treatments.

(ii) Low Tin-bronze alloys can be cold worked.

(iii) Nickel-silvers are copper based alloys that contain copper, nickel and zinc.

(iv) Cold working of annealed pure copper can only produce a small degree of
strengthening.
(v) Gunmetal alloys are used to produce pressure tight valve components for sea
water applications.

(vi) Some aluminium bronze alloys can be quenched to produce a non-equilibrium

martensitic structure similar to the one produced in steel.

(vii) Adding small amounts of silver or cadmium to deoxidized copper, imparts

resistance to softening for the durations and temperatures used in soldering
operations.

(viii) Phosphorous is used to deoxidise copper resulting in a weldable material.

(8 marks)

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