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College of Science and Technology
College of Science and Technology
SCHOOL OF ENGINEERING
P.O. Box: 3900 Kigali, Rwanda, Tel: +250 252 574696/ 574698, Fax: +250 252 571925/ 571924,
E-mail: hmee@cst.ac.rw
DEPARTMENT OF MECHANICAL AND ENERGY ENGINEERING
(Nyarugenege Campus)
SUBJECT CODE & NAME: MEE 3262 - ENGINEERING MATERIALS & METALLURGY
DATE OF SUBMISSION:
SIGNATURE:
Enclosed with:
2. Metallic Materials
Structural aspects of solidification & solid phase transformation in binary systems,
ferrous and non - ferrous metals, steel making processes, heat treatment, TTT diagram.
6. Environmental Degradation
Metal degradation by atmosphere, aqueous & galvanic corrosion, stress corrosion
cracking, methods of corrosion prevention, behaviour of metal at elevated temperatures,
pyrometer, oxidation, scalling and creep. Chemical degradation of ceramics and
polymers, radiation damage surface. Improvement against degradation.
COLLEGE OF SCIENCE AND TECHNOLOGY
SCHOOL OF ENGINEERING
INSTRUCTIONS
a) (4 Marks)
i. What is the difference between corrosion and structure failure in Engineering material?
/ 2 Marks
ii. Give four reasons why we need to understand engineering materials. / 2 Marks
Answer: (4 Marks)
i.
ii. Four reasons why we need to understand engineering materials: Any answer is
acceptable
/ 2 Marks: 0.5 mark each
An understanding of material is fundamental in the study of manufacturing
processes (transformation)
To help us select the best materials for a design
To help us make the design right for the selected materials.
To know available materials, the advantages and disadvantages of these
materials.
Properties of materials, and how these can change (e.g., with time, temperature,
processing, environment, and so on…)
A material composition, properties, structure, processing methods and cost, the
loading on the material and the environment in which the material is used
(Temperature, Chemical, Electrical, Magnetic)
b) Explain how bond rupture occur in polymers by giving one typical example and a solution to
prevent this polymer degradation phenomenon. (5 Marks)
Answer:
o Bond Rupture phenomenon in polymers:
• Rupture of covalent bonds in polymer molecules can be caused by chemical reaction,
exposure to heat or exposure to radiation. Bond rupture results in a reduction in
average molecular weight and associated changes in properties of the material.
/ 2 Marks
• The most common form of bond rupture is that caused by ultraviolet (UV) radiation in
daylight. This can cause polymers to discolour, become brittle, crack and fail. Stabilizer
additives can be added to protect polymers from radiation damage.
/ 2 Marks
• An example of bond rupture due to chemical reaction is the reaction of parts of the
polymer chains in vulcanized rubber with ozone (O3) gas in the atmosphere. This can
result in the cracking of old rubber tyres.
Or
In some polymers, elevated temperatures can result in bond rupture. An example is
poly(vinyl chloride), PVC, which will discolour and change properties at 200 0C in just a
few minutes. (Stabilizers additives can be used to reduce bond rupture due to heating).
/ 1 Mark
c) (9 Marks)
i. What is the result when the concentration of alloying elements is greater than the solubility
limit? / 2 Marks
Answer: / 2 Marks
When the concentration of alloying elements is greater than the solubility limit, there
is
Formation of another different phase by excess atoms, which is a second phase
/ 1 Mark
Different crystal structure and/ or different mechanical properties
/ 1 Mark
ii. With a neat and clear supporting sketch define and explain all steps of float glass process.
/7 Marks
Answer:
Float glass process is a process through which a molten glass is floated over a bath of
molten tin, where it begins to cool to form a flat product, then is slowly cooled and cut into
the required lengths. Is used to form flat sheets of glasses, such as window glass.
/ 2 Marks
Sketch: / 7 Marks: 0.5 Marks each component and 0.5 Mark each step explanation
(note: weighing and mixing, and melting areas are counted in step exolaination)
(a) The microstructure of a Cu-Ag alloy at 775ºC (Figure 1) consists of primary α and eutectic
microstructures. If the mass fractions of these two micro-constituents are 0.73 and 0.27,
respectively, determine the alloy composition. (2 Marks)
Figure 1: Cu-Ag Phase diagram
Answer:
First, you need to realize that primary α refers to the α phase that precipitates out prior to the
eutectic reaction. Thus, the weight fraction primary α is equal to the weight fraction α just
above the eutectic temperature, 779ºC. Similarly, the weight fraction eutectic microstructure
is equal to the weight fraction L just above this temperature.
a) (5 Marks)
i. What is the main material that makes a cooking pan? What are the three advantageous
characteristics to select that material for cooking pan manufacturing?
/2 Marks
Answer: /2 Marks
The main material is Aluminium / 0.5 Mark
The three advantageous characteristics to select that material for cooking pan
manufacturing are (any answer is acceptable): / 1.5 Mark
• Ductile and highly formable (easy to manufacture, Easily machined and cast,
weldable )
• Lightweight (Excellent Strength-to-weight ratio with TS ~ 50-800 MPa, density =
1/3 that of steel )
• High heat conduction (High Thermal Conductivity )
• Inert surface oxide (No contamination): Corrosion resistant
• Tough
• Many alloys available
ii. What are the three effects of metal plastic deformation? /3 Marks
Answer:
Plastic deformation of metals (e.g. During processing operations) can
o Change grain shape
o Cause strain hardening and
o Increase the number of dislocations
b) (5 Marks)
i. Differentiate annealing and grain growth processes? / 3 Marks
ii. What is the purpose of Hall–Petch method? / 2 Marks
Answer:
Grain growth – The increase in size of some grains by diffusion of atoms across grain
boundaries from other grains, and decrease in size (and eventual disappearance) of other
grains. The result is an increase in average grain size and a reduction in the total number of
grains. / 1.5 Marks
c) (5 Marks)
iii. A 0.45%C hypoeutectoid plain-carbon (figure 2) steel is slowly cooled from 9500C to a
temperature just slightly above 7230C. Calculate the weight percent austenite and weight percent
proeutectoid ferrite in this steel. / 3 Mark
Figure 2: Iron carbon phase diagram
Solution: (5 Marks)
i. The structure that is formed when there is a moderate cooling of austenite is Bainite
/ 1 Mark
ii. The most stronger among all structures formed during a certain cooling of austenite
structure is Martensite / 0.5 Mark
and the most ductile is spheroidite / 0.5 Mark
iii.
Autenite ( ) = = = = 57.99% or 58% / 1.5 Mark
Answer: (2 Marks)
Crazing is the formation of crazes for energy absorption to increases the fracture
toughness of the polymer. / 1 Mark
Answer:
The glass-transition phenomenon occurs with amorphous or non-crystalline polymers that, when
cooled from a liquid melt, become rigid solids yet retain the disordered molecular structure that
is characteristic of the liquid state. ( a reversible transition in amorphous materials from a hard
and relatively brittle state into a molten or rubber-like state). This is due to a reduction in motion
of large segments of molecular chains with decreasing temperature. Upon cooling, the glass
transition corresponds to the gradual transformation from a liquid to a rubbery material and
finally to a rigid solid.
Ironmaking – The starting point for the manufacture of steel / 0.5 Mark
Iron is One of the most abundant elements in the world (Iron makes up 5% of the earth’s
crust. Iron exists naturally as various types of iron ore (rocks containing iron oxides)
/ 0.5 Mark
Iron is extracted from iron ore in blast furnace (a large cylinder , lined with refractory
bricks) / 0.5 Mark
The furnace is filled layers of Iron ore, Coke which generates high temperature when
burning, Limestone (calcium Carbonate), and combines with impurities in molten Fe to
form slag that floats on the surface and can be removed. / 0.5 Mark
Air that is preheated to around 11000C is blasted into the furnace through the nozzles
called Tuyeres. / 1 Mark
The high temperature causes the coke to burn, and temperatures of 1650 0C are achieved.
/ 0.5 Mark
At 16500C, Oxygen reacts with carbon (in the coke) to produce carbon monoxide gas, and
Carbon monoxide reacts with iron oxide (in the iron ore) to produce molten iron and
carbon dioxide. / 1 Mark
Molten corrects at the bottom of the blast furnace / 0.5 Mark
Impurities float to the top as slag and are removed / 0.5 Mark
The molten iron is transferred into ladles (each holding up to 160 tons of iron) and
transported to steelmaking plant / 0.5 Mark
a) (3 Marks)
i. As a mechanical engineer, what is the best way to ensure the capability to decide on good
engineering materials? / 1 Mark
Answer:
As mechanical engineer, the best way of ensuring capability to decide on good engineering
materials is to know a little about a lot of engineering materials.
/ 1 Mark
ii. Give four among the most used ways to find information about materials when there is a need
to select a material. / 2 Marks
Answer: / 2 Marks
o Testing /0.5mark
o Material manufacturers or suppliers /0.5mark
o Standard documents /0.5mark
o Textbooks /0.5mark
iii. State the three types of technical ceramics / 3 Marks
Answer:
b) (5 Marks)
Answer: (5 Marks)
i. Fiber-reinforced composites are usually designed to gain a material with a high specific
strength and/or a high specific modulus. / 1 Mark
ii. Factors influencing properties of engineering composites are:
o The properties of the two phases /0.5mark
o The properties of the interface (bonding) between the matrix and the
reinforcement phases. /0.5mark
Answer: (4 Marks)
Cermets are composites of ceramic particles (strong, brittle) in a metal matrix (soft,
ductile) that enhances toughness. / 2 Marks
Portland Cement Concrete - The ingredients for this concrete are portland cement, a fine
aggregate (sand), a coarse aggregate (gravel), and water. / 2 Marks
End!