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)

ACADEMIC YEAR: 2017-2018 EXAMINATION PERIOD: JAN 2018

YEAR OF STUDY: 3 SEMESTER: I Programme: Full Time

SUBJECT CODE & NAME: MEE 3262 - ENGINEERING MATERIALS & METALLURGY

NO. OF STUDENTS: 70 DURATION:2hrs MAX. MARKS:50

DATE OF SUBMISSION:

NAME OF MODULE LEADER: MARIE AIMEE TUYIZERE FLORA

TEL: E-MAIL: +250781518944

SIGNATURE:

Enclosed with:

(i) Module Content √ (ii) Exam Questions. √ (iii) Marking scheme √

Head of Department: ERNEST MAZIMPAKA Date:

INDICATIVE CONTENT

1. Introduction to Engineering Materials

Types of materials, source of materials and their extration, crystalline and amorphous
materials. Application and selection of materials.

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.

3. Ceramics, Glasses & Refractory Materials

Composition, properties, structures of various non -metallic materials, application of

ceramics, glasses, refractory materials, methods of manufacture.

4. Polymers & Rubbers

Polymerization, Structural feature of polymers, thermoplastic polymers, thermosetting
polymers, additives, major mechanical properties, rubber (elastomers), synthesis of
rubber.
5. Composites
Introduction to composite materials, types of composite materials, methods of
fabrication of composite materials, property averaging and major mechanical properties
of composite materials.

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

DEPARTMENT OF MECHANICAL AND ENERGY ENGINEERING

(Nyarugenge Campus)

END OF SEMESTER EXAMINATION -ACADEMIC YEAR 2017-2018

YEAR: 3 SEMESTER: I GROUP: Mechanical and Energy Engineering

MODULE: MEE 3262 - ENGINEERING MATERIALS & METALLURGY

DATE: /01/2018 TIME: 2hours

MAXIMUM MARKS = 50

INSTRUCTIONS

1. This paper contains FOUR (4) questions.

2. Answer THREE (3) Questions only:
Question ONE (1) from Section “A” is Compulsory and Answer any TWO (2) from Section “B”
3. No written materials allowed.
4. Do not forget to write your Registration Number.
5. Write all your answers in the booklet provided
6. Do not write any answers on this questions paper.
7. Start each question in a NEW page
 SECTION: A

Question: 1 [20 Marks]

a) (4 Marks)
i. What is the difference between a concrete and wood material? / 2 Marks
ii. State the rule of mixtures in a composite material / 2 Marks

b) Explain the swelling phenomenon and its consequences (4 Marks)

c) (7 Marks)
i. What is the lightest of commercial metals but relatively weak and its range of tensile
strengths /1 Mark
ii. What are the factors influencing the phase structure of the material? /2.5 Marks

iii. With a neat and clear graph show the effects of recovery, recrystallization and grain growth
on microstructure and grain size; strength, hardness and ductility; and internal residual stress
in the metals. /3.5 Marks

d) For an alloy of Iron carbon of 0.40 wt% C (Figure 1) at a temperature just below the eutectoid,
determine the following: ( 5 Marks)

i. The solute and solvent between both alloy components / 1 Mark

ii. Composition of cementite Fe3C and ferrite α / 1 Mark
iii. The amount of carbide (cementite) in grams that forms per 100 g of steel / 1 Mark
iv. The amount of pearlite and pro-eutectoid ferrite α / 2 Marks
Figure 1: Iron-carbon Phase Diagram
 SECTION: B

Question: 2 [15 Marks]

a) (4 Marks)
i. Give the difference between a primarily metallic bonding and a more covalent bonding in
terms of electronegativity numbers. /1 Mark
ii. What are the two ways to prevent galvanic corrosion? /2 Marks
iii. Why is Ashby plot needed during materials selection? / 1 Mark

b) (3 Marks)
i. With a neat sketch show the point defects in the atomic lattice / 2 Marks
ii. What are the interfacial defects in the atomic lattice? /1 Mark

c) Why is it important to have movement of atoms from lattice site to lattice site? What are the
requirements? (4 Marks)

d) Define the following terms in Engineering Materials: (4 Marks)

i. Fatigue life / 1 Mark
ii. Stress Corrosion Cracking / 1 Mark
iii. Anisotropic material / 1 Mark
iv. Slip / 1 Mark
Question: 3 [15 Marks]

a) (5 Marks)
i. What are the chemical substances composing a soda-line glass? /2 Marks

ii. How is Silicon Carbide ceramic produced to use it as an abrasive? /3 Marks

b) State the three factors influencing the properties of engineering composites (3 Marks)

c) With a simplified neat sketch explain press and blow process. (7 Marks)
Question: 4 [15 Marks]

a) Define the following terms in Engineering Materials: (4 Marks)

i. Edge dislocation / 1 Mark
ii. Wrought metal / 1 Mark
iii. Endurance limit / 1 Mark
iv. Drawing / 1 Mark

b) ( 4 Marks)
i. State four characteristics of a Martensite structure / 2 Marks
ii. State four carbon effects on steel once its content is increased / 2 Marks

c) (7 Marks)
i. State four factors favoring brittle fracture in thermoplastics / 2Marks
ii. Name four major types of elastomers /2Marks
iii. With a neat sketch show different regions of polymer viscoelastic behavior /3Marks

Good Luck!
 MARKING SCHEME
SECTION: A

Question: 1 [20 Marks]

a) (4 Marks)

Solution:
i. The difference between Concrete and wood materials:

 Concrete is a composite of cement, gravel and sand phases. It is cement

strengthened by adding particulates (gravel and sand phases). / 1 Mark
 Wood is a composite of strong, flexible cellulose fibres held together by stiffer
material called lignin. / 1 Mark

ii. The rule of mixtures in composite materials applies to certain properties of composite
materials; it states that the property value is a weighted average of the property values of
the components, the weighting being by proportions of the components in the composite.
/ 2 Marks

b) (4 Marks)

Solution:
Swelling: Some polymers swell when exposed to certain liquids. In the swelling process,
molecules of the liquid are absorbed into the polymer and fit into positions between polymer
chain molecules. This forces the polymer molecules further apart and results in expansion
(or swelling) of the material.
The resulting greater spacing of polymer molecules reduces the strength and hardness of the
material, and increases ductility. Swelling can cause polymers to become weak and to fail.

c) (7 Marks)

Solution:
i. The lightest of commercial metals but relatively weak is Magnesium and the tensile
strengths of its alloys are between 69-345Mpa / 1 Mark

ii. Phase structure of the material is affected by: /2.5 Marks

 Number of different phases in the material
 Types of different phases in the material
 Sizes of different phases in the material
 shapes of different phases in the material and
 distributions of different phases in the material

iii. Solution: (3.5 Marks: 3 Marks for microstructures and graphs, and 0.5 for the
sketch)
With a neat and clear graph to show the effects of recovery, recrystallization and
grain growth on microstructure and grain size; hardness and ductility; and
internal residual stress in the metals.
d)

Figure 2: Iron-carbon Phase Diagram

Solution:

i. Iron is a solvent and Carbon is a solute / 1 Mark

ii. Composition of cementite Fe3C and ferrite α
CFe C = 6.70 wt% C /0.5 Mark

Cα = 0.022 wt% C /0.5 Mark

iii. The amount of carbide (cementite) in grams that forms per 100 g of steel

W Fe C = /0.5 Mark

/0.5 Mark
 Which means that amount of ferrite is W α = 100 -5.7= 94.3 g

iv. The amount of pearlite and pro-eutectoid ferrite

note: amount of pearlite = amount of g just above TE

Cα = 0.022 wt% C
Cpearlite= 0.76 wt% C
Amount of pearlie,
The amount of pearlite, W ɣ = (Co- Cα) / (Cɣ - Cα) × 100 / 0.5 Mark

W ɣ = (0.4 – 0.022) / (0.76 – 0.022) × 100 = 51.2 % 0r 0.512g / 0.5 Mark

The amount of pro-eutectoid ferrite, W α = (Cɣ - Co) / (Cɣ - Cα) × 100 / 0.5Mark

W α = (0.76– 0.4) / (0.76 – 0.022) × 100 = 48.8% or 0.48 g / 0.5Mark

 SECTION: B

Question: 2 [15 Marks]

a) (4 Marks)

Solution:
i. Difference between a primarily metallic bonding and a more covalent bonding in
terms of electronegativity numbers: /1 Mark
 We have a primarily metallic bonding when both Electronegativity values of atoms
in a bonding are low (~< 2.0)
 We have a more covalent bonding when Electronegativity values of atoms in a
bonding are close

ii. Two ways to prevent galvanic corrosion:

(/ 2 Marks: Any answer is allowed: 1 Mark each)

 Electrically insulate different metals from each other

 Select metals of similar reactivity
 Connect a third, even more reactive metal, to both other metals. The more
reactive metal will corrode instead of others. This is a form of cathodic protection

iv. Ashby plot is used to allow an easy comparison of the most important properties of
different materials. /1 Mark

b) (3 Marks)

Solution:
i. A neat sketch showing the point defects in the atomic lattice: /2 Marks
ii. The interfacial defects in the atomic lattice are Grain boundaries and external surfaces of the
material. /1 Mark
c) (4 Marks)
Solution:
It is important to have movement of atoms from lattice site to lattice site because:/2 Marks
 It causes movement of vacancies, solute elements, dislocations, and grain boundaries.
These affect material properties.
 It can cause local changes in composition. This may affect crystal structure, second
phases as well as material properties

The requirements: /2 Marks

 Empty adjacent site (vacancy or empty interstice)
 Sufficient energy to break bonds and to distort the lattice during movement

d) (4 Marks)
Solution:
Definitions:
i. Fatigue life refers to the number of cycles that will cause failure at specified stress
level. /1 Mark
ii. Stress Corrosion Cracking (SCC) is as form of corrosion resulting from the
combination of an applied tensile stress and corrosive environment. (Both the stress
and the suitable environment are required for SCC to occur, and materials can fail
due to SCC at stress levels far lower than the yield stress. /1 Mark

iii. Anisotropic material is a material with the properties that vary depending on the
direction in which they are measured. (directional). /1 Mark
iv. Slip is process of plastic deformation by the movement of planes of atoms. /1 Mar
Question: 3 [15 Marks]

a) (5 Marks)

Solution:

i. Soda-line glass Contains 70% SiO2 plus Na2O (soda) and CaO (lime) /2 Marks

ii. Silicon Carbide is another ceramic used widely as an abrasive and it does not occur as
a mineral.
It is produced by heating mixtures of sand (source of Silicon) and coke (carbon) to a
temperature around 22000C so that SiC and carbon monoxide are formed. / 3 Marks

b) (3 Marks)

Solution:
The properties of engineering composites are influenced by:
o The properties of the two phases (reinforcement and matrix)
o The characteristics of the reinforcement phase (concentration, size, shape,
distribution, orientation) and
o The properties of the interface (bonding) between the matrix and the
reinforcement phases.

c) (7 Marks)

Solution:
A simplified neat sketch of press and blow process: (7 Marks: Drawing and explanation per
step)
 The press & blow process is used to mass produce glass products such as jars for
packaging.
 The process is shown in the diagram below:
 A “gob” of heated glass is dropped into simple mould (1) and pressed into mould to
form the required shape (2 and 3).
 This basic shape is then removed and put into another mould of the required final
shape (4 and 5), where air is blown into in to cause it to form the shape of the mould
(6).
 When cooled, the final product (7) is removed.
Question: 4 [15 Marks]

a) (4 Marks)

Solution:
i. Edge dislocation is an extra partial plane of atoms in the crystal, which ends in the crystal.
/1 Mark
ii. Wrought metal – in which the metal has been worked or can be worked (e.g. rolled or
otherwise formed) after casting. /1 Mark
iii. Endurance limit (Fatigue limit)– stress level below which failure by fatigue will not occur,
regardless of the number of cycles. /1 Mark
iv. Drawing refers to the strength and stiffness of polymers that can be increased by
intentional deformation of the material, in similar way to strain hardening in metals.
/1 Mark

b) ( 4 Marks)

Solution:

i. Four characteristics of a Martensite structure:

/ 2 Mraks (0.5 Mark each : Any answer is acceptable)

• Formed when austenite is very rapidly cooled (quenched) to low temperatures

(approx. room temp.)
• Martensite has a Body-Centered Tetragonal (BCT) crystal structure and is
hard , strong and brittle
• The solubility limit of carbon in martensite is high and the properties of
martensite depend on carbon content
• The transformation from austenite to martensite is not well understood but it
does not occur by diffusion and is very rapid (instantaneous)
• The amount of martensite present in a steel microstructure can be controlled
by heat treatment
• Martensite can be changed by heat treatment to form a less brittle tempered
martensite microstructure.
 ii. Four carbon effects on steel once it’s content is increased:
/ 2 Marks: 0.5 Mark each: any answer is acceptable

 Steel tensile strength increases

 Steel hardenability increases and becomes difficult to machine
 Steel ductility decreases
 Lowers the melting point of steel
 Makes steel easier to harden with heat treatments.
 Lowers the temperature required to heat treat steel
 Increases the difficulty of welding steel.

c) (7 Marks)

Solution:
i. Four factors favoring brittle fracture in thermoplastics are: / 2 Marks: 0.5 Mark each
 Low temperature
 High strain rate
 The presence of stress concentrations
 Large specimen thickness

ii. Four major types of elastomers: / 2 Marks: 0.5 Mark each

 Natural rubber or NR
 Acrylonitrile-butadiene copolymer or NBR
 Chloroprene or neoprene or CR
 Polysiloxane or Silicone

iii. With a neat sketch to show different regions of polymer viscoelastic behavior:
/3 Marks: 2.5 Marks for regions and 0.5 of the sketch
End!