MINISTRY OF SCIENCE AND TECHNOLOGY DEPARTMENT OF TECHNICAL AND VOCATIONAL EDUCATION GOVERNMENT TECHNOLOGICAL COLLEGES / INSTITUTES AGTI Year

II (Metallurgy) Date : 21-9-2006 (Thursday) 11:30 AM MET-02023 CONCEPTS OF MATERIALS SCIENCE 1(a) (b) (c) What are the main classes of engineering materials? What are some of the important properties of each of these engineering materials? Determine the number of vacancies needed for a BCC iron lattice to have a density of 7.87 g/cm3. The lattice parameter of the iron is 2.866 x 10-8 cm. Tungsten has an unusually high melting temperature of 3410C, making it difficult to process into useful shapes. Design a process by which small diameter filaments can be produced from tungsten. Ans: (a)There are five main classes of engineering materials. They are (1) metal (2) ceramic (3) polymers (4) electronic materials (5) composites Metal: have good strength, good ductility and formability, good electrical and thermal conductivity, and moderate temperature resistance. ceramics are strong, serve as good electrical and thermal insulators; are often resistance to damage by high temp and corrosive environments, but are brittle. Polymers have relatively low strength, are not suitable for us at high temp, Have good corrosion resistance, good electrical and thermal insulation. Electronic materials posses unique electrical and optical properties that make Them essential components in electric and communication devices. Composites are mixture of materials that provide unique combinations of Mechanical and physical properties that cannot be found in any single material. Time : 8:30

(c) Tungsten has an unusually high melting nature of 3410C, making it difficult to Into useful shapes. Design a process by which small diameter filaments can be Produced from tungsten. Because of tungstens high melting temperature, most costing processes cannot be used for it. A common method for producing tungsten is by a powder metallurgy process. Powder particles of tungsten oxide (WO3), a ceramic, are heated in a hydrogen atmosphere, the subsequent react in produces metallic tungsten particles and H2O. The tungsten powder particles are consolidated at high temperature and pressure into simple rods. The rods can then be wires-drawn (a forming process) to progressively smaller diameters until the correct size is produced. II.(a) Sketch the following planes and directions within each cubic unit cell: (10 1 ),(012),(211)(3 1 2 ),[ 1 1 1 ],[0 1 2],[11 2 ],[ 1 01] (b) A metal having a cubic structure has a density of 2.6 g/cm3. An atomic weight of 87.62g/mole, and a lattice parameter is 6.0849A. One atom is associated with Each lattice point. Determine the crystal structure of the metal and the packing Factor of this meal. (c) Determine the repeat distance, linear density and picking fraction for BCC Lithium, which has a lattice parameter of 0.3508nm in the [111],[011]and [010]. Ans: (a) (101) (012)

(211)

(31 2 )

[111]

[012]

[1 1 2 ]

[ 1 0 1]

(b)

=2.6g/cm3
Atomic weight crystal structure =? Packing factor =? =87.62 g/mole a0 =6.0849 A =6.0849 x 10-8 cm

no : ofatom / cell atomicweight volumeofunitcell N A = =

No: of atom/cell

volume N A atomicmass
2.0 (6.0849 10 8 ) 3 6.02 10 23 87.62

= 4.026 = 4 atoms /cell crystal structure is FCC. For FCC structure, a0 = 4 ( 2) = no : ofatom / cell volumeofeachatom volumeofunitcell

packing factor

4atoms / cell 4 / 3 r 3 = (a 0 ) 3 4 4 / 3 r 3 4r = ( )3 2

4 / 3 r 3 4 4 3 3 = = 0.74 ( ) r 2
(c) r =1.519 A = 1.519 x 10-8 cm ----------FIG-----Repeat distance =? Linear density =? Packing fraction=? a0 =0.3508 nm= 0.3508 x 10-7cm for BCC lithium, Repeat distance = 3a0 3 0.3508 10 7 = 2 2 = 30.38 x10-9 cm

Linear density

1 1 = repeatdis tan ce 30.38 x10 - 9 cm = 32.92 x 106 l.p/cm

Packing fraction

= linear density x 2 = 32.92 x 106 x 2 x1.519 x 10-8 = 0.9999 (1)

Repeat distance

=
=

2a0 =

2 x 0.3508 x 10-7

49.61 x 10-9 cm 1 1 = repeatdis tan ce 49.61 x 10 -9 = 20.15 x 106 l.p/cm

Linear density

Packing fraction

= linear density x 2 = 20.15 x 106 x 2 x1.519 x 10-8 = 0.612 = a0 = 0.3508 x 10-7 = 1 1 = repeatdis tan ce 0.3508 x 10 - 7 = 28.51 x 106 l.p/cm

Repeat distance Linear density

Packing fraction

= linear density x 2 =28.51 x 106 x 2 x1.519 x 10-8 = 0.866

III.(a) A single crystal of a BCC metal is oriented so that the [001] direction is parallel to the applied stress. If the critical resolved shear stress required for slip is 12000psi, Calculate the magnitude of the applied stress required to cause slip to begin [111] Direction on the (011),(101),( 1 01). (b) Determine the interplanner spacing and the length of Burgers vector for slip on The expected slip system in BCC tantalum.(lattice parameter is 3.3026 A). Repeat, assuming that the slip system is a (111)/[1 1 0]. What is the ratio between the shear stress required for slip for the two systems? Assume the k=2 Ans: (a): = 12000 psi 5

 =?
(011) / [1 1 0] C B A A B C ao A A a0 1 = 3a0 3 1a0 2 a0 1 2 ao B

C C ao A B

3a 0

2a0 a

Cos = Cos = =

cross = Cos Cos cross = cos cos

(101)/[111] Cos = 1a0 1 1 , Cos = = 2 a0 3 2 12000 = 1 1 =29393.87691 psi 2 3

cross = Cos Cos

12000 cross = = 1 1 = 29393.87691 psi cos cos 2 3 ( 1 01) / [111]

B C C C ao B ao A A

2a 0

Cos =

1a0 1 1 , Cos = = 2 a0 3 2

cross = Cos Cos =

12000 cross = 1 1 = 29393.87691 psi cos cos 2 3

(b) for expected slip system for BCC =(110)/ [111], (1 1 0)/ [1 1 1] B
A

A ao

ao

A
A

2a 0

a0 = 3.3026 A =3.3026x 10-8 =0.33026 nm dhkl = a0 h +k +l

2 2 2

(0.33026)nm = 0.23353 nm 2 = 2.33 A

b=

3a0 = 0.28601 nm = 2.8601 A 2 =C exp (hd ) b 0.23353 ) 0.28601 7

BCC

= C exp (- 2

= 0.19534 C Assume slip system and direction; (111) / [1 1 0]

a0 C A a0 h +k +l
2 2 2

2a0
a0

B (0.33026)nm = 0.1907 nm =1.9067 A 3

dhkl

= b

2a0 =

2 x 0.33026 = 0.4671 nm 4.6705 A hd ) b 0.1907 ) 0.4671

assume

= C exp (-

= C exp (- 2 = 0.44198 C

BCC 0.19534 C = = 0.44196 assume 0.44198 C

IV.(a) A force of 100000 N is applied to a 10 mm x 20mm iron bar having a yield Strength of 400 MPa and a tensile strength of 480 MPa. Determine (i) (ii) whether the bar will plastically deform and whether the bar will experience necking

(b) A cyclical load of 1500 lb is to be exerted at the end of a 10 in long aluminum Beam. The bar must survive for at least 106 cycles. What is the minimum diameter of the bar? Ans: (a) F A =100,000 N = 10 x20 mm2 = F A = 100,000 = 500 N/mm2 200


(i)

T y

= 480 MPa = 480 N/mm2 = 400 MPa = 400 N/mm2

the bar will plastically deform = 500 N/mm2 y = 400 N/mm2 = 500 N/mm2 T = 480 N/mm2 = 106 cycles = 10 in 145 psi =2030 psi 1MPa

(ii)

the bar will experience necking

(b)

N L

= 14 MPa (from graph) = 14 MPa x

F = 1500 lb

=
d3 =

10.18 LF d3 10.18LF 10.18 10 1500 = = 75.22 2030

d = 4.22 in V(a) The diffusion coefficient for Cr in Cr2O3 is 6 x10-15 cm2/s at 1400C. Calculate (i) beneath The surface of a 0.20% C steel in 2 hr, when 1.1%C is present at the surface? Assume the iron is FCC, activation energy is 32900 cal/mole, D0 = 0.23 cm2/s. x 2 Dt 0 0.10 0.2 0 0.30 0.40 0.50 0.60 0.70 0.80 erf x 2 Dt the activation energy (ii) the constant D0.

Ans:(a) What temperature is required to obtain 0.50% C at a distance of 0.5 mm

0 0.1125 0.227 0.3286 0.4284 0.5205 0.6039 0.6778 0.7421

0.90 1.00 1.50 2.00 (a) (i)

0.7970 0.8427 0.9661 0.9953

D = 6 x10-15 ,T =727C = 1000K D = 1 x 10-9 , T =1400C = 1673K Q =? D1000 = D0 exp (Q ) RT

D1000
D0 =

e p (x

Q ) R T
Q ) RT ..(2)

.(1)

D1673= D0 exp (-

D1673 Q D0 = exp () RT From equation 1& 2 D1000 Q exp() RT

D1673 Q = exp() RT

6 10 -15 110 9 = Q Q exp() exp() 1.987 1000 1.987 1373

1 6 10 -6 = -4 exp( -5.0327 10 -4 Q ) exp( -3.0082 10 Q )

6 x 10
-6

exp(-5.0327 10-4 Q ) = exp(-3.0082 10-4 Q ) = exp [(-5.027 +3.0082) x10-4] =exp (-2.0188 x 10-4 Q) =-2.0188 x 10-4Q = -2.0188 x 10-4Q

6 x 10-6 6 x 10-6 Ln 6 x 10-6 -12.0238

10

- 12.0238 =5.9559 cal/mol - 2.0188 x 10 - 4 = 59.559 x1013 cal/mol

(ii) D0 =? D1000 6 10 15 6 10 15 3 Q D0 = = = 0.0624 59.559 10 = exp() exp() 0.997 RT 0.987 1000 (a) T =? Cx = 0.5% C0 = 0.2% Cs = 1.1% x t = 0.5 mm =0.05cm = 2 hr = 7200s

the iron is FCC structure Cs - C x x = erf ( ) Cs - C0 2 Dt x 1.1 - 0.5 = erf ( ) 2 Dt 1.1 - 0.2 0.6 0.9 = erf ( 0.05 ) 2 D 7200

0.67 = erf ( 0.7 =

0 .0 5 D 2 0 70

0.05 2 D 7200 0.05 2 D 7200

D =

D =4.2 x 10-4 D Q = 1.772 x 10-7 = 32900 cal/mol Q ) RT

D0 =0.23cm2/s D = D0 exp(-

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1.772 x 10-7 1.772 x 10 -7 0.23

=0.23 exp(= exp(-

32900 ) 1.987T

32900 ) 1.987T

170.236 x 10-9 = T =

2 0 390 1 8T .9 7
32900 1.987( 14.0766 )

T =1176.2543 K T = 903.2543C VI Define the following: (i) (iii) (v) (vii) (ix) coefficient of thermal expansion (ii) allotropy hardness test Ficks first law Hall Petch equation cold working (iv) modulus of resilience (vi) interstitial diffusion (viii) strain hardening coefficient (x) diffusion coefficient

(i) coefficient of thermal expansion The amount by which a material changes its dimensions when the Temperature changes. A material with a low efficient of thermal Expansion tends to retain its dimensions when temperature changes. (ii) allotropy The characteristics of a material being able to exist in more than one crystal Structure depending on temperature and pressure. (iii) hardness test Measures the resistance of a material to penetration by a sharp object. Common hardness tests included the Brinell test, Rockwell test, kno test, And Vickers test. (iv) Modulus of resilience The maximum elastic energy absorbed a material when a load is applied.

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(v)

Ficks first law The equation relating the flux of atoms by diffusion to the diffusion coefficient and the concentration gradient. [J =-D J = flux (atoms/cm2.s) D = diffuse coefficient (cm2/s) c = concentration gradient (atoms/cm3 .cm ) x c ] x

(vi) Interstitial diffusion Diffusion of small atoms from one into rstitial position to another in the Crystal structure. (vii) Hall Petch equation
1/ 2 [ y = 0 + kd ]

y = yield strength
d = average diameter

0 and k are the constant for the metal

(viii) Strain hardening coefficient The effect that strain has on the result strength of the materials. A material With a high strain hardening coefficient obtains higher strength with only Small amounts of deform atm or strain. (ix) Cold working Deformation of a metal below the crystallization temperature . During cold Working the number of dislocations increase, causing the (x) Diffusion coefficient A temperature depended coefficient related to the rate at which atoms diffuse . The diffusion coefficient depends on temperature and activation energy.

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