QUESTION BANK Sub Code/Name: Engineering Materials & Metallurgy Year/Sem: II / III UNIT- I CONSTITUTION OF ALLOYS & PHASE

DIAGRAMS PART A (2 Marks) 1. What is an alloy? A substance having metallic properties and being composed of two or more chemical elements of which atleast one is an elemental metal. 2. Define solid solution. A single solid homegeneous crystalline phase containing two or more chemical species. 3. Define solute and solvent. The component of either a liquid or solid solution that is present to a lesser or minor extent, the component that is dissolved in the solvent. The component of either a liquid or solid solution that is present to a greater or major extent, the component that is dissolves the solute. 4. What are the different types of solid solutions? The different types of solid solutions are Substitutional solid Solution and Interstial solid Solution 5. Explain the Substitutional solid Solution. A solid allloy in which the solute atoms are located at some of the lattice points of the solvent, the distribution being random. 6. Explain the Interstial solid Solution. A solid solution in which the solute atoms occupy positions within the lattice of the solvent. 7. What is phase diagram? and its importance. A physically homogeneous and distinct portion of a material system. 8. Differentiate between eutectic and eutectoid. An isothermal reversible reaction in which

(i) (ii)

A liquid solution is converted into two or more intimately mixed solids on cooling is eutectic. A solid phase is converted into two or more intimately mixed solids on cooling is eutectoid.

9. Differentiate between peritectic and peritectoid. An isothermal reversible reaction in which (i) A liquid phase reacts with a solid phase to produce another solid phase on cooling is pertectic. (ii) A solid phase reacts with a second solid phase to produce yet a third solid phase on cooling is peritectoid.

10. What is mean by "allotropy of iron"? The reversible reaction in which iron exist in two crystal structure. 11. Define ferrite and austenite. Ferrite is an interstitial solid solution of 0.025%C disssolved in B.C.C. iron. Austenite is an interstitial solid solution of carbon in F.C.C. iron with maximum solublity of 2% carbon 12. Define cementite, pearlite. Cementite is a iron carbide with chemical formula Fe3C, containing 6.67%C. Pearlite is a very fine platelike or lamellar mixture of ferrite and cementite. 13. Define martensite, bainite. Martensite is an intersticial supersaturated solid solution of carbon in iron having a body centered tetragonal lattice. Bainite is a decomposition product of austenite consisting of an aggregate of ferrite and carbide. 14. Differentiate between steel and cast iron. Steel is an alloy of iron and carbon with carbon upto 2% Cast iron an alloy of iron and carbon with carbon above 2% 15. What is meant by hypo eutectoid, hypereutectoid steel? Hypo eutectoid steel has carbon in the range of 0 to < 0.8%. Hyper eutectoid steel has carbon in the range of >0.8% to < 2.0%.

16. What is meant by hypo eutectic, hyper eutectic C.I? Hypo eutectoid C.I has carbon in the range of >2.0% to < 4.3%. Hyper eutectoid C.I has carbon in the range above 4.3%. 17. What are cooling curves? A graph plotted with temperature in y axis and compsition in x axis at ideal coolin time is cooling curves. 18. Drawn the cooling curve for the pure metal, binary solid solution and binary eutectic system? For pure metal and eutectic complete liquid to complete solid state is at single tempurature. For binary complete liquid to complete solid state may be at different tempurature.

UNIT-II HEAT TREATMENT METHODS PART-A (2 Marks) 1. What is meant by "heat treatment"? and its purpose. Heating and cooling a solid metal or alloy in such a way as to obtain desired condition and properties. 2. List the various stages of a heat treatment process. During heat treatment the material is subjected to controlled heating and stabilizing at that temperature depending upon the section thickness and cooling it to room temperature at desired rate. 3 .A low carbon steel in the normalized condition is stronger than the same steel in the annealed condition. Why? The rate of cooling is faster in normalising than annealing so ferritic conversion is lees.

4. Case carburizing heat treatment is not generally carried out for medium carbon steel. Why? Medium carbon steels are hard material if carbon is induced further the material will become brittle. 5. What is "critical cooling rate" in hardening of steel? The minimum rate of continuous cooling just sufficient to prevent undesired transformations. 6. What are the factors affecting the CCR? Composition of steel, temperature of hardening and purity of steel are the factors that affect CCR. 7. What is the microstructure of an austempered of steel? What is the advantage of austempering heat treatment? A austempered steel wil have 100% bainite structure, it has got high resistance to impact and less distortion. 8. What is the principle of surface hardening in induction hardening process? It is quench hardening in which the heat is generated by electrical induction. 9. What is the need for providing a tempering treatment after quench hardening of steel? During quench hardening their will be thermal stress and are prone for cracking, so to remove the stress tempering is done. 10. What is meant by normalizing? and its purpose. Heating a ferrous alloy to a suitable temperature above the transformation range and then cooling in air to a temperature substantially below the transformation range to produce uniform structure, grain refinement, reduce internal stress. 11. Differentiate between normalizing and full annealing. In Normalising the cooling is done outside the furnace whereas in annealing cooling is done inside the furnace. 12. Differentiate between full annealing and process annealing. Full annealing is done at austensing temperature. Process annealing is done at subcritical temperature to reduce effects of cold working.

13. What is quenching? List some of the quenching medium. Rapid cooling in a suitable medium eg brine, water, oil is quenching. 14. What are the factors should be considered while selecting a quenching medium? Thermal conductivity, severity of quenching, viscosity are some of the factors to be considered for selection of quenching media. 15. What are the factors affecting the hardness? Percentage of carbon, quenching medium, quenching temperature, size of the object to be quenched, homogeneity of austenite, and rate of cooling are the factors that affect hardness. 16. What is martempering and austempering? In martempering Steel is heated to above the critical range to make it all austenite and then quenched into a salt bath maintained at a temperature above Ms to get tempered martinsite. In austempering Steel is heated to above the critical range to make it all austenite and then holing isothermally to allow the austenite to transform to bainite and slow cooling to room temperature. 17. What is meant by hardnability? What are the factors affecting it. Hardenablity of a steel is defined as the property which determines the depth and distribution of hardness induced by quenching from the austenite condition. Composition of steel, austenite grain size, structure of steel and quenching media are the factors affecting it. 18. What is difference between hardness and hardnability? Hardness is a single point measurement whereas hardenablity describes distribution of hardness. 19. In What way cyaniding differs from carburizing? In cyaniding a case rich in nitrogen is achieved where as in carburising case rich in carbon is achieved. 20. In What way flame hardening differs induction hardening?

Flame hardening is a selective hardening with combustible gas flame as source of heating whereas in induction hardening the source of heat input is an induced electric current.

UNIT-IV FERROUS & NON-FERROUS METALS PART A (2 Marks) 1. What are the effects of Cr and Mo in low alloy steels? Cr prevents corrosion and oxidation and adds strength at high temperature. Mo provides fine grains, raises tensile and creep strength at high temperature. 2. What are the effects of Mn and Si in low alloy steels? Mn markedly increases strength and hardness, counters brittleness from sulphur. Si improves oxidation strength and strengthens low alloy steel. 3. What are the effects of V and W in low alloy steels? V is a powerful cardibe former, adds resistance to wear and heat. W increase hardness, promote fine grains and resist heat. 4. What is the purpose of magnesium treatment in producing S.G iron? Magnesium produce graohite in spheroidal form in as cast condition. 5. What is meant by precipitation hardening? It is the hardening caused by the precipitation of a constituent from a supersaturated solid solution. 6. What is the main strengthening mechanism in high strength aluminum alloy? Solution treatment is the main strengthening mechanism which involves heating an alloy to a suitable temperature, holding at the temperature long enough to allow one or more consituents to enter into solid solution. 7. What is meant by stainless steel? Stainless steels are described by composition as containing 4% or more chromium and generally more than 50% iron and they may contain such alloying additions as Ni, Mo,Ti, & Mn.

8. How can you classify tool steel? and its properties Tool steels are classsifies as high speed steel, air hardened steel, oil hardned steel, water hardened steel, hot work steel and shock resistance steel. It has good thouhness, wear resistance, machinablity and resistance to softnees on heating. 9. What are HSLA steel? Where are they used? HSLA is a high strength low alloy steel with <0.2%C containing small amounts if alloying elements. It purpose is weight reduction through increased strength. It is widely used in structural and construction areas.

10. What are marageing steel? Give its composition. Marageing means matensitic plus aging. It consist 18% Ni, 7-10% Co, 3-5.5.5 % Mo, 0.1-0.8% Ti, 0.05-0.15% Al, <0.03%C, < 0.10% Si, < 0.01% Mn, S & P remaining Fe. 11. What are the main difference between brass and bronze? Brass is an alloy of Cu and Zn, whereas bronze is an alloy of Cu and Pb. 12. List the types of brass. Types of brass are Cu-Zn alloy, Cu-Pb-Zn alloy or leaded alloy and Cu-Zn-Sn alloy or tin brass. 13. What are gunmetals? and its composition. Gun metal is an alloy of copper, (10%)tin and (2%)Zinc used for making bearing, steam pipe fitting, marine casting and hydraulic valves and gears. 14. What is Babbitt metal? and its composition. Babbitt metal is a tin based bearing material. It has 90% tin, 10% copper . 15. What are cupronickels? What is the use of Monel metal? These are Copper-Nickel alloys that contain up to 30%Nickel, it has got high resistance to corrosion. Monel metals are used at high temperature places, and highly corrosive environment. 16. List the bearing materials that are commonly used.

The widely used bearing materials are white metals, copper-base alloys, aluminium-base alloys, plastic materials, and ceramics. 17. What are the characteristics of bearing materials? Bearing material should possess sufficient hardness and wear resistance, low coefficient of friction, sufficient melting point, high thermal conductivity, good casting qualities, good resistance to corrosion, shock resistance and ductility.

UNIT-V NON-METALLIC MATERIALS PART A (2 Marks) 1. What are polymers? Polymers are many units joined together by a chemical reaction. 2. List out four attractive characteristics of polymers. Low density, good corrosion resistance, low coeficient of friction and good mouldablity are some of the four attractive characterstics of polymer. 3. What is polymerization?

Polymerisation is defined as the process of growing large molecules from small ones. 4. Differentiate addition and condensation polymerization. Addition polymerization is a kinetic chain reaction whereas condensation polymerization is inter-molecular reaction. Addition polymerization is completed in seconds whereas condensation polymerization needs hours and even days to complete. 5. Why are additives added to polymers? Additives are most often added to polymers to improve tensile and compressive strengths, abrasion resistance, toughness, dimensional and thermal stability and other properties. 6. Distinguish between thermoplastics and thermosetting plastics. Thermoplastics can be resoftened and remoulded by application of heat and pressure.thermosetting plastics cannot be remoulded. 7. Name four ethenic polymers (polymers that have the basic monomers structure of ethylene). Linear polymers, branched polymers, cross-linked polymers, network polymers are some of the homopolymers.

8. Draw the molecular structure of polyethylene and poly propylene.

9 ..Draw the molecular structure of phenol formaldehyde polymer (PF) and urea formaldehyde polymer (UF).

10. Give to example of particulate reinforced metal matrix composites and ceramic matrix composites. 1. Sintered aluminium powder 2. cerment

11. What is the importance of alumina and silicon nitride? Alumina ceramics are used for any type of load-bearing aplication. They are used for rocket nozzles, pump impelers, pump liners, check valves, nozzles subjected to erosion and for support members in electric devices. Silicon nitrides are widely used as cutting tool materias. 12. What are the characteristics of engineering ceramics? Ceramics are in organic, non metallic materials that are heat treated to have abrasive resistance, heat resistance compressive strength, oxidation and reduction resistance. 13. List the properties and application of PVC. They are polyvinyl chloride, they ahve good flame, electrical, chemical, oil, abrasion and weather resistance. They are used as valves, fitting, floor tiles, wire insulations, toys, phonograph records, vinyl automobile roofs, etc. 14. What are bakelites? and state their application. It is a thermosetting phenol formaldehyde resin, formed from an elimination reaction of phenol with formaldehyde, usually with a wood flour filler. Bakelite was particularly suitable for the emerging electrical and automobile industries because of its extraordinarily high resistance - not only to electricity, but to heat and chemical action. 15 Name any four engineering ceramics. Glasses, clay products, refractory, abrasives are engineering ceramics. 16. What are composites? The term composite can be defined as a material composed of two or more different materials, with the properties of the resultant material being superior to the properties of the individual materials that make up the composite. 17. How are composites materials classified? Composites are classified as particle-reinforced, fiber-reinforced and structural composites. 18. List the application of composite materials.

Composites are used in aircrafts, missilies, space hardwares, automobiles electrical, electronics and marine application.