DEPARTMENT OF MECHANICAL ENGINEERING

COMPLETE COURSE FILE (Academic year)

Course Title:

1. Course details

2. Course plan
3. Assessment
tools and data
4. Attainment of
CO

MATERIAL SCIENCE AND METALLURGY

Contents
1.1 Primary info
1.2 Course Content (Syllabus)
1.3 Text books
1.4 Reference books
2.1 Course learning objectives
2.2 Course outcomes
2.3 Validation of course outcomes
2.4 Mapping of COs with POs
3.1 Definition of assessment tools
3.2 Assessment data
4.1 Measuring CO attainment
4.2 Remarks

Page No
1
2
5
5
6
6
7
7
8
14
44
46

********************************

1. Course details
1.1 Primary information:
1.
2.
3.

4.
5.
6.
7.
8.

Course Code
L-T-P
Marks (Min/Max)
VTU Exam
Internal Assessment
Pre-requisite
Teaching Department
Course Duration
Faculty Representative
Course Faculty

: 10ME32A
: 4-0-0
: 50/125
35/100
0/25
: Physics, Chemistry
: Mechanical Engineering
: 52 Hours
:
:

1.2 Course Content (Syllabus):

Topic Title

1. Crystal
Structure

2. Mechanical
Behaviour

3. Failure of
Materials

Description
BCC, FCC and HCP Structures
- coordination number
- atomic packing factors
Crystal imperfections
- point, line & surface imperfections
Atomic Diffusion:
- diffusion phenomenon
- Ficks laws of diffusion
- factors affecting diffusion
Stress-strain diagram showing
- ductile and brittle behaviour of
materials
- linear and nonlinear elastic
behaviour and properties
- mechanical properties in plastic
range; yield strength, offset yield
strength, ductility, ultimate tensile
strength, toughness
Plastic deformation of single crystal
- slip and twinning
Fracture:
- Type I, Type II and Type III
Creep:

Topic Level Outcomes

At the end of the topic students will be able to
1. Draw unit cells for BCC, FCC and HCP crystal
structures.
2. Find the atomic packing factor for BCC, FCC and
HCP crystal structures.
3. Compute the density of metals having FCC, BCC
and HCP crystal structures given their unit cell
dimensions.
4.

Name and describe different crystal imperfections.

5.

Describe the mechanism of atomic diffusion.

1.

Explain the ductile-brittle and linear-nonlinear

elastic behaviour of materials.

2.

Evaluate the mechanical properties of a material

through stress strain diagram.

3.

Identify plastic deformation by slip and twinning

in materials.

1. Differentiate

and fatigue.

failure of materials by fracture, creep

Duration

06 Hours

06 Hours

07 Hours

4. Solidification

5. Phase
Diagram II

- description of the phenomenon with

examples
- three stages of creep
- creep properties
- stress relaxation
Fatigue:
types of fatigue loading with
examples
mechanism of fatigue
fatigue properties
fatigue testing and S-N diagram
Mechanism of solidification
- nucleation
- crystal growth
- cast metal structures
Phase Diagram I
- solid solutions
- Hume Rothary rule
- substitutional and interstitial solid
solutions
- intermediate phases
- Gibbs phase rule
Construction of equilibrium diagrams
involving complete and partial
solubility, lever rule.
Iron carbon equilibrium diagram
- description of phases
- solidification of steels and cast
irons
- invariant reactions

2. Explain

the different types of fracture modes,

creep stages and fatigue loading.

3. Explain

the phenomenon of creep and its

properties.

4. Explain

mechanism of fatigue failure for a material

and plot SN diagram.

1.

Explain the mechanism of solidification by

nucleation and grain growth for pure metals and
alloys.

2.

Enumerate the significance of cast structure of

metals and the methods to control it.
07 Hours

3.

Construct phase diagram for simple binary alloys.

4.

Identify the formation of interstitial or

substitutional solid solutions and intermediate
phases.

1.

Construct the Iron-Carbon equilibrium diagram

and discuss the invariant reactions in it.
06 Hours

2.

Interpret the formation of steel and cast irons using

an iron-carbon diagram

6. Heat treating
of metals

7. Ferrous and
non-ferrous
materials

8. Composite
Materials

TTT curves
Continuous cooling curves
Heat treatment techniques
- annealing and its types,
normalizing, hardening,
- tempering, martempering,
austempering
- hardenability and surface hardening
methods like carburizing,
cyaniding, nitriding, flame
hardening and induction hardening
- age hardening of aluminium-copper
alloys
Properties, Composition and uses of
- Grey cast iron, malleable iron, SG
iron and steel
- Copper alloys: brasses and bronzes
- Aluminium alloys: Al-Cu, Al-Si,
Al-Zn alloys
Definition
Classification
types of matrix materials &
reinforcements
fundamentals of production of FRP's
and MMC's
advantages and application of
composites

1.

Explain the process details of various heat

treatment processes.
07 Hours

2.

Suggest a suitable heat treatment technique for the

desired materials and properties.

1.

State the areas of application of commonly used

engineering materials.
06 Hours

2.

Suggest the selection of materials based on the

property requirements

1. Explain

the production techniques for some

common FRPs and MMCs
07 Hours

2. List

out the advantages and applications of

composite materials

1.3 Text Books:

1. Foundations of Materials Science and Engineering, Smith, 4th Edition McGraw Hill,
2009
2. Materials Science, Shackleford., & M. K. Muralidhara, Pearson Publication 2007.
1.4 Reference Books:
1. An Introduction to Metallurgy; Alan Cottrell, Universities Press India Oriental Longman
Pvt. Ltd., 1974.
2. Engineering Materials Science, W.C.Richards, PHI, 1965.
3. Physical Metallurgy; Lakhtin, Mir Publications.
4. Materials Science and Engineering, V.Raghavan, PHI, 2002.
5. Elements of Materials Science and Engineering, H. VanVlack, Addison- Wesley Edn.,
1998.
6. Materials Science and Engineering, William D. Callister Jr., John Wiley & Sons. Inc, 5th
Edition, 2001.
7. The Science and Engineering of Materials, Donald R. Askland and Pradeep.P. Phule,
Cengage Learning, 4lh Ed., 2003.

2. Course plan
2.1 Course Learning Objectives (CLOs):
1. To impart knowledge on structure property correlations for commonly used engineering
materials.
2. To help the students to understand the mechanical behavior, deformation characteristics
and the modes of failure of materials.
3. To enable the students to understand the effect of solidification mechanism of metals on
the resulting microstructure and properties as well as effect of subsequent heat treatments
on the material properties.
4. To train the students to interpret the iron carbon equilibrium diagram for the formation of
steel and cast irons.
5. To educate the students about the conventional engineering materials, their characteristics
and applications as well as the recent trends in materials such as composites.
6. To kindle an enthusiasm among the students to carry on lifelong learning in the field of
metallurgical and materials science.
2.2 Course Outcomes (COs):
At the end of the course the students will be able to
1. Explain the crystal structure of commonly used engineering materials and their
characteristic properties.
2. Interpret the deformation characteristics and behavior of materials when subjected to
loads till their failure.
3. Explain the solidification mechanism and heat treatment techniques and the control
measures to obtain a suitable microstructure for specific property applications.
4. Indicate the properties, composition and applications of ferrous, non-ferrous materials
and composite materials and suggest a suitable material for specific applications.

2.3 Validation of Course Outcomes

CO1

CO2

CO3

CO4

Course Outcome
POs-Levels
Explain the crystal structure of commonly used
engineering materials and their characteristic
PO1:2
properties.
Interpret the deformation characteristics and
PO1:2
behavior of materials when subjected to loads till
PO5:1
their failure.
Explain the solidification mechanism and heat
PO1:3
treatment techniques and the control measures to
PO2:1
obtain a suitable microstructure for specific
property applications.
Indicate the properties, composition and
applications of ferrous, non-ferrous materials and
PO5:2
composite materials and suggest a suitable material
for specific applications.

Cognitive Level
Understanding
(Level 2)
Analyzing
(Level 4)
Applying
(Level 3)

Understanding
(Level 2)

POs-Levels: 1-Slightly, 2-Moderately, 3-Highly

Cognitive Levels: 1 to 6 as per Blooms Taxonomy

2.4 Mapping of COs with POs

CO1
CO2
CO3
CO4

PO1
(a)
X
X
X

PO2
(b)

PO3
(c)

PO4
(d)

PO5
(e)

PO6
(f)

PO7
(g)

PO8
(h)

PO9
(i)

PO10
(j)

PO11 PO12 PO13

(k)
(l)
(m)

X
X
X
X

3. Assessment tools and data

3.1 Assessment tools
The assessment tools to be used for CAY are;
Internal assessment
Assignments
Quizzes
I. Internal Assessment:
Internal Test I (Date)
Q.No Question
1
2
3
4

5 (a)

5 (b)

What is packing factor? Find the packing factor for

FCC?
What is diffusion? Explain the unsteady state of
diffusion with example?
Differentiate between ductile and brittle material? Name
five examples for each?
The unit cell of chromium is cubic and contains 2
atoms. Determine the dimension of the dimension of the
chromium unit cell and atomic radius. Given atomic
weight of chromium=52 & density of chromium=7.19
g/cm3
A Steel rod of 10mm die & 1.5m length is subjected to
an axial tensile test of 10KN. Determine (a) Stress (b)
strain (c) Elongation. Take E=205*106 KN/m2
Explain any one of this (a) Edge dislocation (b) screw
dislocation.

Expected Outcome

Refer Appendix I
(IA Scheme and Solutions)

Cognitive
Level
Remembering

TLO
Measured
1.2

Understanding

1.5

Understanding

2.1

Applying

1.3

Applying

2.2

Understanding

2.3

Marks

Internal Test II (Date)

Q.No Question
1
2
3

Expected Outcome

Explain Hume-Rothary rules governing the formation of

substitutional solid solution
Explain the mechanism of solidification for pure metals.
a) Draw Fe-Fe3C phase diagram and label all the regions
indicating the invariant reactions with the temperature
and composition for the same.
b) From the above phase diagram calculate the amount of
eutectic present in the pearlite using lever rule.
Refer Appendix I
c) Also sketch the typical microstructure for the
(IA Scheme and Solutions)
following
(i) eutectoid steel at room temperature
(ii) hypo-eutectic cast iron having 3% carbon at 910
C and at room temperature
a) Explain with neat sketch the different stages of creep
formation?
b) What is fatigue failure? Draw S-N curve for steel and
aluminum?

Cognitive
Level
Remembering

TLO
Measured
4.4

Understanding
Remembering

7
8

4.1
5.1

Understanding

Understanding

Understanding

3.2

Understanding

3.4

Marks

Internal Test III (Date)

Q.No Question
1

2
3

a) From fundamentals distinguish clearly between alloy

and composites.
b) Classify the composites based on the matrix and
reinforcements.
List down the production methods of metal matrix
composites. Explain any one with neat sketch.
What is meant by heat treatment? What are its
objectives?

Expected Outcome

Refer Appendix I
(IA Scheme and Solutions)

Cognitive
Level
Understanding

TLO
Measured
6.2

Remembering

6.1

Understanding

6.1

Remembering

8.1

Marks

4
5

Define hardenabilty. Explain the process which is used

to find the hardenability of steel.
What is Case hardening? Explain pack carburizing
process.

Understanding

8.2

Understanding

8.1

II. Assignments:
A.
No

Questions

1. What are the three primary bonds in materials? Which is the strongest? Why?
2. Find out from the Handbook of materials the melting points of the following metals and
cite the details of the handbook referred.
a) Plain Carbon Steel (0.3 % Carbon)
b) Aluminium
c) Magnesium
d) Copper
3. How does the mechanical property (strength and ductility) of a material vary with its grain
size? Explain. (Refer Hall-Petch Relation)
4. How does the presence of defects in a crystal structure and alloying alter the properties of a
material? Explain.
5. Explain strain hardening.
6. Explain how grain boundaries impede dislocation motion and why a metal having small
grains is stronger than one having large grains.
7. Following are the tensile test results of a steel specimen having a 30 mm diameter and 200
mm length. Extension at a load of 50kN = 0.1mm. Load at elastic limit = 230kN.
Maximum load = 300kN. Total extension = 50 mm. Diameter of rod at failure = 20 mm.
Calculate (i) Young's modulus (ii) Ductility
8. A low carbon steel rod is subjected to tensile load of 7000 kg. Assuming no volume change
during extension, determine (i) Engineering stress and engineering strain. (ii) True stress
and true strain. The initial diameter of the rod is 13 mm and after application of load
12mm.

Cognitive
Level
Remembering

TLO
Date of
Measured Submission

understanding

Understanding

2.1

Analyzing

1.4

Understanding

2.3

Analyzing

2.3

Applying

2.2

Applying

2.3

1. What do you mean by alloying? How is it different from a pure metal with reference to
Understanding
mechanical properties and microstructure?
2. Why is undercooling necessary for nucleation? Explain the concept of volume free energy
and surface free energy with its effect on undercooling for homogeneous and Understanding
heterogeneous nucleation.

Date

4.1
Date
4.1
10

3. What is a phase diagram? Why is it necessary?

4. Explain phase rule and lever rule with emphasis on a binary eutectic phase diagram.
5. Sketch the typical microstructure for the following at room temperature:
(a) Pure iron
(b) Plain carbon steel with 0.4 % carbon
(c) Eutectoid steel
(d) Cast iron with 4.5 % carbon
6. Plot the eutectic region of a Fe-Fe3C system and find the eutectic present in an alloy of 3.5
%C at 1000 C.
7. What is an Invariant reaction? Draw the pictorial representation of the following invariant
reactions:
(a) Eutectic reaction
(b) Eutectoid transformation
(c) Peritectic reaction

Understanding
Understanding

4.3
4.4

Remembering

5.2

Analyzing

5.1

Analyzing

5.1

III. Quizzes:
Quiz 1
SL
No.
1.
2.

3.

4.
5.

Questions
Repeatable entity of a crystal structure is known as
(a) Crystal
(b) Unit cell
(c) Grain
Atomic packing factor is
(a) Volume fraction of atoms in a unit cell
(c) Distance between two adjacent atoms

(d) Lattice

(b) Projected area fraction of atoms on a plane

(d) None

Choose the correct lattice parameters for a hexagonal crystal system

(a) a=b=c , == 0deg, =120deg
(b) a=bc , ==90deg, =120deg
(c) a=b=c , ===120deg
(d) a=bc , ===120deg
Following is not the 2-dimensional imperfection
( ) Di location
(b) Grain boundary
(c) Twin boundary
(d) External surface
The yield strength for a material with well-defined elastic to plastic transition showing an upper and lower
yield point is measured as
(a) stress at 0.2% offset strain
(b) average of stresses at upper and lower yield point

Answer

TLO
Measured

Unit Cell

1.1

Volume
fraction of
atoms in a unit
cell
a=bc ,
==90deg,
=120deg

1.2

1.3

Dislocation

1.4

average stress at
lower yield
point

2.1

11

6.

7.

(c) average stress at lower yield point

(d) stress at upper yield point
For a tensile experiment the ductility is measured as
(a) percentage elongation in length
(b) percentage reduction in area
(c) both
(d) None of the above
Plastic deformation results from the following
(a) Slip
(b) Twinning
(c) Both
(d) None

both

2.2

Both

2.3

Quiz 2
SL
No.
1
2
3
4
5
6
7

Questions
The slow and progressive deformation of a material with time at constant stress is known as
(a) Fracture
(b) Fatigue
(c) Creep
Usually materials with following crystal structure fail in ductile mode
(a) HCP
(b) FCC
(c) BCC
(d) None
Creep rate in ternary stage
(a) Decreases
(b) Increases
(c) Constant
(d) None
SN curve gives information about
(a) Fatigue
(b) Creep
(c) Failure
(d) All
For homogeneous nucleation occurs in the presence of
(a) Impurities
(b) Undercooling
(c) Both (a) & (b)
(d) None
As the grain size decreases the hardness of a material
(a) Decreases
(b) Increases
(c) Has no effect
(d) None
A binary phase diagram is a plot of
(a) Temp. Vs Time
(b) Temp. Vs
(c) Temp. Vs Pressure
(d) None
Composition
Eutectoid reaction can be represented as
(a)

9
10

Creep

TLO
Measured
3.1

FCC

3.2

Increases

3.3

Fatigue

3.4

Answer

(b)

Maximum percentage of carbon in austenite is

(a) 0.02 %
(b) 0.8 %
The upper critical temperature for steel

(c)

Undercooling
Increases
Temp. Vs
Composition

4.1
4.2
4.3

4.4

(d)
5.1

(c) 2.1 %

(d) 4.3 %

2.1 %
5.2
12

11

12
13
14
15

(a) varies with carbon

(b) is constant
(c) depends on rate
(d) none of these
%
of heating
Annealing of steel is done
(a) to soften the metal (b) improve
(c) refine grain size
(d) all of these
machinability
Suggest a suitable heat treatment to increase hardness without resorting to severe quenching.
(a) Annealing
(b) Normalizing
(c) Martempering
(d) Carburizing
Bronze is an alloy of
(a) Copper & Zinc
(b) Copper & Tin
(c) Iron & Brass
(d) Iron & Zinc
Which of the following is a continuous production technique used for production of FRP
(a) Filament winding
(b) Vacuum bag moulding (c) Spray up process
(d) Pultrusion
The function of a matrix phase in a composite is
(a) Improve impact and fracture resistance
(b) Provide strength and stiffness to composite
(c) Both (a) and (b)
(d) None

varies with
carbon %
all of these

6.1

Martempering

6.2

Copper & Tin

7.1 & 7.2

Pultrusion
Both (a) and (b)

8.1
8.2

13

3.2 Assessment data:

I Internal Assessment Marks
Marks Scored

Sl. No.

USN

Name

Q. No.

Max

5
5
5
5
5
5
5
5
5
5
4
5
5
NA
4
3
5
3
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5

4
0
2
0
1
4
1
4
4
1
4
4
2
1
1
2
1
3
4
1
4
1
1
4
1
2
4
4
1
4
1
1
4

5
1
5
0
5
5
NA
5
5
3
4
5
5
2
5
2
1
1
5
4
5
5
5
5
4
5
5
4
5
5
5
4
5

3
0
1
0
2
3
0
3
2
0
3
3
0
1
NA
0
0
1
3
1
1
1
0
3
1
0
3
3
0
3
3
1
3

5 [a] 5 [b]
5
1
2
0
5
5
3
5
5
5
5
5
3
NA
2
5
NA
1
5
4
5
NA
5
4.5
1
1
5
5
2
3
5
2
5

3
2
2
1
1
3
1
3
3
3
3
3
2
3
0
3
1
3
3
3
3
3
3
3
3
3
3
2
2
3
3
0
3

Total Marks 870 289 712 266.5 649 396.5

Average Marks 4.10 1.55 3.39 1.46 3.12 2.02
Avearage Marks (Percentage) 82.08 38.84 67.81 48.81 62.40 67.43
TLO/s which is/are assessed by the question 1.2 1.5 2.1 1.3 2.2 2.3
14

II Internal Assessment Marks

Marks Scored
Q. No.
Sl. No.

USN

Name

Max

5
5
5
5
5
5
5
5
5
0
5
5
5
5
3
5
5
5
5
4
5
5
5
5
5
5
Total Marks 912
Average Marks 4.36
Avearage Marks (Percentage) 87.27
TLO/s which is/are assessed by the question 4.4

4 [a] 4 [b]

7
13
8
5
3
NA
NA NA
6
NA
8
3
3
2
NA NA
3
12
NA NA
4
10
NA NA
7
NA
NA
5
4
NA
8
2
5
5
NA NA
6
NA
8
2
5
5
NA NA
5
8
NA NA
4
NA
8
4
4
NA
NA NA
5
NA
4
1
5
0
NA NA
4
10
NA NA
6
NA
8
4
7
13
NA NA
2
4
NA NA
3
NA
8
5
6
NA
7
1
5
NA
8
5
7
11
NA NA
3
NA
8
3
3
NA
6
5
912
971.5
700 442.5
4.51
6.75
5.88 3.75
64.50 51.90 73.53 75.00
4.1 5.1 & 5.2 3.2 3.4
19

III Internal Assessment Marks

Q. No.
Sl. No.

USN

Name

Max

1 [a] 1 [b]

3
0
NA
3
2
NA
NA
NA
2
NA
3
2
NA
2.5
2.5
2.5
1.5
Total Marks 136
Average Marks 2.00
Avearage
AvearageMarks
Marks(Percentage)
(Percentage) 66.67
TLO/s
which
is/are
assessed
by
the
TLO/s which is/are assessed by thequestion
question 8.2

3
NA
NA
0
2.5
NA
NA
NA
0
NA
1
2.5
NA
2
0
1.5
0
107
1.81
60.45
8.1

5
4
5
5
0
1
NA NA
NA NA NA NA
5
1
0.5
4
5
4
NA
5
NA NA NA NA
5
NA NA NA
NA NA NA NA
4
1
4
3
NA NA NA NA
4
1
1
NA
5
4
5
5
NA NA NA NA
0
NA
5
NA
4
4
1
1
0
4
5
0
4
0
0
0
197 203.5 349 170
2.94 3.04 2.81 2.66
58.81 75.93 56.29 53.13
8.1 6.1 6.2 6.1
24

Quiz 1 Result
Sl.No.

USN

Average Marks (Percentage)

TLOs Assessed by the question

Name

Quiz score
1

62%

51%

50%

36%

19%

53%

67%

1.1

1.2

1.3

1.4

2.1

2.2

2.3

30

Quiz 2 Result
Sl. No. USN
USN

Name

Name

Quiz score
Quiz score
1
0
0
0
1
1

2
0
0
0
0
1

3
1
1
0
1
0

4
1
1
1
1
1

5
1
1
0
1
0

6
1
1
1
1
1

7
1
0
0
1
1

8
0
1
0
0
1

9
1
0
0
1
0

10
1
0
0
1
0

11
0
0
0
1
1

12
0
1
0
1
0

13

14
1
0
1
0
0

15
0
0
0
0
0

Average Marks (Percentage)

43

33

58

52

48

74

68

34

30

50

44

25

47

21

17

TLOs Assessed by the question

3.1 3.2 3.3 3.4 4.1 4.2 4.3 4.4 5.1 5.2 6.1 6.2 7.1&7.2 8.1 8.2

0
0
1
1

34

Assignment Marks
Marks Scored

Sl. No.

USN

Name

Assigment No.

A1

A2

Q. No.

(8 Questions)

(7 Questions)

Max

5
3
5
3
5
5
4
5
5
5
5
3
4
4
4

5
2
5
4
3
5
3
2
3
5
5
4
5
5
4

Total Marks
586
575
Average Marks
3.93
3.86
Avearage Marks (Percentage)
78.66
77.18
TLO/s which is/are assessed by the question 1.4, 2.1, 2.2, 2.3 4.1, 4.3, 4.4, 5.1, 5.2

43

4. Attainment of Course Outcomes

4.1 Measuring CO attainment:

TLO
No.
Topic Learning Outcome
1.1 Draw unit cells for BCC, FCC and HCP crystal
structures.
1.2 Find the atomic packing factor for BCC, FCC
and HCP crystal structures.
1.3 Compute the density of metals having FCC, BCC and
HCP
crystal structures given their unit cell dimensions.
1.4 Name and describe different crystal imperfections.
2.1

2.2

2.3
3.1
3.2

3.3
3.4
4.1
4.2
4.3

Explain the ductile-brittle and linear-nonlinear elastic

behaviour
of materials.
Evaluate the mechanical properties of a material
through
stress strain diagram.
Identify plastic deformation by slip and twinning in
materials.
Differentiate failure of materials by fracture, creep and
fatigue.
Explain the different types of fracture modes, creep
stages
and fatigue loading.
Explain the phenomenon of creep and its properties.

Contribution to CO
Attained
Attainment
Level of
Percentage
Bloom's Assessment
Average
Attainment
Taxonomy Tool Used Weightage Assessment CO1 CO2 CO3 CO4
Goal
Remembering
Quiz 1
0.25
62.22
15.56
Applying

IA 1

0.25

82.08

20.52

Quiz 1

0.25

49.63

12.41

Quiz 1

0.25

35.56

8.89

IA 1

0.2

67.81

13.56

IA 1

0.2

62.40

12.48

IA 1

0.1

67.43

6.74

Quiz 2

0.1

43.14

4.31

IA 2

0.2

73.53

14.71

Quiz 2

0.1

57.84

5.78

IA 2

0.1

75.00

7.50

IA 2

0.1

64.50

6.45

Quiz 2

0.1

73.53

7.35

Quiz 2

0.1

67.65

6.76

Applying

Remembering
Understand

Analyzing

Understanding
Understanding
Understanding

Understanding

Explain mechanism of fatigue failure for a material and Understanding

plot SN diagram.
Explain the mechanism of solidification by nucleation Understanding
and grain growth for pure metals and alloys.
Enumerate the significance of cast structure of metals
Applying
and the methods to control it.
Construct phase diagram for simple binary alloys.
Remembering

44

4.4
5.1
5.2
6.1
6.2
7.1
7.2
8.1
8.2

Identify the formation of interstitial or substitutional

solid solutions and intermediate phases.
Construct the Iron-Carbon equilibrium diagram
and discuss the invariant reactions in it.
Interpret the formation of steel and cast irons
using an iron-carbon diagram
Explain the process details of various heat treatment
processes.
Suggest a suitable heat treatment technique for
the desired materials and properties.
State the areas of application of commonly used
engineering materials.
Suggest the selection of materials based on the
property requirements
Explain the production techniques for some
common FRPs and MMCs
List out the advantages and applications of
composite materials

Understanding
Understanding
Understanding
Understanding
Understanding
Remembering
Understanding
Understanding
Remembering

IA 2

0.1

87.27

8.73

IA 2

0.2

51.90

10.38

Quiz 2

0.1

50.00

5.00

IA 3

0.2

75.93

15.19

IA 3

0.1

56.29

5.63

Quiz 2

0.2

47.06

9.41

Quiz 2

0.2

47.06

9.41

IA 3

0.3

60.45

18.14

IA 3

0.3

66.67

20.00

Total Attainment of CO1 57.37

Total Attainment of CO2
Total Attainment of CO3
Total Attainment of CO4

65
65.09

65
65.49

65
56.96

65

45

4.2 Remarks:
Course Coordinator:

Module Coordinator:

(Course & Module Coordinator)

(HOD Mech Dept)

46

Appendix I
(IA Scheme & Solutions)

I Internal Assessment - Scheme of evaluation & Solution

Q.No Solution
1.
What is packing factor? Find the packing factor for FCC?

Marks
5
(1)

Atomic Packing Factor

The Atomic Packing Factor (APF) is the fraction of volume in a crystal
structure that is occupied by the atoms.
i.e., APF =
=

=
(4)

FCC:

From ABC,
AC2+BC2= AB2
2

Number of atoms per unit cell,

Volume of each atom,

Volume of a unit cell,

=4

Therefore,
APF =

APF = 0.74
i.e., 74 % of the space available in a FCC unit cell is occupied by atoms.

47

2.

What is diffusion? Explain the unsteady state of diffusion with example?

Atomic diffusion
From an atomic perspective diffusion may be defined as the mass flow
process by which atoms or molecules migrate from lattice site to lattice site
within a material resulting in the uniformity of composition as a result of
thermal agitation.
Ficks second law of diffusion:
Most practical diffusion situations are usually of unsteady state. i.e., the
diffusion flux and the concentration gradient at some particular point in
solid vary with time resulting in net accumulation or depletion of
diffusing species.

Therefore,

4
(1)

(3)

Where,
= rate of composition change
= co ncentration gradient
D = diffusivity, m2/s

Fig: Concentration profile for unsteady state diffusion

If diffusion coefficient is independent of concentration;

=D
i.e., the rate of composition change is equal to the diffusivity times the rate of
concentration gradient.
The solution to the above equation can be obtained by applying appropriate
boundary conditions.
Fort = 0,
C = C0 (0 x )
For t > 0,
C = Cs (at x = 0) and C = C0 (at x = )
Applying the above boundary conditions the solution can be obtained as,
= 1 erf
From the above equation
parameters
3.

may be determined at any time and position if the

and D are known

Differentiate between ductile and brittle material? Name five examples for
each?

48

Ductile

Brittle

Materials can withstand larger strain Material fracture at lower strain

before fracture
Large amount of yielding and yield No yield point and less yielding
point in some cases
Low youngs modulus and ultimate Comparatively large
stress
Capable of absorbing large quantities Comparatively small
of energy before fracture

4.

Necking is observed before fracture

Catastrophic failure without warning

Ex: steel, aluminum, gold etc

Ex: glass, cast iron, concrete etc

The unit cell of chromium is cubic and contains 2 atoms. Determine the
dimension of the dimension of the chromium unit cell and atomic radius.
Given atomic weight of chromium=52 & density of chromium=7.19 g/cm3

Solution : chromium = cubic structure

Atomic data= A=52
Density = =7.19 Mgm-3

V=2.401*10-23 cm3
w.k.t cubic structure, volume=V=a3
a=0.288nm
5.a)

A Steel rod of 10mm die & 1.5m length is subjected to an axial tensile test
of 10KN. Determine (a) Stress (b) strain (c) Elongation. Take E=205*10 6
KN/m2

(3)
Solution : original dia=do=10mm
Original length=Lo=1.5m=1.5*103mm
Load =P=1KN
E=205*106 kN/m2

49

w.k.t

(Youngs modulus)

(1)

Elongation (
w.k.t stain(

5.b)

(1)

Explain any one of this (a) Edge dislocation (b) screw dislocation.

Edge Dislocation
It is created in a crystal by insertion of an extra plane of atoms i.e., a half plane
as shown in figure. The edge of the half plane terminates within the crystal, this
is termed as dislocation line. The atoms above the dislocation line are squeezed
together and are in a state of compression while the atoms below are pulled
apart and are in a state of tension. Edge dislocation is represented by the
symbol for positive dislocation and for negetive dislocation.
Screw Dislocation
It is said to be formed in perfect crystal when part of the crystal displaces
angularly over the remaining part under the action of shear stress. The upper
front region of the crystal is shifted one atomic distance to the right relative to
the bottom portion. The screw dislocation derives its name from the spiral or
helical path that is traced around the dislocation line by the atomic planes of
atoms. Screw dislocation is represented by the symbol
for clockwise or
positive dislocation and for counterclockwise or negtive dislocation.

50

II Internal Assessment
Q.No Solution
Marks
Answer both questions from Part A and any one from Part B.
Part A
1.
Explain Hume-Rothary rules governing the formation of substitutional
5
solid solution.
These are the rules governing the formation of substitutional solid solutions;
(5x1)
1) Crystal structure factor: for complete solid solubility of two elements, they
should have the same type of crystal structure.
2) Relative size factor: the atoms of the solute and the solvent should be
approximately of the same size (difference in radii should be less than
15%).
3) Chemical affinity: the two metals should have very less chemical affinity.
4) Electronegativity (tendency to acquire electrons): the two metals should
have less electronegativity; higher the electronegativity of two elements
greater will be the chance of forming an intermediate phase.
5) Relative valence factor: among the metals, the one with the lower valency
tends to dissolve more of a metal of higher valency than vice versa. For
example, in a Ni-Al system; Ni has valency of 2 which dissolves 5% Al,
but Al has valancy of 3 and dissolves only 0.04% Ni.
2.

Explain the mechanism of solidification for pure metals.

Solidification in pure metals

Pure metals have a clearly defined melting or freezing point. i.e., it solidifies at
a constant temperature.The evolution of latent heat is associated with
solidification and as a result temperature remains constant. An equilibrium
cooling of pure metal maybe assumed as shown in figure 3.9. It is also seen that
if a pure metal is cooled rapidly or otherwise when it is very pure it may cool
with some amount of undercooling.

51

Dendritic growth
Pure metals solidifying with a negative temperature gradient may result in
uneven projection of interface due to the thermal undercooling. The tip of the
projection is at a region of greater undercooling than the remainder of the
interface and will have a tendency to grow further into the liquid. The solids
grow in a stem perpendicular to the surface. The latent heat evolved tends to
lower the amount of undercooling at the main interface. The protrusion grows
into a spike while the growth of main interface is somewhat retarded. The spike
grows and branches develop on it, this branched structure is known as a
dendrite. The rate of dendritic growth depends upon the amount of
undercooling in the liquid ahead of the advancing dendrite.
Part B
3.a)

Draw Fe-Fe3C phase diagram and label all the regions indicating the invariant
reactions with the temperature and composition for the same.

8
(6+2)

3.b)
3.c)

4.a)

From the above phase diagram calculate the amount of eutectic present in the
pearlite using lever rule.
Also sketch the typical microstructure for the following
(i) eutectoid steel at room temperature
(ii) hypo-eutectic cast iron having 3% carbon at 910 C and at room
temperature
Explain with a neat sketch the different stages of creep formation?
Explanation

2
3

8
(4)

52

(4)

4.b)

What is fatigue failure? Draw S-N curve for steel and aluminium?
Explanation

5
(2)

(3)

III Internal Assessment

Q.No Solution
1.a)
From fundamentals distinguish clearly between alloy and composites.

Marks
3

In an alloy, the element getting introduced (solute) dissolves into the metal
getting alloyed (solvent) to form a solid solution. It is a kin to salt dissolving in
water to form a salt solution except that the alloy is in solid form. One cannot
distinguish
them.
In the case of composite, the metal forming the base of the composite (matrix)
and the added element remain un dissolved and could be identified. In the case
of metal matrix composite, one finds carbon fibers or a ceramic material in the
matrix of metal.
1.b)

Classify the composites based on the matrix and reinforcements.

3
53

Classification based on Reinforcements

2.

List down the production methods of metal matrix composites. Explain

any one with neat sketch.
For listing out production methods -1 marks
For sketch-2 marks
For explanation-2 marks.

3.

What is meant by heat treatment? What are its objectives?

Heat treating is a group of industrial and metalworking processes used to alter
the physical, and sometimes chemical, properties of a material. The most
common application is metallurgical.

4
(1)

54

Objectives (at least three)

4.

Define hardenabilty. Explain the process which is used to find the

hardenability of steel.

(3)
5

Definition-1 marks
Sketch-2 marks
Explanation-2 marks

5.

What is Case hardening? Explain pack carburizing process.

Definition-1 marks
Sketch-2 marks
Explanation -2 marks

55