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ME6403Engineering Materials and Metallurgy Department of Mechanical Engineering 2016-2017
ME6403 ENGINEERING MATERIALS AND METALLURGY L T P C

3 0 0 3
OBJECTIVES:
To impart knowledge on the structure, properties, treatment, testing and applications of metals and non-metallic
materials so as to identify and select suitable materials for various engineering applications.
UNIT I ALLOYS AND PHASE DIAGRAMS 9

Constitution of alloys – Solid solutions, substitutional and interstitial – phase diagrams, Isomorphous, eutectic,
eutectoid, peritectic, and peritectoid reactions, Iron – carbon equilibrium diagram. Classification of steel and cast
Iron microstructure, properties and application.
UNIT II HEAT TREATMENT 10

Definition – Full annealing, stress relief, recrystallisation and spheroidising – normalising, hardening and
Tempering of steel. Isothermal transformation diagrams – cooling curves superimposed on I.T. diagram CCR –
Hardenability, Jominy end quench test - Austempering, martempering – case hardening, carburizing, Nitriding,
cyaniding, carbonitriding – Flame and Induction hardening – Vacuum and Plasma hardening. .
UNIT III FERROUS AND NON-FERROUS METALS 9

Effect of alloying additions on steel- α and β stabilisers– stainless and tool steels – HSLA, Maraging steels –
Cast Iron - Grey, white, malleable, spheroidal – alloy cast irons, Copper and copper alloys – Brass, Bronze and
Cupronickel – Aluminium and Al-Cu – precipitation strengthening treatment – Bearing alloys, Mg-alloys, Ni-
based super alloys and Titanium alloys.
UNIT IV NON-METALLIC MATERIALS 9

Polymers – types of polymer, commodity and engineering polymers – Properties and applications of various
thermosetting and thermoplastic polymers (PP, PS, PVC, PMMA, PET,PC, PA, ABS, PI, PAI, PPO, PPS, PEEK,
PTFE, Polymers – Urea and Phenol formaldehydes)- Engineering Ceramics – Properties and applications of
Al2O3, SiC, Si3N4, PSZ and SIALON –Composites-Classifications- Metal Matrix and FRP - Applications of
Composites.
UNIT V MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS 8

Mechanisms of plastic deformation, slip and twinning – Types of fracture – Testing of materials under tension,
compression and shear loads – Hardness tests (Brinell, Vickers and Rockwell), hardness tests, Impact test lzod
and charpy, fatigue and creep failure mechanisms.
TOTAL : 45 PERIODS
TEXT BOOKS:
1. Avner,, S.H., “Introduction to Physical Metallurgy”, McGraw Hill Book Company,1994.
2. Williams D Callister, “Material Science and Engineering” Wiley India Pvt Ltd, Revised Indian Edition 2007
REFERENCES:
1. Raghavan.V, “Materials Science and Engineering”, Prentice Hall of India Pvt. Ltd., 1999.
2. Kenneth G.Budinski and Michael K. Budinski, “Engineering Materials”, Prentice Hall of India Private
Limited, 4th Indian Reprint 2002.
3. Upadhyay. G.S. and Anish Upadhyay, “Materials Science and Engineering”, Viva Books Pvt. Ltd., New Delhi,
2006.
4. U.C.Jindal : Material Science and Metallurgy, "Engineering Materials and Mettalurgy", First Edition, Dorling
Kindersley, 2012.
1
St.Joseph’s College of Engineering
COURSE OUTCOMES
On Completion of the course the student will be able:
To identify the material constituents from phase diagram and to understand the classification
CO404.1
of steels and cast iron.
CO404.2 To understand the classification of various heat treatment process.
CO404.3 To understand the effects of alloying elements and Engineering applications of ferrous and
non-ferrous metals
CO404.4 To understand the engineering applications of non-metallic materials.
CO404.5 To understand the various deformation mechanisms and testing of various mechanical
properties of materials
MAPPING BETWEEN CO AND PO, PSO WITH CORRELATION LEVEL 1/2/3
ME6403 PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 PSO3
CO404.
1 3 2 2 2 - 2 2 2 - - - 2 2 3 3
CO404.
2 3 2 2 2 - 2 2 2 - - - 3 2 3 3
CO404.
3 3 2 2 2 - 2 2 2 - - - 3 2 3 3
CO404.
4 3 2 2 2 - 2 2 2 - - - 3 2 3 3
CO404.
5 3 2 3 2 - 2 2 2 - - - 3 2 3 3
RELATION BETWEEN COURSE CONTENT WITH COs

UNIT – I - ALLOYS AND PHASE DIAGRAMS
S.No Knowledge Topics Course Outcome

level
1. Ap,An,U UNIT – I - ALLOYS AND PHASE DIAGRAMS CO404.1
2. Ap,An,U UNIT – II HEAT TREATMENT CO404.2
3. Ap,An,U UNIT – III FERROUS AND NON-FERROUS CO404.3
4. Ap,An,U METALS
UNIT – IV NON-METALLIC MATERIALS CO404.4
5. Ap,An,U,E UNIT – V MECHANICAL PROPERTIES AND CO404.5
DEFORMATION
Ap – Apply; An – Analyze; U – Understand, E- Evaluate,C-Create
2
UNIT – I - ALLOYS AND PHASE DIAGRAMS

PART A
1. What is an alloy?
A metal alloy, or simply an alloy, is a mixture of two or more metals or a metal (metals) and a non-
metal (non-metals).
2. Define solid solution. [Nov/Dec 2011]
A solid solution is formed when two metals are completely soluble in liquid state and also completely
soluble in solid state. In other words, when homogeneous mixtures of two or more kinds of atoms (of
metals) occur in the solid state, they are known as solid solutions.
3. Differentiate between substitutional and interstitial solid solution.[M/J 2009,2015]
[N/D2007, 2014,2015]
In substitutional solid solution, the solute atoms (impurities) substitute for parent solvent atoms in a
crystal lattice. E.g.,Cu-Ni system,Cu-Zn system and Au-Cu system
In interstitial solid solution, the solute atoms fit into the space between the solvent or parent atoms.
4. State Hume Rothery’s rules for formation of substitutional solid solutions. (Or) State
the conditions under which two metallic elements will exhibit solid solubility.
[A/ M2009,2014, 2015]
1. Size factor: The atoms must be of similar size, with less than a 15% difference in atomic radius
(in order to minimize the lattice strain).
2. Crystal structure: The materials must have the same crystal structure.
3. Valence: The atoms must have the same valence.
4. Electro negativity: The atoms must have approximately the same electro negativity.
5. What are intermediate phases?
If an alloying element is added in excess of the limit of solid solubility, a second phase appears
along with the primary solution. If the second phase differs in both crystal structure and properties
from primary solid solution, then it is known as an ‘intermediate’ phase..
6. Define ‘phase’. What different kinds of phases are possible?
A phase is defined as any physically distinct, homogeneous and mechanically separable portion of a
substance. Three different kinds of phases are solid, liquid and vapour..
7. What are the advantages of the equilibrium diagrams?
1.To show what phases are present at different compositions and temperature under equilibrium
conditions.
2.To indicate the equilibrium solid solubility of one element in other element.
3.To indicate the temperature range over which solidification of a material occurs.
4.To indicate the temperature at which different phases start to melt.
8. State Gibb’s phase rule. [May/Jun 2014, 2016]
Gibb’s phase rule is given by F=C-P+2 where,
F=degrees of freedom of system or number of variables (such as temperature, pressure or
composition) that may be changed independently without altering the equilibrium;
C=number of components (usually elements or compounds) forming the system; and
P=no of phases present in the system.
The constant 2 in the equation implies that both temperatures and pressure are allowed to change.
9. What is a liquidus line, a solidus line and a solvus line?
In a phase diagram, liquidus line is the line or boundary that separates liquid and liquid+solid
phase regions.
A Solidus line is a line or boundary that separates solid and solid+liquid phase regions.
A Solvus line separates single-phase solid regions from two-phase solid regions.
10. What is the information that can be obtained from each point in a phase diagram?
Using a phase diagram, one can obtain at least the following three informations.1. The phases that are
present, 2. The composition of each phase, and 3. The amount of each phase present.
11. What is tie-line?
A tie line is simply an isothermal line drawn through point of consideration, extending across the
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two-phase region and terminating at the phase boundary lines on either side.
12. Explain the lever-law calculation and what information does it provide?
Phase fraction = (Opposite arm of lever / Total Length of Tie line)
Phase percentage = ( Opposite arm of lever /Total length of Tie line) X 100
Using the lever law calculations, one can compute the phase fraction and the phase percentage.
13. What is meant by invariant reaction? [Nov/Dec 2013,2015]
The eutectic reaction is also called an invariant reaction since it occurs under equilibrium conditions at
a specific temperature and alloy composition that cannot be varied.
14. Define the Eutectoid reaction. Give examples. [Nov/Dec 2014] [May/Jun 2012,2016]
In the eutectoid reaction a solid phase decompose into two other solid phases
upon isothermal cooling. Austenite a solid solution of carbon and gamma iron, decomposes
in to pearlite a mixture of two solids alpha iron and iron carbide
In the Fe-Fe3C equilibrium diagram the eutectoid reaction takes place at the temperature of
727°C, at the cmposition of 0.8% of C, Austenite is converted into Pearlite mixture during
cooling.
15. What is eutectic reaction? [Nov/Dec 2011, 2013] [M/J-2016]
Upon cooling a liquid phase is transformed into the two solid phases at eutectic temperature.The opposite
reaction occurs upon heating. This is called eutectic reaction. In general the eutectic mixture with in a
simple binary alloy system is the lowest melting point mixture within that alloy system.
16. Distinguish between peritectic and peritectoid reactions. [Nov/Dec 2014]

The peritectic reaction can be written as
Solid 1 +Liquid = Solid 2
The
peritectoid reaction can be written as
Solid 1 + Solid 2 = Solid 3
17. Define: ferrite and austenite. [May/Jun 2013]

Ferrite is a primary solid solution based on iron having BCC structure. Maximum solubility of
carbon in iron is 0.025% carbon at 723°C, while its solubility at room temperature is only about
0.008%.
Austenite is a primary solid solution based on iron having FCC structure. The maximum
solubility of carbon in FCC iron is about 2% at 1140°C.
18. Define: Cementite and Pearlite.
Cementite is the name given to the carbide of iron (Fe3C). It is the hard, brittle, intermetallic
compound of iron with 6.69% of carbon.
Pearlite is the eutectoid mixture of ferrite (87.5%) and cementite (12.5%). It is formed when
austenite decomposes during cooling. It contains 0.8% of carbon.
19. Define: martensite, and bainite.
Martensite is the super saturated solid solution of carbon in iron. It is formed when a steel
is very rapidly cooled from the austenitic state.
Bainite is a decomposition product of austenite, consisting of an aggregate of ferrite and
carbide. Bainite has hardness in between the hardness of pearlite and martensite.
20. What is meant by eutectoid, hypoeutectoid, hypereutectoid steels?[M/J 2007 [N/D 2013]
Steels that contain 0.8% C (the eutectoid amount of carbon) are called eutectoid steels.
Steels having less than 0.8% C are known as hypoeutectoid steels.
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Steels having more than 0.8% C are known as hypereutectoid steels.

21. How do cast irons differ from steels in terms of carbon content?
Composition from 0.008% to 2% carbon represent steel and those above 2% carbon represent cast
iron.
22. Distinguish between hypoeutectic and hypereutectic cast irons.

Cast irons that contain less than 4.3% C are termed as hypoeutectic whereas cast irons that
contains more than 4.3% C termed as hypereutectic.
23. Define polymorphism and Allotropy.
Polymorphism is a physical phenomenon where a material may have more than one crystal structure. A
material that shows polymorphism exists in more than one type of space lattice in the solid state. If
the change in structure is reversible, then the polymorphic change is known as allotropy. The best
known example for allotropy is iron.
24. Name the various micro structures of Fe-Fe3C phase diagram.
Various micro sturctures of Iron carbon equilibrium diagram areFerrite, Austenite,
Pearlite, Cementite, Ledeburite, Martensite, Troostite, Sorbite and Bainite.
25. Draw a typical cooing curve of pure metal and a soild solution? (NOV/Dec -2015)
PART B
1. What are cooling curves? Explain the time-temperature cooling curve of an pure metal, binary solid
solution and binary eutectic system?
2. Plot and explain with examples (a) a binary phase diagram for two metals which are completely soluble
in liquid and solid states. [May/Jun 2014]
(b) a phase diagram for binary eutectic alloy system ? [May/Jun 2013][April/May 2015]
3. What are the micro-constituents of iron-carbon alloys ? Explain the general characteristics of each.
4. Draw iron-iron carbide equilibrium diagram and mark all salient temperatures and composition fields
and phase reactions involved in it ? [Nov/Dec 2014,2015] [April/May 2015,2016]
5. Describe the phase changes that occur when a molten 0.35% C steel solidifies and cools slowly from
1700° C to room temperature. Also draw the probable microstructure of steel at about 800°C and 25 °C.
[Nov/Dec-2015] [May/Jun 2014]
6. Name the phase reactions occurring in Fe –Fe 3C system.What are the temperatures and compositions at
which they occur? [Nov/Dec2013, 2014][May/Jun 2012]
7. Explain the primary crystallization of eutectoid steels, hypoeutectoid steels and hypereutectoid steels.
[May/June -2016]
8. Explain the primary crystallization of eutectoid cast irons, hypoeutectoid cast irons and hypereutectoid
cast irons. [May/June -2016]
9. Two metals A and B have melting points at 900 °C and 800°C .The alloy pair forms an eutectic at 600°C
of composition 60% B and and 40%A. A and B have unlimited mutual solubilities.Their solid
solubilities are as follows: 10%B in A at 600°C and 5%B in A at 0°C. 12% A in B at 600°C and 4% A
in B at 0°C. Assume liquidous, solidous and solvus lines to be straight, no solid state reactions other
than solubility changes occur in the series.(i) Draw the phase diagram for series and label all the
temperatures,compositions and fields (ii) Find the number, type, extent and composition of the phases
present in an alloy of composition 60%A and 40%B at 200 °C ?
10. Two metals A and B have 100% mutual solubilities in the liquid and solid states. The melting point of
pure metals A and B are 800°C and 600 °C respectively. Details of start and end of solidifications of
various alloys in the series as follows:
Alloy Compositions Temperature at the Temperature at the end
start of of solidification
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solidification
90% A +10% B 798°C 750°C
70% A +30% B 785°C 705°C
50% A +50% B 757°C 675°C
30% A +700% B 715°C 645°C
10% A +90% B 650°C 615°C
(i) Draw the phase diagram of the series if there are no solid state reactions and label all the regions. (ii)
Determine the number, relative amount and concentration of phases present in an alloy of 40%A and
60% B at 700°C and 400°C ?
UNIT – II HEAT TREATMENT
PART A
1. What are the purposes of the processing heat treatments?
1. To relieve internal stresses. 2. To improve machinability. 3. To refine grain size.
4. To soften the metal. 5. To improve hardness of the metal surface.
6. To improve mechanical properties (like tensile strength, hardness, ductilit y, etc.)
2. Draw the cooling curve for a pure metal and an alloy.
3. List the various stages of a heat treatment process.

Stage 1: Heating a metal/alloy beyond the critical temperature.
Stage 2: Holding at that temperature for a sufficient period of time to allow necessary changes to
occur.
Stage 3: Cooling the metal/alloy (i.e., quenching) at a rate necessary to obtain the desired
properties. That is, cooling at a rate necessary to obtain the desired changes in the nature
form, size and distribution of micro-constituents.
4. What is meant by annealing? List the different types of annealing and mention its
purpose?
Annealing is defined as a softening process consisting of heating the steal to a temperature at
or near the critical point, holding there for a proper time and then allowing it to cool slowly in the
furnace itself.Types: a) Full annealing. b) Process annealing. c) Stress relief annealing.
d)Recrystallisation annealing, and e) Spheroidise annealing.
1. To relieve or remove stresses. 2. To induce softness. 3. To refine grain structure, 4. To alter
ductility, toughness, electrical, magnetic or other properties. 5. To remove gases.
6. To produce a definite microstructure.
5. What is meant by full annealing? [May/Jun 2012]
Full annealing consists of heating the steels 15 degrees to 40 degrees centigrade above A 3
temperature in case of hypoeutectoid steels and above A 1 temperature in case of hypereutectoid steels
and cooling very slowly in the furnace itself. Austenitic steel is the most ductile of the steels and has a
very high relative strength. It is held at this temperature until all the material transforms and then slowly
cools in a furnace to about 50 degrees Celsius when it can be then cooled through convection in the
room. In this process hardness and strength are restored by additional heat treatments after machining
6. What is meant by process annealing? [May/Jun 2013]
Process annealing is applied to cold worked materials to negate effects of cold work.
Commonly sandwiched between two cold work operations, it improves ductility. This is used
to treat worked metals, such as two pieces of metal that have been welded together. This
makes it possible for the metal to undergo further work without fracturing. The metal is heated to just
below the A1 temperature line (see blue arrow); it is held there long enough for the metal to change the
6
size and distribution of its grain structure and then cooled naturally in air. This process is cheaper than
Full Annealing or Normalizing because the metal is not heated to high temperatures
7. What is meant by stress relief annealing and spheroidizing ? State its importance.
[Nov/Dec 2013] [Nov/Dec 2014]
Stress relief – purpose of it is to remove stresses. Temperatures are low such that cold work
effects are not affected. Reduces the residual stresses in large castings and welded parts.
These stresses are caused by thermal cycling or work hardening. The metal is heated to 600
degrees Celsius (see green line), held at that temperature level for over an hour and then
cooled in air.
Spheroidizing: Medium and high carbon steels are too hard to machined. Prolonged
cycling between temperatures just below and above A1 line will develop spheroidite structure.
This results in maximum softness and ductility.
8. Differentiate between normalizing and full annealing. [April/May 2015]
S. Normalising Full Annealing
No.
Normalizing is similar to full annealing, Heating above UCT cooling very
1 but cooling is established in still air slowly in the furnace itself
i n s t e a d in the furnace
Normalising is more economical than full
annealing (since no furnace is required to Full annealing is costly
2
control the cooling rate).
3 Normalising is less time consuming. Full annealing is more time
Normalising temperature is higher than full Annealing temperature is lower
4 annealing. than normalising.
5 It provides a fine grain structure. It provides coarse grain structure.
9. What is quenching? List some of the quenching medium generally used in industries.
[May/Jun2014]
Quenching refers to accelerated cooling.Some of the quenching medium that are use generally in
industries are: 5-10% caustic
soda, 5-20% brine (NaCl), cold water, warm water, mineral oil (obtained during the refining of
crude petroleum), animal oil, vegetable oil (such as linseed, cottonseed, and rapeseed).
10. What are the factors should be considered while selecting a quenching medium?
1.Desired rate of heat removal. 2. Required temperature interval.3. Boiling point. 4.Viscosity. 5. Flash
point (if combustible).6. Stability under repeated use. 7. Possible reactions with the material
being quenched. 8. Cost.
11. What are the three stages for quenching?
Stage 1: Vapour-jacket stage. Stage 2: Vapour-transport cooling stage. Stage 3: Liquid Cooling stage.
12. What does the term hardening refer to? What are the factors that affect the hardness?
Hardening refers to the heat treatment of steel which increases its hardness b y quenching.The
hardness obtained from the hardening process depends upon the following factors: 1. Carbon
content, 2. Quenching medium, 3. Specimen size, and 4. Other factors
13. Distinguish the work hardening process with the age hardening process.
Work hardening also known as strain hardening, is the process of hardening a metal, while working
on it (under cold-working conditions).
Age hardening also known precipitation hardening, is the process of hardening a metal
when allowed to remain or age after heat treatment.
14. The tempering process usually follows hardening process. Justify. [Nov/Dec 2013]
The martensite which is formed during hardening process is too brittle and lacks good ductility and
toughness. Hence, it cannot be used for more applications. Also the internal residual stresses that
are introduced during hardening have a weakening effect. The ductility and toughness of martensite
can be enhanced and these internal stresses are relieved by a heat treatment process known as
tempering.
15. What is the significance of TTT diagram in the heat treatment of steel?[May/Jun2014]
The TTT diagram is most useful in giving an overall picture of the transformation
behaviour of austenite. This e n a b l e s t h e m e t a l l u r g i s t t o interpret the response of a steel
to any specified heat treatment. Using a TTT diagram, one can plan practical heat treatment
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operations to get desirable microconstituents, to control limited hardening or softening, and the time
of soaking.
16. What is CCT diagram?
The CCT diagram is a plot of temperature versus the logarithm of time for a steel alloy of definite
composition. It is used to indicate when transformations occur as the initially austenitised material is
continuously cooled at a specified rate. In addition, it is also used to predict the final microstructure
and mechanical characteristics.
17. Define the term critical cooling rate(CCR).What are the factors affecting it? Nov/Dec 2014]
The slowest rate of cooling of austenite that will result in 100% martensite transformation is known as
the critical cooling rate.
Factors affecting the critical rate are: 1. Chemical composition of steel, 2. Hardening temperature,
and 3. Metallurgical nature (i.e, Purity) of steel.
18. What is the difference between hardness and hardenability?[May/Jun 2015, 2014,2012]
[Nov/Dec 2014,2015]
The term hardness is the property of a material by virtue of which it is able to resist abrasion,
indentation and scratching. It is a mechanical property related to strength and is a strong function of
the carbon content of a metal.
On the other hand, hardenability is the susceptibility of a material to get hardened. It is affected
by the alloying elements in the material and grain size.
19. What is martempering and austempering? [April/May 2015] [M/J-2016]
Martempering, also known as marquenching, is a interrupted cooling procedure used for
steels to minimize stresses, distortion and cracking of steels that may develop during rapid quenching.
Austempering is an isothermal heat treatment process, usually used to reduce quenching distortion
and to make tough and strong steels.
20. List some of the surface-hardening techniques employed for altering surface chemistry?
and Which type of surface hardening process that does not involve composition change?
[N/D 2015] [May/Jun 2013]
1. Diffusion methods:a) Carburizing, b) Nitriding, c) Cyaniding, and d) Carbonitriding.
2. Thermal methods: a) Flame hardening, and b) Induction hardening.
Thermal surface hardening process involves no composition change while heat treatment.
21. Explain briefly about carbonitriding.
Heat steel at 700–800 °C (1300–1600 °F) in an atmosphere of carbonaceous gas and
ammonia. Then quench in oil. Surface hardness 55 to 62 HRC. Case depth 0.07 to 0.5 mm
(0.003 to 0.020 in.). Less distortion than in carburizing. This process can be applied to bolts,
nuts, and gears.
22. What is flame hardening?
This involves heating the surface of a steel with an oxyacetylene flame (transforming the structure of
the surface layers to austenite), and then immediately quenching the surface with cold water (changing
the austenite to martensite). The depth of hardening depends on the heat supplied per unit surface area
per unit time. Thus, the faster the burner is moved over the surface, the less the depth of hardening.
23. What is temper embrittlement?
The tempering of some steels may result in a reduction of toughness as measured by impact tests.
This is termed as temper embrittlement.
24. Define Recrystallisation ? [Nov/Dec 2014]
Recrystallisation is a process accomplished by heating whereby deformed grains are replaced by a
new set of grains that nucleate and grow until the original grains have been entirely consumed.
25. Name any two shallow hardening process? [M/J-2016]
Case-hardening or surface or shallow hardening is the process of hardening the surface of a metal
object while allowing the metal deeper underneath to remain soft, thus forming a thin layer of harder
metal (called the "case") at the surface. 1.Case carburizing 2.Cyaniding 3.Nitriding
PART B
1. Compare and contrast the different process of Annealing ? [May/June-2012,2013,2014]
2. Explain briefly the various tempering processes. Compare and contrast Austempering and
Martempeirng processes? [April/May 2015] .[Nov/Dec 2012,2014,2015]
3. (a)Describe the normalising process of heat treatment?
(b)Differentiate between normalising and full annealing? [Nov/Dec 2014]
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4. Explain the Jominy end-quench method of determining hardenability. List the factors affecting
hardenability? [May/Jun2012,2013,2015,2016] [Nov/Dec 2015]
5. What do you understand by Isothermal transformation ? Draw a neat sketch of the TTT diagram for a
eutectoid steel and label the regions. Mark the different products formed on this diagram?
[Nov /Dec2012, 2013] [April/May 2015 ]
6. (a) What is a CCT diagram? (b) Describe various cooling curves on TTT diagrams.How such curves
drawn? (c) Write short notes on critical cooling rate? [May/June -2016]
(b)Brief on hardening and tempering of steel w.r.to rate of cooling and tempering temperature
respectively? [Nov/Dec 2015]
7. What is meant by Case hardening of steels ? Briefly explain the various types of Carburising?
[Nov/Dec 2015]
8. Explain the process of nitriding and Cyaniding .List and discuss the advantages of nitriding over
carburising? [Nov/Dec 2013]
9. Describe the flame hardening process with the aid of neat sketch .Also brief the advantages,
disadvantages and applications of flame hardening? [Nov/Dec 2013]
10. Explain the principle of Induction hardening and compare with flame hardening process?
[May/Jun 2013, 2014]
UNIT – III FERROUS AND NON-FERROUS METALS
PART A
1. What are three primary groups of plain carbon steels? [May/Jun 2013]
1. Low-carbon steels: Those contain less than 0.25% carbon.
2. Medium-carbon steels: Those containing between 0.25 and 0.60% carbon.
3. High-carbon steels: Those containing more than 0.60% carbon.
2. What are the primary effects of chromium, and copper as alloying elements in steel?
[April/May -2013,2014 2015]
Effects of alloying chromium: Increases corrosion and oxidation resistance, increases
hardenability, increases high-temperature strength, and resists abrasion and wear (with high
carbon).
Effects of alloying copper: Increases strength, and increases corrosion resistance.
3. What is the effect of alloying Silicon and Cobalt in steels? [Nov/Dec 2014][M/J-2016]
Silicon improves oxidation resistance, strengthens low alloy steels and acts as a deoxitizer.
Cobalt contributes to red hardness by hardening ferrite, improves mechanical properties such as tensile
strengths, fatigue strength and hardness, refines the graphite and pearlite, a mild stabilizer of carbides,
improves heat resistance and retards the transformation of austenite and thus increases hardenability
and freedom from cracking and distortion.
4. Which alloy elements are basically a) carbide(stabilizers) formers, and b) graphite stabilizers)
promoters? [April/May 2015]
a) Carbide formers: Cr, W, Ti, Mo, Nb, V, and Mn. b) Graphite promoter: Si, Co, Al, and Ni.
5. What makes a stainless steel “stainless”? [Nov/Dec 2013]
The chromium oxide (extremely dense-thin) protective layer acts as a barrier to retard further
oxidation, rust or corrosion. As this steel cannot be stained easily, it is called stainless steel.
6. What are the required properties of a tool steel? [Nov/Dec 2013]
Tool steels should have the following properties:
1. Good toughness, 2. Good wear resistance, 3. Very good machinability,
4. Slight change of form during hardening, 5. Little risk of cracking during hardening.
5. Resistance to softening on heating.
7. What is meant by 18-4-1 high speed steel?
A widely used high-speed tool steel is 18-4-1 high speed steel. This steel contains 18% tungsten,
4% chromium, and 1% vanadium. It is considered to be one of the best of all purpose tool steels.
8. What are HSLA steels? Where are they used? [Nov/Dec 2014] [April/May 2015]
HSLA steels are nothing but high-strength low-alloy steels. HSLA steels, also known as micro
alloyed steels, are low-carbon steels containing small amounts of alloying elements.These HSLA
steels are widely used as structural or constructional alloy steels.
9. What are Maraging steels? Give its composition. [Nov/Dec 2013]
Maraging steels are low-carbon, highly alloyed steels. These are very high- strength materials that
an be hardened to obtain tensile strengths of up to1900 Mpa. Composition: Maraging steels
contain 18% nickel, 7% cobalt, and small amounts of other elements such as titanium. The
9
carbon content is low, generally less than 0.05%.

10. What are the features that make cast iron an important material?
1. It is a cheap metallurgical substance,2. Good castability,3. Good mechanical rigidity and good
strength under compression.4. Good machinability can achieved when a suitable composition is
selected.
11. What is the difference between malleable cast iron and ductile cast iron? [Nov/Dec 2014]
Malleable cast iron is produced by heat treating unalloyed white iron. The ductile (or SG or
nodular) cast iron is produced by adding magnesium and/or cerium to molten cast iron.Both
malleable and ductile cast irons have the nodules, also called spheroids. But the nodules of ductile
cast irons are more perfect spheres.
12. What are the primary effects of adding Ni, and Mo in cast irons? [May/Jun 2012]
S.No. Alloying General effects
element It has graphitizing effect on cementite. So ittends to produce a
grey iron.
1. Nickel (Ni) It has a grain-refining effect, which helps to prevent the
formation of coarse grain.
It also toughens thin sections.
It increases the hardness of thick sections. It also
2. Molybdenum improves toughness.
13. (Mo)
List the outstanding properties of copper and some typical applications.
The copper possesses the following properties:1. Very high electrical conductivity.
2. Very high thermal conductivity.3. Exhibits excellent resistance to corrosion.
4. Very soft, ductile and malleable.
Copper is extensively used for manufacturing power cables, telephone cables, cables for computer
networks, printed circuit boards, connectors, etc.
14. What is the main difference between a brass and a bronze.Also List at least four types
of brasses used. [May/Jun-2013]
Brass is an alloy of copper and zinc whereas bronze is an alloy of copper and tin.
Gliding metal (or commercial bronze), cartridge brass, standard brass (or cold working brass),
Muntz metal (or yellow metal), Naval brass, Admiralty brass.
15 List some bronze alloys.? [May/Jun 2013]
Bell bronze, phosphor bronze, aluminium bronze, silicon bronze, coinage bronze and leaded bronze.
16. How do you classify Cast irons?
Cast iron types : 1.Grey C.I 2. White C.I 3.Maleable C.I 4. Spheroidal graphite C.I.
17. What are gun metals? Give its composition.?
Gun metals are alloys of copper, tin, and zinc.
Composition of admiralty gun metal: 88 Cu, 10 Sn, 2 Zn, 2 (max) Ni.
18. State the composition, properties and applications of cupronickel and Monel metal.
[Nov/Dec 2014]
The composition of the alloys can vary from 90% Cu–10% Ni to 70% Cu–30% Ni.
Uses: As heat exchanger or condenser tubes in evaporators of desalination plants, process industry
plants, air cooling zones of thermal power plants, high-pressure feed water heaters and Cupronickels
are alloys of copper and nickel.
Monel consists of ( in %) Ni - 66 , Cu- 31.5, Fe- 1.35, Mn- 0.9 plus residuals.
Uses of monel metal: For making propellers, pump fittings, condenser tubes, steam turbine blades,
sea water exposed parts, tanks, and chemical and food handling plants.
19. What is Duralumin and mention its applications?
Duralumin is an alloy of aluminium and copper.
Composition: 94 Al, 4Cu, 0.5 Mg, 0.5 Mn, 0.5 Si, 0.5 Fe.
Typical applications: For aircraft and automobile industries; for making electric cables, in
surgical and orthopaedic implements or gadgets, etc.
20. What is meant by precipitation hardening? [ May/Jun 2012] [Nov/Dec 2013,2014]
Precipitation hardening, also known as age hardening, is the most important method of improving
the physical properties of some of the non-ferrous alloys by solid state reaction.
21. Differentiate between natural ageing and artificial ageing.
The ageing process done at room temperature is often called natural ageing. Natural ageing takes a
prolonged period of time in terms of several days to reach maximum strength.Ageing at high
10
temperature of 190° C to 260° C accelerates the precipitation process and the time required is
reduced considerably. This process is called artificial ageing.
22. What are the required characteristics of a bearing material?
1. Bearing material should possess sufficient hardness and wear resistance.2. It hould have a low
coefficient of friction.3. It should be tough, shock-resistant, and sufficiently ductile.
4. It should have a sufficient melting point, and high thermal conductivity.5. It hould have good
casting qualities, and good resistance to corrosion.
23. What are super alloys? [May/Jun 2014]

Super alloy is a general term used to describe the nickel-base and cobalt-base alloys which have
been developed for use at elevated temperatures.
Super alloys produce a combination of high strength as elevated temperature,resistance to creep at
temperatures up to 1000° C, and resistance to corrosion.
24. What is meant by Babbit metal ? Give its composition and applications.[Nov/Dec 2011]
` What is the typical constituent microstructure of bearing alloy? (Nov/Dec-2015) [M/J-2016]
Also called as white metal, it is an alloy used to provide the best bearing surface in a plain bearing. It
has properties that help reduce friction which make it a good material to use in a plain bearing. The
structure of the alloy is made up of small hard crystals dispersed in a matrix of softer alloy.
Common compositions for Babbitt alloys:
1) 90% tin 10% copper, 2) 89% tin 7% antimony 4% copper , 3) 80% lead 15% antimony 5% tin
Applications: Internal combustion engines use Babbitt metal which is primarily tin-based because it
can withstand cyclic loading. Lead-based Babbitt tends to work-harden and develop cracks but it is
suitable for constant-turning tools such as sawblades.
25. Which type of steel is used for surgical instruments? (Nov/Dec-2015)
316 stainless steel, also referred to as marine grade stainless steel, is a chromium, nickel, molybdenum
alloy of steel that exhibits relatively good strength and corrosion resistance. Along with the titanium
alloy Ti6Al4V, 316 stainless is a common choice of material for biomedical implants and surgical
instruments.
PART B
1. Describe the properties and typical applications of Low, Medium and high carbon steels?
2. (a)Summarise the effect of the following elements as alloying additions to steels: Mn, Si, Cr, Mo, V,
Ti, Al, Si, Cu, W ? [Nov/Dec 2013]
(b) Breif on the influence of alloying elements in steel under classification of carbide former and non
carbide former? [Nov/Dec 2015]
3. Describe the different types of stainless steels, making reference to approximate compositions,
structures, heat treatments and applications ? [May/Jun 2012] [Nov/Dec 2015]
4. Write an engineering brief about (a)Tool steels (b) HSLA steels (c)Maraging steels (d)High speed
steels? [April/May 2014,2015,2016] [Nov/Dec 2014]
5. Describe the structures of main types of Cast iron and explain the factors which affect the structure
of Cast iron? [Nov/Dec 2015]
6. Discuss the composition, properties and typical applications of Copper alloys?
[ Nov/Dec 2014] [May/Jun 2012]
7. (a)Explain the composition, properties and typical applications of Aluminium alloys?
(b) What are the types of titanium alloy, their composition, properties and applications?
[Nov/Dec 2015]
8. Explain the process of Precipitation strengthening treatment for the Al-4%Cu system?
[MAY/JUN- 2014,2015,2016] [Nov/Dec 2015]
9. a.What are the necessary metallurgical characteristics required in a good bearing metal?
b.Compare and contrast lead- base, tin-base, copper-base and aluminium-base bearing
alloys. [Nov/Dec 2014] [MAY/JUN- 2014]
10. What is an alloy steel ? How are alloy steels classified. Explain them?
UNIT – IV NON-METALLIC MATERIALS

PART A
1. What are polymers? [May/Jun 2013] [Nov/Dec 2014]
Polymers are composed of a large number of repeating units of small molecules called
manometers.
11
Polymers may be defined as giant organic, chain-like molecules having molecular weight from
-1
10000 to more than 1,000,000 g.mol .
2. What is meant by the term ‘unsaturated molecule’? State its significance in plastics.
[May/Jun 2014]
A compound in which the valence bonds of the carbon atoms are not satisfied is said to be
unsaturated. Such unsaturated molecules are important in the polymerization i.e., joining
together of small molecules into large one having the same constituents.
3. What is polymerisation? [M/J-2016]

The mechanism in which the smaller molecules are combined to form the larger molecules.
Types:Addition polymerization and Condensation polymerization.
4. Define the term ‘degree of polymerisation’? [May/Jun-2012]
Degree of polymerisation is the number of repetitive units (or mers) present in one molecule of a
polymer. Mathematically,
Degree of polymerisation = ( Molecular weight of a polymer/ Molecular weight of a single
monomer.)
5. What is the difference between addition polymerisation and condensation polymerisation?
Addition polymerisation, also known as chain reaction polymerisation, is a process by which two
o r more chemically similar monomers are polymerized to form long chain molecules.
Condensation polymerisation, also known as step-growth polymerisation, is the formation of
polymers by stepwise intermolecular chemical reactions that normally involve at least two different
monomers.
6. Why are additives added to polymers?
The various polymer additives include:
1. Filler materials, 2. Plasticizers, 3. Stabilizers, 4. Colorants, 5. Flame retardants,
6. Reinforcements, and 7. Lubricants.
7. Name any four commodity plastics and engineering plastics?. [May/Jun 2012]
Commodity plastics: i) Polyethylene (PE), ii) Polypropylene (PP), iii) Polystyrene(PS),
iv) Polyvinyl chloride (PVC).
Enginering Plastics: i) Ethenic, ii) Polyamides, iii) Cellulosics, iv) Acetals.
8. Distinguish between thermoplastics and thermosetting plastics. [April/May 2015]
S.
No. Thermoplastics Thermosetting
They are formed by addition They are plastics
formed by
1. polymerisation. condensation polymerisation.
They are l ine a r polymers, so they are They are composed of three
2. composed of chain molecules. dimensional networks of cross-
Softening is possible on reheating Softening linked molecules.
is not possible on
3. (because of the weak secondary forces). reheating
They can be easily moulded on (because They cannot of strong covalent
be remoulded
4. remoulded into any shape. into any new shape.
5. They can be recycled again. They cannot be recycled.
9. Name any four thermoplastics and thermosetting plastics.

Thermoplastics: Polythenes, Polypropylene, Polystyrenes, PVC.
Thermosetting plastics: Polyesters, phenolics, epoxides, melamine formaldehyde.
10. What are the following ‘acronyms’ refer to: PE, PP, PS, PVC, PTFE, PMMA.? [May/Jun 2012]
PE: Polyethylene; PP: Polypropylene; PS: Polystyrene; PVC; Polyvinyl chloride;
PTFE: Polytetrafluro ethylene; PMMA: Polymethyl methacrylate.
11. List the properties and typical applications of PVC.
Properties: Good low-cost, general purpose materials; ordinary rigid, but can be made flexible with
plasticizers; susceptible to heat distortion.
Typical applications: Pipes, valves, fittings, floor tiles, wire insulations, toys, phonograph records,
safety glass interlayers.
12. What are acrylic materials? Name any two. [Nov/Dec 2013]
Acrylic materials are thermoplastic polymers based on the polymerization of esters of acrylic acid
and/or methacrylic acid.
12
The most commonly used acrylic polymers are:

1. PMMA (Polymethyl methacrylate), 2. PAN (Polyacrylonitrile).
13. Write short notes on nylons. & PMMA and its applications? (Nov/Dec-2015)
Polyamides (PA), also known as nylons, are the products of condensation reactions between an
amine and an organic acid.
There are number of common polyamides. They are usually designated as nylon 6, nylon 6/6,
nylon 6/10, nylon 6/12, nylon 11, and nylon 12. These suffixes refer to the number of carbon
atoms in each of the reacting substances involved in the condensation polymerization process.
PMMA is a strong and lightweight material, It also has good impact strength, higher than both glass
and polystyrene, PMMA transmits up to 92% of visible light (3 mm thickness), and gives a
reflection about 4% from each of its surfaces due to its refractive index . It filters ultraviolet (UV)
light at wavelengths below about 300 nm (similar to ordinary window glass).
14. What are bakelites? Also state their applications.
Phenolics, also known as Bakelites, are the oldest family of thermosetting plastics. The most
important phenolic materials is the polyformaldehydes. Typical applications include electrical
plugs, sockets, switches, telephones, door knobs and handles, adhesives, coatings, and laminates.
15. List the characteristics of urea-formaldehyde.
1. They are similar to the phenolics. 2. They are hard and rigid thermosets.
3. They have good electrical insulation properties. 4. They are light in colour.
5. They exhibit good resistance to most chemicals.
16. List some of the distinct characteristics of engineering ceramics.
1. High resistance to abrasion and wear. 2. High strength at high temperature.
3. Good chemical stability. 4. Good electrical insulation characteristics.
17. Name any four engineering ceramics. List the applications of Engineering Ceramics? [M/J 2016]
1. Alumina (Al2O3). 2. Silicon carbide (SiC). 3. Silicon nitride (Si3N4).
4. Partially stabilized zirconia (PSZ), and 5. Sialons.
Ceramics can be used in place of steel for ball bearings, Advanced composite ceramic and metal
matrices have been designed for most modern armoured fighting vehicles, Knife blades: the blade
of a ceramic knife will stay sharp for much longer than that of a steel knife, Carbon-ceramic brake
disks for vehicles are resistant to brake fade at high temperatures
18. What is meant by PSZ?
Partially stabilized zirconia (PSZ) is nothing but a zirconium oxide (ZrO2) that has been blended
and sintered with some other oxide such as magnesium oxide (MgO), calcium oxide (CaO), and
yttria (Y2O3), to control crystal structure transformations.
19. What are sialons? State their applications. and Al2 O3 ? (N/D-2015) May/Jun-2014]
The name sialon is an acronym derived from the ingredients involved, namely Si formed when
aluminium and oxygen partially substitute for silicon and nitrogen in silicon nitride.Sialons are
used for cutting tool materials, dies for drawing wire and tubes, rock-cutting and coal-cutting
equipment, nozzles and welding shields.
Alumina is used in a wide variety of applications which reflect its inertness, temperature resistance and
electrical resistance. Al2O3 is significant in its use to produce aluminium metal, as an abrasive owing
to its hardness, and as a refractory material owing to its high melting point
20. What is the role of matrix material in a composite?
The matrix usually provides the major control over electrical properties, chemical behaviour, and
elevated-temperature use of the composite.
21. List the various matrix materials used.
1. Polymers: Kevlar,nylon, polyethylene. 2. Metals: Be, Boron, W.
3. Glass: E-glass, S-glass. 4. Carbon: HS (high strength), HM (high modulus).
5. Ceramics: Al2O3, B4C, SiC, ZrO2. 6. Whiskers: Al2O3, Cr, graphite, SiC, Si3N4.
22. What are cermets? What are two common uses of cermets?
The term ‘cermet’ refers to ceramic-metal composite containing between 80 and 90 % of ceramic.
Cermets are composed of ceramic particles in metallic matrix.
Typical applications: Cutting tools, slip gauge, wire-drawing dies, rocket motor and jet-engine
parts.
23. What is ABS and state any two of its applications. [Nov/Dec 2013]
Acrylonitrile-butadiene-styrene graft copolymer
13
(ABS). TECARAN ABS is an amorphous

thermoplastic, which has high impact strength even at
low temperatures. The moisture absorption of ABS is
low.
Special types of this material are suitable for electroplating. It has high impact strength, even
at low temperatures, low moisture absorption, poor resistance to weathering and suitable for
Electroplating.
24. What is meant by metal matrix composites? Give one example each to matrix material
and reinforcement used? [April/May 2015]
A metal matrix composite (MMC) is composite material with at least two constituent parts, one
being a metal necessarily, the other material may be a different metal or another material, such as a
ceramic or organic compound. Material: AlMg1SiCu + 20 vol. % Al2O3P used for Drive shaft for
people and light load motor vehicles
25. What is Fibre reinforced Plastics? Mention its advantages? [NOV/DEC 2014] [M/J -2016]
Fibre-reinforced plastic (FRP) (also fibre-reinforced polymer) is a composite material made of a
polymer matrix reinforced with fibers. The fibres are usually glass, carbon,aramid, or basalt. Rarely,
other fibres such as paper or wood or asbestos have been used. The polymer is
usually an epoxy, vinylester or polyester thermosetting plastic, and phenol formaldehyde resins.
Advantages : Inherent Corrosion Resistance, low weight-to-strength ratio, lower cost
PART B
1. What is polymerization? Describe addition polymerization and condensation polymerization with
examples? [May/Jun 2013,2014,2016]
2. (a).Describe the difference between thermoplastics and thermosetting plastics? [Nov/Dec 2012]
(b).Explain the differences between commodity plastics and Engineering Plastics?
3. What are the properties and application of thermo plastics PVC, PET, PP , PC PMMA, ABS,PEEK
PTFE ? [Nov/Dec 2013,2014,2015][May/Jun 2012,2015]
4. What are the properties and application of thermosetting plastics PF,UF,Polyesters,Epoxides,
Polyurethanes ? [Nov/Dec 2012] [May/Jun 2013]
5. Discuss the properties and typical applications of the following engineering Ceramics (i) Al 2 O, (ii)SiC,
(iii) Si3 N4 , (iv) PSZ (v) Sialons [May/Jun 2014,2015] [Nov/Dec 2015]
6. Describe the following terms a) Linear polymer b) Branched polymer c) chain stiffening
d) Cross linked polymer. [Nov/Dec 2012]
7. (a) Classify composite materials and list two properties and application of them?
[Nov/Dec 2015]
(b)Explain the difference in strengthening mechanism between dispersion-strengthened and large-
particle reinforced composites?
8. Write short note about the different types of matrix materials and reinforcement materials used to make
polymer matrix composites. [May/Jun 2014]
9. (i) Explain the strengthening mechanism of fibre-reinforced composites?
[N/D- 2014][M/J-2016]
(ii)List the advantages, Limitations and applications of composite materials ?
10. What are the properties and application of thermo plastics PE, PS, PAN, PA, POM,PC, PPO, PPS, PI,
PAI ?
UNIT – V MECHANICAL PROPERTIES AND DEFORMATION
PART A
1. Distinguish between elasticity and plasticity. [May/June -2016]
Elasticity is the property of a material by virtue of which it is able to retain its original shape and size
after the removal of the load.
Plasticity is the property of a material by virtue of which a permanent deformation (without
fracture) takes place, whenever it is subjected to the action of external forces.
2. Differentiate between ductility and malleability.
Ductility is the property of a material by virtue of which it can be drawn into wires before rupture
takes place.
Malleability is the property of a material by virtue of which it can withstand deformation under
14
compression without rupture.

3. What do you mean by toughness and stiffness?
Toughness is the property of a material by virtue of which it can absorb maximum energy
before fracture takes place.
Stiffness is the property of a material by virtue of which it resists deformation.
4. What is the effect of the grain size on the mechanical properties of the materials?
[May/Jun 2014]
The materials having smaller grains (i.e., fine grained structure) have high yield strength, high
tensile strength, and more hardness. Also fine grain results in better resistance to cracking and better
surface finish.
The materials having grains (i.e., coarse grained structure), exhibit better workability,
hardenability, forgeability and creep resistance. But coarse grains result in poor surface finish, less
tough and have greater tendency to cause distortion.
5. Distinguish between elastic and plastic deformation of solid. [May/Jun 2013]
S.
No. Elastic deformation Plastic deformation
It is the deformation of a body It is the deformation of a body
1. with completely disappears as Soon as which remains even after
the external load is removed from the Removing the external load from the
body. body.
2. It obeys Hook’s law. It does not obey Hook’s law.
The elastic deformation is the beginning The plastic deformation takes
3. of the progress of deformation. place after the elastic
deformation has stopped.
6. Define the terms slip and twinning. [Nov/Dec 2013] [Nov/Dec 2014]
Slip may be defined as the sliding of blocks of the crystal over one another along definite a
mirror image of the other part.
Twinning is the process in which the atoms in a part of a crystal subjected to stress, rearrange
themselves so that one part of the crystal becomes a mirror image of the other part.
7. State the Schmid’s law and write the equation for critically resolved shear stress.
The stress required at a given temperature to initiate slip in a pure and perfect single crystal, for a
material is constant. This is known as Schmid’s law.
8. What are the causes of twins?

1. Mechanical twins: Twins that are produced by mechanical deformation are called mechanical
twins.
2. Annealing twins: Twins that are produced by annealing are called annealing twins.
9. List the different types of fracture in a material.
1. Brittle fracture, 2. Ductile fracture, 3. Fatigue fracture, and 4. Creep fracture.
10. State the Griffith’s criteria.
A crack will propagate when the decrease in elastic energy is at least equal to the energy required to
create the new crack surface.
11. Distinguish between brittle fracture and ductile fracture.
S.
No. Brittle fracture Ductile fracture
15
It o c c u r s w i t h n e g l i g i b l e It occurs with large plastic

1. p l a s t i c deformation. deformation.
It occurs at the point where micro It occurs in some localised region
2. crack is more. where the deformation is very large.
The rate of crack propagation is The rate of crack propagation is slow.
3. rapid.
4. Failure is due to the direct stress. Failure is due to the shear stress.
12. What is meant by fatigue fracture?
A fatigue fracture is defined as the fracture which takes place under repeatedly applied
fatigue stresses.
13. What is S-N diagram? What is the significance of it? [May/Jun 2012,2014]
The S-N diagram is a graph obtained by plotting the number of cycles of stress reversals (N)
required to cause fracture against the applied stress level (S). Using S-N diagram, the fatigue life of
a material can be determined.
14. What is meant by super plasticity?
The ability of some metals to deform plastically by 1000 – 2000 % at high temperature and low loading
rates.
15. What is creep? Draw a typical creep curve and show different creep stages on it.
[May/Jun2013,2015] (Nov/Dec-2015)
What are the characteristic features of fracture surface of creep rupture component?
Creep fracture is the fracture that takes place due to excessive creeping of metals under
steady loading. Deformation that occurs under constant
load/stress and elevated temperatures which is time-
dependent is known as creep. Creep deformation
(constant stress) is possible at all temperatures above
absolute zero. However, it is extremely sensitive to
temperature. Hence, creep in usually considered
important at elevated temperatures (temperatures greater
than 0.4 Tm, Tm is absolute melting temperature).
16. Define endurance limit in a fatigue test.
[Nov/Dec 2014]
It is also known as fatigue limit, The fatigue limit is a maximum stress amplitude below which the
material never fails, no matter how large the number of cycles is. Fatigue life: Number of cycles to fail
at specified stress level. Fatigue strength: stress at which fracture occurs after specified number of
cycles (e.g. 107 )
17. What is meant by fracture toughness?
Fracture toughness is a property which describes the ability of a material containing a crack to resist
fracture, and is one of the most important properties of any material for many design applications.
18. Draw the stress – strain diagram for ductile material. [April/May 2015]
19. What is meant by Slip plane, Slip direction and Slip system?
16
Dislocations move on a certain crystallographic plane and the plane of greatest atomic density : slip
plane. Dislocations move in a certain crystallographic direction and the close packed direction within
the slip plane: slip direction. The Feasible combination of a slip plane together with a slip direction is
considered as a slip system is called a slip system
20. Define Fatigue. What are the factors affecting fatigue strength?
Fatigue fracture is the fracture that occurs under repeatedly applied fatigue stresses. This fracture occurs
at a stress well below the tensile strength of the materials
1. Fatigue strength is influenced by many factors such as chemical composition, grain size, and
amount of cold working.
2. Fatigue strength is high at low temperatures and gradually decreases with rise in temperature.
3. Environmental effects such as corrosion of the product by moisture decreases the fatigue
strength.
4. The design of the product also influences the fatigue strength.
21. How can you prevent fatigue fracture?
The following methods can be adopted to prevent the fatigue failure.
1. Use of good design to avoid stress concentration by eliminating sharp recesses and severe
stress raisers.
2. Control of the surface finish by avoiding damage to surface machining, punching,
stamping, shearing, etc.
3. Reduction of corrosion environmental effects by surface heat treatments like polishings,
coatings, carburizing, nitriding, etc.
4. The material should have fine grain structure and also it should be free from residual stresses
and dislocations.
22. What is meant by creep fracture. What are the factors affecting creep?
The creep is defined as the property of a material by virtue of which it deforms continuously
under a steady load.
1. Grain, 2. Thermal stability of the micro-structure,3. Chemical reactions, 4. Prior strain.
23. How can you prevent the creep fractures?
The following methods can be adopted to prevent the creep failure.
1. Use of coarse grained materials will avoid creep fracture.
2. Strain hardening can be done to avoid creep fracture.
3. The material should be free from any residual stresses and dislocations.
4. Precipitation-hardened alloys can be used to avoid creep fracture.
24. What is the difference between Izod and Charpy impact testing methods?
[May/Jun 2012] [Nov/Dec 2014]
Based on the types of specimen used on impact testing machine, the impact tests can be classified
into: 1. Izod test, and 2. Charpy test. Izod test uses a cantilever specimen of size 75
mm×10mm×10mm. Charpy test uses a simply-supported test specimen of size
5mm×10mm×10mm.
25. State the advantages of Rockwell hardness testing over other techniques?(N/D -2015)
Rockwell is the only one that allows direct reading of the hardness value without need of optical reading
as per Vickers and Brinell methods. Therefore, it is the most rapid method and the only one that can be
fully automated. Rockwell Hardness tester uses smaller penetrates than the Brinell testers.
PART B
1. Explain the different types of mechanical properties and mechanism of plastic deformation by slip and
twinning. [May/Jun 2014,2016] [Nov/Dec 2012,2015 ]
2. What is brittle fracture? Explain the Griffth’s theory on brittle fracture and deduce an expression for the
critical stress required to propagate a crack simultaneously in a brittle material?
3. What is meant by ductile fracture? Explain the mechanism of it?
4. Explain the mechanism of fatique fracture. How can we prevent ?
5. (i) Describe a tensile test to determine various tensile properties [April/May 2015]
(ii)Explain the procedure of (i)a compression test (ii) a shear test?
[May/Jun2012] [Nov/Dec 2014]
6. a) List the various types of hardness testing. Write a short note on Rockwell, brinell and Vickers
hardness and their significance. [May/Jun2012,2016] [April/May 2015]
7. Explain and distinguish Izod test and Charpy test to determine the impact strength of a material. Also
mention the application of Impact test? [Nov/Dec 2012,2013,2015] [April/May 2015]
8. Write an engineering brief about the creep test with a typical curve?.
17
[Nov/Dec 2014, 2015]

9. Sketch and describe the fatigue test .Draw the S-N curve for mild steel and aluminium and explain its
features. Explain the procedure used to obtain S-N diagram.?
[Nov/Dec 2014,2015][May/Jun-2013,2014]
10. Derive an expression for critical resolved shear stress in a material subjected to uniaxial
tensile loading ?
18

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ME6403Engineering Materials and Metallurgy Department of Mechanical Engineering 2016-2017

ME6403 ENGINEERING MATERIALS AND METALLURGY L T P C

UNIT I ALLOYS AND PHASE DIAGRAMS 9

UNIT II HEAT TREATMENT 10

UNIT III FERROUS AND NON-FERROUS METALS 9

UNIT IV NON-METALLIC MATERIALS 9

UNIT V MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS 8

On Completion of the course the student will be able:

MAPPING BETWEEN CO AND PO, PSO WITH CORRELATION LEVEL 1/2/3

RELATION BETWEEN COURSE CONTENT WITH COs

S.No Knowledge Topics Course Outcome

Ap – Apply; An – Analyze; U – Understand, E- Evaluate,C-Create

UNIT – I - ALLOYS AND PHASE DIAGRAMS

16. Distinguish between peritectic and peritectoid reactions. [Nov/Dec 2014]

17. Define: ferrite and austenite. [May/Jun 2013]

Steels having more than 0.8% C are known as hypereutectoid steels.

22. Distinguish between hypoeutectic and hypereutectic cast irons.

3. List the various stages of a heat treatment process.

carbon content is low, generally less than 0.05%.

23. What are super alloys? [May/Jun 2014]

UNIT – IV NON-METALLIC MATERIALS

3. What is polymerisation? [M/J-2016]

9. Name any four thermoplastics and thermosetting plastics.

The most commonly used acrylic polymers are:

(ABS). TECARAN ABS is an amorphous

compression without rupture.

8. What are the causes of twins?

11. Distinguish between brittle fracture and ductile fracture.

It o c c u r s w i t h n e g l i g i b l e It occurs with large plastic

[Nov/Dec 2014, 2015]

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