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Material Science Conventional Question and Answer PDF
Material Science Conventional Question and Answer PDF
Material Science Conventional Question and Answer PDF
Q-1:
A-1:
What are coordination number of BCC, FCC and HCP crystal structure?
CN, the coordination number, which is the number of closest neighbors to which an atom is bonded.
CN of BCC structure is 8
CN of FCC structure is 12
CN of HCP structure is 12
BCC
FCC
HCP
Q-2:
A-2:
What are packing factors of BCC, FCC and HCP crystal structure?
APF, the atomic packing factor, which is the fraction of the volume of the cell actually occupied by
the hard spheres. APF = Sum of atomic volumes/Volume of cell.
APF of BCC structure is 0.68
APF of FCC structure is 0.74
APF of HCP structure is 0.74
Q-3:
A-3:
How many slip planes are there in BCC, FCC and HCP crystal structure?
Crystal
BCC
FCC
HCP
Q-4:
A-4:
[1 2 0]
Slip Planes
{110}, {112}, {123}
{111}
Basal plane, Prismatic & Pyramidal planes
Crystalographic Directions
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[1 3 3]
a/3, b, c
[1 1 0 0]
[1 2 0]
a/2, -b, 0c
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Q-5:
A-5:
[ 2 2 1]
[632]
[10 1 0]
Plane
ABCD
Page 3 of 14
Q-6:
A-6:
Q-7:
A-7:
Q-8:
A-8:
What is the type of solid solution (a) copper and nickel (b) Iron and carbon
(a) copper and nickel
Cu-Ni forms a sunstitutional solid solution. If a melt of Cu and Ni with any composition is
cooled, a solid solution begins to freeze out. This solid solution is richer in Ni than the liquid
solution. As the two phase system of solid plus melt is cooled further, the mole fractin of Ni
decreases in both the solid solution and the liquid melt.
(b) Iron and carbon
Fe-C forms an interstitial solid solution; the C atoms occupy interstices in the crystal
structure of substance Fe. The Fe-Fe3C is characterized by five individual phases. Five
phases that exist in the Fe-C diagram are: ferrite (BCC) Fe-C solid solution, -austenite
(FCC) Fe-C solid solution, -ferrite (BCC) Fe-C solid solution, Fe3C (iron carbide) or
cementite - an inter-metallic compound and liquid Fe-C solution.
Q-9:
A-9:
Following empirical curves are used to estimate mean stress effects on fatigue life
a. Soderberg (USA, 1930)
b. Goodman (England, 1899)
c. Gerber (Germany, 1874)
d. Morrow (USA, 1960s)
Q-11: Explain the difference between Soderberg line and Goodman line.
A-11:
Alternating stress ( a ) =
Mean stress ( m ) =
max min
2
max + min
2
Yield strength = y
Ultimate TensileStrength = u
1.
Goodman Line
2.
Soderberg Line
a m
+
=1
e ut
a m
+
=1
e y
Most actual test data tend to fall above the Goodman line.
The Soderberg line is very conservative and seldom used.
Q-12: What are creep resistant alloy? Give composition of Nimonic 90 and Vitallium HS 21.
A-12: Creep resistant alloy
To make creep resistance alloy we have to strengthen the solid solution by mechanisms which cause
dislocation locking and those which contribute to lattice friction hardening.
The alloy can also be hardened by precipitation. Some solute alloying elements is added in reducing
the rate of climb and cross-slip processes.
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Example: The nickel alloy (Inconol, Nimonic), ferritic steel, austenitic steel 16-25-6, etc.
Composition of Nimonic 90
Cr-20%, Co-16%, Ti-2.3% Al-1.40 %, Fe-0.5%, C-0.08%, Mn-0.06%, Si-0.017% and Ni -58%
Composition of Vitallium HS 21
C 0.25%, Cr 27%, Ni 3 %, Mo 5%, Fe 1%, Mn 1%, Si -1%, Co - bal
Q-13: Differentiate between temper embrittlement and hydrogen embrittlement.
A-13: Temper embrittlement
Tempering of some steels may result in a reduction of toughness what is known as temper
embrittlement. This may be avoided by (1) compositional control, and/or (2) tempering above 575oC
or below 375oC , followed by quenching to room temperature. The effect is greatest in Martensite
structures, less severe in bainitic structures and least severe in pearlite structures. It appears to be
associated with the segregation of solute atoms to the grain boundaries lowering the boundary
strength. Impurities responsible for temper brittleness are: P, Sn, Sb and As. Si reduces the risk of
embrittlement by carbide formation. Mo has a stabilizing effect on carbides and is also used to
minimize the risk of temper brittleness in low alloy steels.
Hydrogen embrittlement
Hydrogen embrittlement is more failure than a form of corrosion, but it is often results from the
hydrogen, produced from corrosion. Atomic hydrogen produced during corrosion diffuses
interstitially through crystal lattice, and interferes with dislocation motion, leading to failure. It is
similar to stress corrosion in the sense that ductile materials experience brittle failures as a result.
Counter measures to hydrogen embrittlement include: heat treatment to reduce strength of the
alloy; removal of source of hydrogen; baking the component to drive out any dissolved hydrogen.
Q-14: What is diffusion couple? Give two examples.
A-14: Diffusion couple is made by two metals A and
B. Two containers of two metals are joined
together by removing the barrier between
them. This couple is heated for an extended
period at a higher temperature, but certainly
lower than the melting points of A and B, and
then cooled to room temperature. It is
observed that atoms A have migrated into
atoms B and atoms B have migrated into
atoms A. There is a net flow of atoms from
higher concentration to lower concentration
regions. This type of diffusion is known as
inter-diffusion or impurity diffusion.
Example
(i)
Copper and Nickel couple
Gold and Silver couple
(ii)
Q-15: Explain how annealing and normalizing are diffusion controlled processes?
A-15: Annealing can be defined as a heat treatment process in which the material is taken to a high
temperature, kept there for some time and then cooled. Carbon atoms diffuse in BCC and FCC by
interstitial diffusion process. High temperatures allow diffusion processes to occur fast. The time at
the high temperature (soaking time) must be long enough to allow the desired transformation to
occur.
Normalizing is used to refine the grains and produce a more uniform and desirable size distribution.
It involves heating the component to attain single phase (e.g.: austenite in steels), then cooling in
open air atmosphere. In normalizing also high temperature allows diffusion process to occur fast.
Q-16: What is a Eutectic system? Explain copper/silver and lead/tin eutectics.
A-16: Many binary systems have components which have limited solid solubility, e.g.: Cu-Ag, Pb-Sn. The
regions of limited solid solubility at each end of a phase diagram are called terminal solid solutions
as they appear at ends of the diagram.
Many of the binary systems with limited solubility are of eutectic type, which consists of specific
alloy composition known as eutectic composition that solidifies at a lower temperature than all other
compositions. This low temperature which corresponds to the lowest temperature at which the liquid
can exist when cooled under equilibrium conditions is known as eutectic temperature. The
corresponding point on the phase diagram is called eutectic point. When the liquid of eutectic
composition is cooled, at or below eutectic temperature this liquid transforms simultaneously into
two solid phases (two terminal solid solutions, represented by and ). This transformation is
known as eutectic reaction and is written symbolically as:
Liquid (L) solid solution-1 () + solid solution-2 ()
This eutectic reaction is called invariant reaction as it occurs under equilibrium conditions at a
specific temperature and specific composition which can not be varied.
Thus, this reaction is represented by a thermal horizontal arrest in the cooling curve of an alloy of
eutectic composition. A typical eutectic type phase diagram is shown in figure-4 along with a cooling
curve.
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cooling
R
heating
Page 8 of 14
cooling
R
heating
Page 9 of 14
Austempering is different from martempering in the sense that it involves austenite-to bainite
transformation. Thus, the structure of austempered steel is bainite. Advantages of austempering are
improved ductility; decreased distortion and disadvantages are need for special molten bath; process
can be applied to limited number of steels.
Carbonitriding
Carbonitriding is a lower cost surface hardening process that provides a thin, high hardness case on
lower hardenability steels. Carbonitriding involves the diffusion of both carbon and nitrogen into the
base steel. The carbon provides the base metal with a high carbon surface, and the nitrogen provides
the case with an added boost of hardenability to insure full case hardness. The addition of nitrogen
makes the carbonitriding process especially suited to plain, low carbon steel that would not
otherwise respond to standard carburizing. Carbonitriding is usually carried out in a temperature
range of 820-900C in a gaseous atmosphere adding between 0.5 to 0.8% carbon and 0.2-0.4% (< 5%)
nitrogen to the surface of plain carbon steel or low alloy steel.
Q-23: What are the high-strength low-alloy steel?
A-23:
High-strength low-alloy steel (HSLA) is a type of alloy steel that provides better mechanical
properties or greater resistance to corrosion than carbon steel.
HSLA steels vary from other steels in that they are not made to meet a specific chemical composition
but rather to specific mechanical properties.
They have low carbon content between 0.050.25% to retain formability and weldability.
Other alloying elements include up to 2.0% manganese and small quantities
of copper, nickel, niobium, nitrogen, vanadium, chromium,
molybdenum, titanium, calcium, rare
earth elements, or zirconium.
Copper, titanium, vanadium, and niobium are added for strengthening purposes.
These steels are not strengthened by heat treatment due to low carbon content.
Q-24: Give composition and use of (a) Hadfield steel (b) Maraging steel (c) Spring Steel (d) Rail
Steel (e) Invar Steel
A-24:
Composition
Use
(a) Hadfield steel
C 1.1 to 1.4%, Mn 11-14%, rest Fe
Jaw crusher plate, Nuts and
bolts, Chains
(b) Maraging steel
C <0.03%, Ni-25%, Co 7-10%, Mo 3 -5%, Ti Aircraft under carriage parts,
1.75 %, Al- 0.2%, other trace, rest Fe
portable bridges and booster
motor in missile
(c) Spring Steel
C 0.55 0.65%, Si 0.1 0.35%, Mn 0.7 1.0 Spring
%, Cr 0.4 0.6%, Ni 0.4 0.7%, Mo 0.15
0.25%, rest Fe
Ni 32%, Fe-68%
Rail
Precision measuring
instrument, survey measuring
tapes
Applications of Superalloy?
Gas Turbine Engines
Blades, vanes, disks, combustors
Space Vehicles
Rocket motors
Nuclear Reactors
Submarines
Petroleum Equipment
Composition
Waspalloy
Cr-19%, Co-13%, Ti-3%, Al 1.4%, Zr 0.06 %,
C 0.08%, rest Ni
Inconel
Cr 15%, Ti 2.4%, Al 1%, Nb 1%, Ta 1%, Fe
7%, C 0.04%, rest Ni
Use
For
high
temperature
application upto 900oC
For
high
temperature
application upto 820oC
Q-27: What are PTFE, Nylon 6, Nylon 610, Perspex, where they are used?
A-27:
What is?
Use
PTFE
Fluorocarbons (PTFE or TFE) or Teflon. It Anticorrosive seals, chemical
is chemically inert in almost all pipes and valves, bearings, anti
environments,
excellent
electrical adhesive coatings, high
properties; low coefficient of friction; may be temperature electronic parts.
used to 260oC; relatively weak and poor
cold-flow properties.
Nylon 6
Synthetic fibers
Nylon 610
Polyhexamethylene sebacamide
Flexible tubes
Perspex
PMMA-polymethyle methacrylate
Domestic article
Q-28: What are conducting polymers and conducting ceramics? Give 2 examples of each.
A-28: Conducting Polymers
Due to the kind of bonding, polymers are typically electrical and thermal insulators. However,
conducting polymers can be obtained by doping, and conducting polymer-matrix composites can be
obtained by the use of conducting fillers. They decompose at moderate temperatures (100 400oC),
and are lightweight. Other properties vary greatly. . The most recent research in this has been the
development of highly conducting polymers with good stability and acceptable processing attributes.
Example: Polyacetylene, Polyphenylene, Polypyrroles
Conducting Ceramics
Conductive ceramics, advanced industrial materials that, owing to modifications in their structure,
serve as electrical conductors. Like metals, conducting ceramics have overlapping electron energy
bands and are therefore excellent electronic conductors. They constitute complex systems based on
oxide and non-oxide phases.
Examples: lead oxide (PbO), ruthenium dioxide (RuO2), bismuth ruthenate (Bi2Ru2O7)
Page 12 of 14
Q-29: What are silicon carbide and silicon nitride, what are their strength and hardness?
A-29: Silicon carbide (SiC)
It is known as one of best ceramic material for very high temperature applications. It is used as
coatings on other material for protection from extreme temperatures. It is also used as abrasive
material. It is used as reinforcement in many metallic and ceramic based composites. It is a
semiconductor and often used in high temperature electronics.
Ultimate tensile strength of SiC is 300 MPa
Hardness of SiC is 2500 VPN (Vickers Pyramid Number)
Silicon nitride (Si3N4)
It has properties similar to those of SiC but is somewhat lower, and found applications in such as
automotive and gas turbine engines.
Ultimate tensile strength of Si3N4 is 580 MPa
Hardness of Si3N4 is 2300 VPN (Vickers Pyramid Number)
Q-30: What are dispersion strengthened and particulate composites? Give two examples of
each.
A-30: Dispersion-strengthened composites
In this composite, particles are of 0.01-0.1 m in size.
Strengthening occurs as a result of dislocation motion hindrance. It is similar to that of
precipitation hardening in metals.
Matrix bears the major portion of the applied load, while dispersoids obstruct the motion of
dislocations.
Example: thoria (ThO2) dispersed Ni-alloys (TD Ni-alloys) with high-temperature strength; SAP
(sintered aluminium powder) where aluminium matrix is dispersed with extremely small flakes of
alumina (Al2O3).
Particulate composites
These composites contain large number of coarse particles.
These composites are designed to produce combination of properties rather than increase the
strength.
Mechanical properties are characterized by rule-of-mixtures.
Particulate composites are usually made of all three conventional engineering materials, namely
metals, polymers and ceramics.
Example: tungsten carbide (WC) or titanium carbide (TiC) embedded cobalt or nickel based cutting
tools. Aluminium alloy castings containing dispersed SiC particles are widely used for automotive
applications including pistons and brake applications.
Q-31: Describe the following
(a) Ceramic matrix composite
(b) Metal matrix composite
(c) Carbon Carbon Composite
A-31: (a) Ceramic matrix composites (CMCs)
They are a subgroup of composite materials as well as a subgroup of technical ceramics. They consist
of ceramic fibers embedded in a ceramic matrix, thus forming a ceramic fiber reinforced ceramic
(CFRC) material. The matrix and fibers can consist of any ceramic material,
whereby carbon and carbon fibers can also be considered a ceramic material.
(b) Metal Matrix Composites (MMC)
Metal Matrix Composites are composed of a metallic matrix (aluminium, magnesium, iron, cobalt,
copper) and a dispersed ceramic (oxides, carbides) or metallic (lead, tungsten, molybdenum) phase.
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