UNIVERSITY OF MALTA

FACULTY OF ENGINEERING
B.ENG. (HONS.) COURSE
MECHANICAL ENGINEERING STREAM
YEAR III and IV SEMESTER II
May/June 2014 SESSION OF EXAMINATIONS

MME 3210

Materials Processing Techniques

Tuesday 10th June 2014

09:15 11:15 hours

This paper contains FIVE questions. You are to attempt FOUR questions.

Stationery: Use of calculators is allowed

1.

(a) List one casting technique that can be classified as:

(i) Permanent Pattern;
(ii) Permanent Mould;
(iii) Expendable Mould and Pattern.
(3 Marks)

(b) There may exist numerous candidate material processing techniques for a particular
product. The choice of processing technique is based on its attributes but also on the
product design specification. Discuss.
(10 Marks)

(c) Heat flows away of a casting/moulding as it solidifies. State the most significant
barrier to heat flow for the following processes:
(i) Sand Casting;
(ii) Injection Moulding;
(iii) Gravity Die Casting.

For each of the three processes, give the relationship between the growth of the
solidifying material and time, and explain briefly the effect of heat transfer on process
performance.
(12 Marks)

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2.

(a) Write notes on the homogenous nucleation of solids.

(10 Marks)

(b) The microstructure of a gravity die cast single phase alloy which solidified under a
normal (positive) temperature gradient comprised a dendritic microstructure. Explain
the mechanism behind this type of solidification.
(15 Marks)

3.

(a) A friction hill arises during bulk forming. Briefly explain why. Give an example of
a process where the friction hill is essential and another in which it is not.
(7 Marks)

(b) Using Considere's construction show how the yield stress and work hardening rate
of a material affect formability.
(6 Marks)

(c) Explain how the temperature and strain rate affect the formability of metals. In your
answer you are to make reference to the kinetics of dislocation generation and
movement.
(12 Marks)

4.

(a) List three reasons why it is far from ideal to produce a stainless steel kitchen sink
using casting technology.
(3 Marks)

(b) What are the factors affecting the tooling pressure in open die forging? How can the
required tooling pressure be reduced?
(6 Marks)

(c) Bulk forming processes are modelled using either lower bound or upper bound
analysis. Briefly explain the main principles of these analytical methods and give an
example where each would be the most applicable.
(10 Marks)

(d) During the production of a wrought microstructure a forming texture is developed.

Explain how this is developed and how it can influence the mechanical properties.
(6 Marks)

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5.

(a) State whether the following statements are true or false.

i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.

Squeeze casting usually produce high quality products.

During bulk deformation it is the hydrostatic stress component that cause the
material to flow.
Tensile hydrostatic stresses are important during bulk forming as they prevent
crack formation.
The grain size controls the mechanical properties of an alloy casting.
Casting fluidity is not influenced by alloy composition.
There are similarities between spherulitic growth in polymers and dendritic
growth in alloys.
The strain rate sensitivity of metals increases with the homologous temperature.
Superplastic materials can be plastically deformed to high strains with the
formation of small tensile necks.
Both closed die forging and open die forging are very flexible processes.
Pressure die casting is usually associated with high density castings.
A sheet material with a Strain ratio R>1 will strain in the plain of the sheet in
preference to thinning.
In sheet metal forming, Forming Limit Diagrams help design both component
and tooling.
Hydroplastic forming is applicable to all ceramic materials.
Conventional powder metallurgy processing often results in fully dense
components.
Mass feeding is the only feeding mechanism in long freezing range alloys.
(15 Marks)

(b) Briefly describe the mechanisms that can occur when powder components are
sintered and how they affect densification.
(10 Marks)

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