‘Name (CAPs) _ DT022/3 —DT023/3._International Name (Signature) Question 1: From 20 mm diameter test specimen cast iron ‘Load (N) Length (mm) — 0 40.0000 I 23,000 40.0185 75,000 40.0555 90,000 40.2000 105,000 40.6000 120,000 | F560 131,000 44.0000 (maximum) 125,000 47.5200 (fracture) After fracture, the gauge length is 47.42 mm and the diameter is 18.35 mm. Plot the data in the form of a stress-strain graph and determine: (i) The yield strength, Gi) The tensile strength, (iii) Modulus of elasticity. (iv) Ductility (% elongation), (¥) Ductility (% reduction in area), (vi) Stress at fracture, (vii) Modulus of resilience. Note: 1 Pa= 1 Nim? IMPa= IMN = 10°N = in tm 10° mn? mm? ‘Erasmus ‘Thursday 27°! January 2016 (Wk1)Name (CAPs) T0223 -DT023/3_— International Erasmus Name (Signature Friday 28" January 2016 (Wk1) Question 2: ‘The following figure shows observations made when a 100 mm length of 10 mm diameter steel bar was loaded in tension. The equation given is for a trend line that has been fitted to the straight portion of the graph. 50 ' aT 45 1 35 Load (kN) B 1 7 15 2 25 Extension (mm) Determine the following: (a) The estimated yield stress, in MPa. (b) The ultimate tensile stress, in MPa. (©) The Young’s modulus, in GPa. (@) The Modulus of Resilience, in MPa. (©) The 0.2% proof stress, in MPa. (8) Estimate the percent ductility, and (g) Estimate the toughness.Name (CAPs) _ T0223 _DT023/3.—International_~—-Erasmus Name (Signature )_ ‘Thursday 4% February 2016 (Wk2) Question 3: ‘A flat stee! bar measuring SO mm by 20 mm by 3 m long is placed in tension, supporting, a load of 5 tonnes. (a) If the Young’s modulus of the bar is 220 GPa, what is the length of the bar when supporting the load? (b) If the Poisson’s ratio of the steel is 0.35, what are the dimensions of the steel section when supporting the load? (©) If the 0.2% proof stress of the steel is 200 MPa, what load would be required to give ar extension of 0.2%. Give your answer in tonnes.) (d) If the load calculated in (c) is applied, and then reduced by half, what is the final length (with the load still applied)? versible Poisson’s ratio = lateral strain/strain in direction of load.Name (CAPITALS), DT022/3 or DT023/3 Name (Signature ) Friday 5® February 2016 (Wk2) Group A GroupB GroupC Group D Key words: Ferrite, Pearlit Question , Cementite, Austenite, a-iron, y-iron, 8-iron, FexC, Eutectoid, Eutectic, Liquid. Explain with the aid of sketches how you would make steel samples which would contain the following phases: © Martensite, + Bainite, and « Pearlite and Ferrite‘Name (CAPITALS), DT022/3 or DT023/3 Friday 12" February 2016 (Wk3) | Name (Signature Group A Group B Group € Group D. Question 5: Using the isothermal transformation diagram for an iron-carbon alloy of eutectoid composition, specify the nature of the final microstructure (in terms of micro-constituents present and approximate percentages) of a small specimen that has been subjected to the following time-temperature treatments: In each case assume that the specimen begins at 760°C and that it has been held at this temperature long enough to have achieved a complete and homogeneous austenite structure, (@) Rapidly coo! to 250°C, hold for 10 seconds, and quench to room temperature, (b) Rapidly coo! to 350°C, hold for 10" seconds, and quench to room temperature, and (©) Rapidly cool to 650°C, hold for 10 seconds, and quench to room temperature. In each case (a, b and c) explain using the isothermal transformation diagram what happens at each stage of the process. A = Austenite, B = Bainite, F = Ferrite, M = Martensite, and P = Pearlite 809. temper 700 A 600 : = | 400} i | 200] Misa 200 0: MHA cas 1 ants0% | ans0% | 100} | | | | 4 10% 104 10"Name (CAPITALS) _ DT022/3. or DT023/3 Name (Signature ) Thursday 18" February 2016 (Wk4) Group A Group B Group C Group D Question 6 —(c) and (d): Using the isothermal transformation diagram for an alloy steel (type 4340) specify the nature of the final ‘microstructure (in terms of miero-constituents present and approximate percentages) of a small specimen that has been ‘subjected to the following time-temperature treatments: In each case assume thatthe specimen begins at 760°C and ‘that it has been held at this temperature long enough to have achieved a complete and homogeneous austenite structure, (@) Rapidly cool to 450°C, hold for 10* seconds, and quench to room temperature (6) Rapidly cool to 250°C, hold for 100 seconds, and quench to room temperature. (©) Rapidly cool to 620°C, hold for 10" seconds, and quench to room temperature. (@) Rapidly cool to 620°C, hold for 10* seconds, rapidly cool to 350°C for 500 seconds, and quench to room temperature, In each case (a, b, ¢ and d) explain what happens at each stage of the process. ‘A= Austenite, B = Bainite, F = Ferrite, M = Martensite, and P = Pearlite In your answers include a sketch of the TTT diagram to illustrate the process stages involved and explain clearly the evolution of the microstructural composi Mi50%) 30%) 200-= | 100} i | 00 Time (8) Figure. TTT diagram for an alloy steel (type 4340). 6‘Name (CAPITALS) DT022/3 ~— or DT023/3 Name (Signature ) Friday 19% February 2016 (Wk4) Group A Group B Group C Group D uestion 7: In terms of hardness and hardenability, using sketched of CCC diagrams explain the essential differences between a, A.0.4% plain carbon steel, and b. A0.4% carbon with 0.3% Ni plus 0.4% Crallloy.DT022/3_ — or DT023/3 \ | Name (CAPITALS) | Name (Signature ) Friday 26" February 2016 (Wk5) | Group A Group B Group C Group D Question Compare and contrast the following processes for hardening plain carbon and alloy steels in terms of their relative advantages and limitations, c. Austempering dd. Martempering‘Name (CAPITALS), __. DT022/3. or DT023/3 Name ( ature ) ‘Thursday 20" February 2014 (Wk4) Question 7: ‘The following figure shows a TTT diagram for an Eutectoid steel. What would the corresponding Continuous Curve look like? ‘What phases are possible to form from continuous cooling curves for Eutectoid steels? Is it possible to form Bainite? 800 J ; A Seer e a“ we Tempera M(start) a an 10 1 10610 1g— 10108 Time(s) Figure. TTT diagram for a eutectoid steel. 12‘Name (CAPITALS)_ DT022/3 or DT023/3 Name (Signature ) __. Thursday 3° March 2016 (Wk6) Group A Group B Group € Group D Question 9(a):. Explain the mechanism of the following fracture,Name (CAPITALS)__ DT022/3 or DT023/3 Name (Signature ) Friday 4" March 2016 (Wk6) Group A Group B Group C Group D Question 10 (a): ‘The Young’s modulus for a cast iron is 6 GPa. This batch of cast iron contains internal pores of 100 microns with a radius of curvature of 9 microns. Will a cast iron component from this batch fail at an applied stress of 250 MPa? What is the size of the internal pore below w! curvature? the material will not fail, given the same radius ofName (CAPITALS) _____ DT022/3. or DT023/3 ‘Name (Signature ) e ‘Thursday 10 March 2016 (Wk7) Group A Group B Group C Group D Question 10 (b) A relatively large plate of glass is subjected to a tensile stress of 40 MPa. If the specific surface energy and modulus of elasticity for this glass are 0.3 J/m? and 69 GPa, relatively, determine the maximum length of surface flaw that is possible without fracture. 19| Name (CAPITALS) DT022/3. or DT023/3 Name (Signature ), Friday 11" March 2016 (Wk7) Group A Group B Group € Group D Question 1 1. A large steel plate used in a nuclear reactor must support a stress of 350 MPa in tension during service. What is the largest internal flaw size that this material can support, given that the fracture toughness for the steel is 88 MN.mr2?, 2. A ceramic matrix composite contains internal flaws as large as 0.01 mm in length. The plane strain fracture toughness is 45 MPa.m! and the tensile strength is 550 MPa. At what stress will the crack grow at within the composite to cause it to fail? Assume f= 1. 3. An aluminum alloy that has a plane strain fracture toughness of 27 MN.n*? fails when a stress of 290 MN.m? is applied. Observation of the fracture surface indicates that fracture began at the surface of the part. Estimate the size of the flaw that initiated fracture. Assume f=1. 4. A polymer that contains internal flaws 1 mm in length fails at a stress of 25 MPa, Determine the plane strain fracture toughness of the polymer. Assume 1. 20Name (CAPITALS) Name (Signature ) Group A Question 1 Group B _ DT022/3 ~~ or DT023/3 | Friday 11 March 2016 (Wk7) Group C Group D ‘The following data were obtained from a creep test for a specimen having an initial gauge length of 50mm ‘and an initial diameter of 15mm. The initial stress applied to the material is 67 MN/m2, The diameter of the specimen just before fracture is 13.2mm, Gauge length (mm) Time (hy 0 100) 200 400 1000 2000 4000 6000 7000 8000 (fracture) Draw the creep curve and determine: ‘The instantaneous strain, ‘The steady state creep rate, ‘The duration at which the steady state or linear creep rate occurs, and The rupture time. 21a ace Name (CAPITALS), p03 or Name (Signature ), Friday 18tt" March 2016 (Wk8) ee Question 13: Creep Curves strain at 7M /me Se Sirain a FORINT Strain at 89 MIN Strain mm) ‘9000 From the above creep curves draw the corresponding Isometric Stress-Time Diagram. 23