1)Basic Metallurgy metals & process

1.deiscribe in simple terms the production of pig iron from pig iron ore
-Pig iron is produced in the blast furnace sector. The raw materials used include ore, sinter, coke, lime and various
aggregates. To ensure that the production process maintains a high and stable level of quality, these materials have to be metered
precisely and supplied to the blast furnace in batches
2.describe principles of open heart the bessemer and more modem process used in the production of steel from pig iron
ore
-Once all the steel has melted, slag forming agents, such as limestone, are added. The oxygen in iron oxide and other
impurities decarburized the pig iron by burning excess carbon away, forming steel. To increase the oxygen contents of the heat,
iron ore can be added
3.explain the principle differences between sand casting,die casting,centrifugal casting,forging,cold working and hot rolled
plate, bars, and other sections
Hot Rolled Steel
Hot rolling is a mill process which involves rolling the steel at a high temperature (typically at a temperature over 1700° F), which is
above the steel’s recrystallization temperature. When steel material is above the recrystallization temperature, it can be shaped and
formed easily, and the steel can be made in much larger sizes. Hot rolled steel is typically cheaper than cold rolled steel due to the
fact that it is often manufactured without any delays in the process, and therefore the reheating of the steel is not required (as it is
with cold rolled). When the steel cools off it will shrink slightly thus giving less control on the size and shape of the finished product
when compared to cold rolled.
Cold Rolled SteelCold rolling is a metal working process in which metal is deformed by passing it through rollers at a
temperature below its recrystallization temperature. Cold rolling increases the yield strength and hardness of a metal by introducing
defects into the metal’s crystal structure. These defects prevent further slip and can reduce the grain size of the metal, resulting in
Hall-Petch hardening.
Forged Steel-Forging offers uniformity of composition and structure. Forging results in metallurgical recrystallization and
grain refinement as a result of the thermal cycle and deformation process. This strengthens the resulting steel product particularly in
terms of impact and shear strength
Cast SteelWe use castings for a wide range of wearparts and components that are too large, complicated, intricate or
otherwise unsuitable for the forging process. We can forge parts up to 50kgs but the sheer energy required to forge larger items
make casting a much more viable alternative.
4.state the normal range of carbon content in mild steel,tool steel,cast steel and cast iron
-Although ranges vary depending on the source, the amount of carbon typically found in mild steel is 0.05% to 0.25%
by weight, whereas higher carbon steels are typically described as having a carbon content from 0.30% to 2.0%. If any more
carbon than that is added, the steel would be classified as cast iron
5.Describe the principal differences between ferrous and non-ferrous
-The simple answer is that ferrous metals contain iron, and non-ferrous metals don't. That means each type of ferrous
and non-ferrous metal has different qualities and uses. Ferrous metals contain iron, and are known for their strength. Think
steel, stainless steel, carbon steel, cast iron.
6.give examples of application of non-ferrous metals in marine engineering.
-The simple answer is that ferrous metals contain iron and non-ferrous metals do not. The more in-depth answer is that
ferrous metals and non-ferrous metals each have their own distinctive properties. These properties determine the applications they
are most suited for.
Non-ferrous metals have been used since the beginning of civilization. The discovery of copper in 5,000 BC marked the end of the
Stone Age and the beginning of the Copper Age. The later invention of bronze, an alloy of copper and tin, started the Bronze
Age.The use of ferrous metals started in around 1,200 BC when iron production started to become commonplace. This ushered in
the Iron Age.
7.state the purpose of the alloying elements nickel,chromium and molybdenum in steels used in marine engineering.
The high melting point of molybdenum makes it important for giving strength to steel and other metallic alloys at high
temperatures. It is also added to metallic alloys because of its resistance to corrosion. ... Molybdenum is used in stainless steels
in amounts up to 8% and most commonly in the range from 2 to 4%.

8.Identify the metal used in non-ferrous alloys commonly employed in marine engineering.
-The metals used in non-ferrous alloys commonly employed in marine engineering are nickel alloys particularly MONEL
METAL. This alloy contains 68% nickel, 30% copper, 1% iron and small additions of Manganese and other elements

2) properties and uses

1 explain in simple terms What influence the choice of materials for marine engineering component?
-It is important to that we understand the specific usage of a certain material, the conditions on where the materials is
likely to fail and how to effect an efficient repair. Bad materials mean accidents, and accidents cost lives as well as a lot of money, or
possible loss of ship.

2. Describe in simple terms what is meant by the following mechanical properties.

A.elasticity-the ability of a body to resist a distorting influence and to return to its original size and shape when that
influence or force is removed. Solid objects will deform when adequate forces are applied to them.
 B.brittleness-A material is brittle if, when subjected to stress, it breaks without significant plastic deformation. Brittle
materials absorb relatively little energy prior to fracture, even those of high strength.
C.hardness-Resistance of a material to deformation, indentation, or penetration by means such as abrasion, drilling,
impact, scratching, and/or wear, measured by hardness tests such as Brinell, Knoop, Rockwell, or Vickers. Since there is no
standard hardness scale, each test expresses its results in its unique (and arbitrarily defined) measure. For some metals (such as
steel) the hardness and tensile strength are empirically related. Hardness of pliable materials such as plastics and rubbers is
measured by instruments such as durometer.
D.strength-strength of a material is its ability to withstand an applied load without failure or plastic deformation. The field of
strength of materials deals with forces and deformations that result from their acting on a material.
E.toughness-toughness is the ability of a material to absorb energy and plastically deform without fracturing. One
definition of material toughness is the amount of energy per unit volume that a material can absorb before rupturing. ... Toughness
requires a balance of strength and ductility.
F.ductility-Ductility is when a solid material stretches under tensile stress. If ductile, a material may be stretched into a
wire. Malleability, a similar property, is a material's ability to deform under pressure (compressive stress). If malleable, a material
may be flattened by hammering or rolling.
G.Malleability-Malleability is a substance's ability to deform under pressure (compressive stress). If malleable, a material
may be flattened into thin sheets by hammering or rolling. ... Some do not; for example lead has low ductility but high malleability.
Malleability is a physical property of matter, usually metals
H.plasticity-plasticity describes the deformation of a material undergoing non-reversible changes of shape in response to
applied forces. For example, a solid piece of metal being bent or pounded into a new shape displays plasticity as permanent
changes occur within the material itself.

3.Explain what is meant by low,medium andwor high carbon steels

Low carbon steel is a type of steel that has small carbon content, typically in the range of 0.05% to 0.3%. Its reduced
carbon content makes it more malleable and ductile than other steel types. Low carbon steel is also known as mild steel
Medium-carbon steels (AISI 1029-1053, 1137-1151, and 1541-1552) can be heat treated to have a good balance of
ductility and strength. These steels are typically used in large parts, forgings, and machined components.
Steel that has more than 0.3 percent carbon, and is thus harder and less formable and machinable than low-carbon steel.
Used mainly for cutting EDGEs, compression springs, farming and gardening equipment, and other high-wear application
4.compare the tensile strength,ductility and hardness of low-, medium- and high-
Often called mild steels, low-carbon steels have less than 0.30 percent carbon and are the most commonly used grades.
They machine and weld nicely and are more ductile than higher-carbon steels. Medium. ... Increased carbon means increased
hardness and tensile strength, decreased ductility, and more difficult machining.
5. State the uses of low- medium and high carbon steels.
low Carbon Steels - Principal Design Features & Applications
It is a relatively low strength steel, but it may be quenched and tempered for increased strength. Used for applications such as cold
headed fasteners and bolts
Medium carbon steel or threaded steel bar is used for crankshafts, couplings, and cold headed parts. When greater
strength and hardness is desired in the rolled condition, then 1045 medium carbon steel can be used. It is also used in gears,
shafts, axles, bolts, studs, and machine parts
High carbon steel is used for applications in which high strength, hardness and wear resistance are necessary, such as
wear parts, knives, saw blades, springs, gear wheels, chains, brackets
6. Describe the properties of cost iron and give an example of its use.
The composition of Ductile Cast Iron is: Carbon ( 3.5 to 3.9 %) , Silicon ( 2.25 to 2.75 %) and Iron. What are the properties
of Ductile Iron? It has crystalline structure, so it acts as a strong metal for compression but is brittle in tension. It can be easily
moulded into intricate shapes and complex designs
examples:It is used in making pipes, to carry suitable fluids.

 It is used in making different machines.

 It is used in making automotive parts.
 It is used in making pots pans and utensils.
 It is used in making anchor for ships
7. Define an alloy
a metal made by combining two or more metallic elements, especially to give greater strength or resistance to corrosion
 8.state the uses of aluminum,copper,zinc,lead ,tin,antimony.
aluminum- Aluminium is used in a huge variety of products including cans, foils, kitchen utensils, window frames, beer
kegs and aeroplane parts
copper-copper's most common use is in electrical equipment such as wiring and motors. Because it corrodes slowly,
copper is used in roofing, guttering, and as rain spouts on buildings. It is also used in plumbing and in cookware and cooking
utensils.
zinc-oxide is widely used in the manufacture of very many products such as paints, rubber, cosmetics, pharmaceuticals,
plastics, inks, soaps, batteries, textiles and electrical equipment. Zinc sulfide is used in making luminous paints, fluorescent lights
and x-ray screens.
lead-is still widely used for car batteries, pigments, ammunition, cable sheathing, weights for lifting, weight belts for diving,
lead crystal glass, radiation protection and in some solders. It is often used to store corrosive liquids
tin-It takes a high polish and is used to coat other metals to prevent corrosion, such as in tin cans, which are made of tin-
coated steel. Alloys of tin are important, such as soft solder, pewter, bronze and phosphor bronze. A niobium-tin alloy is used for
superconducting magnets.
antimony-is alloyed with lead to increase lead's durability. Antimony alloys are also used in batteries, low friction metals, type metal
and cable sheathing, among other products. Antimony compounds are used to make flame-proofing materials, paints, ceramic
enamels, glass and pottery.
9.state the components metals of brass,bronze and white metal.
brass-is a metal alloy that is always made with a combination of copper and zinc. By varying the amount of copper and
zinc, brass can be made harder or softer. Other metals—such as aluminum, lead, and arsenic—may be used as alloying agents to
improve machinability and corrosion resistance
Bronze-is an alloy consisting primarily of copper, commonly with about 12–12.5% tin and often with the addition of other
metals (such as aluminium, manganese, nickel or zinc) and sometimes non-metals or metalloids such as arsenic, phosphorus or
silicon.
White metal-alloys are generally made up of these metals: Antimony, Tin, Cadmium, Bismuth, and Zinc, though which
ones being used vary based on the need.
10.state the uses of the above alloys
Typical improvements include corrosion resistance, improved wear, special electrical or magnetic properties,
and heat resistance. Other times, alloys are used because they retain the key properties of component metals, yet are less
expensive.
11. Explain why the above alloy are suitable for the uses in the above objective
Alloys are used because their chemical and physical properties are superior for an application than that of the pure
element components. Typical improvements include corrosion resistance, improved wear, special electrical or magnetic properties,
and heat resistance
12. Identify samples of metals described in the above objectives

3)Non-metallic materials
1.Explain the reasons for using the following filler in polymers:
a)Glass-Glass fibers are used to increase the mechanical properties of the thermoplastic or thermoset such as flexual
modulus and tensile strength, There is normally not an economic benefit for adding glass as a filler materia
b)mica-In order to help improve the surface adhesion, sometimes coupling agents, which act as a binder between the
polymer matrix and filler, are used in polymer composites. Coupling agents that could be considered with mica to form a composite
include silanes, zirconates, titanates, and stearic acid.
2.state that polymers can be plastic,rigid semi-rigid or elastomeric
polymers can be thermoplastic or thermosetting. Although all plastics are in a liquid state at some point in processing and
are solid in the finished state, once a thermoset polymer is formed, it cannot be melted and reformed.

4)process
1.explain the purpose of heat treatment.
-Heat treating is a process utilized to change certain characteristics of metals and alloys in order to make them
more suitable for a particular kind of application. Most carbon steels and carbon alloy steels can be heat treated for the purpose of
improving mechanical properties such as tensile and yield strength.
2.describe the following heat treatment process and the types of steel to which they might be applied
 -Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve the desired result
such as hardening or softening of a material. Heat treatment techniques include annealing, case hardening, precipitation
strengthening, tempering, carburizing, normalizing and quenching.
5)heat treatment of carbon steel
1.state how low carbon steels can be cases hardened
Both carbon and alloy steels are suitable for case-hardening; typically mild steels are used, with low carbon content,
usually less than 0.3% (see plain-carbon steel for more information).
2.state why how low carbon steels are sometimes cases hardened
-The main purpose of case hardening process is to provide low carbon steel with superficial high carbon content,
without affecting the inner or the core of the metal in its composition. ... Cementing or Carburizing – which helps introducing
additional carbon
3.describe terms of a suitable heat-treatment process for common carbon steels, given the properties required.
-In special silicon steels used for transformer laminations annealing develops the particular microstructure that confers the
unique electrical properties.
-Annealing requires heating to above the As temperature, holding for sufficient time for temperature equalisation followed
by slow cooling
4.complete items of information in a table which gives the following details for the tempering of high carbon steel:
A.temperature
B.colors
-Heat treating (or heat treatment) 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. Heat treatments are also used in the
manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme
temperatures, to achieve the desired result such as hardening or softening of a material. Heat treatment techniques include
annealing, case hardening, precipitation strengthening, tempering, carburizing, normalizing and quenching

6)Materials under load

A.define stress as the internal resistance per unit area of material to an externally applied load
-Stress is the internal resistance, or counterforce, of a material to the distorting effects of an external force or load.
These counter forces tend to return the atoms to their normal positions. The total resistance developed is equal to the external
load. This resistance is known as stress
B.define strain as the deformation produced in a material by an externally applied load.
-Engineering strain is defined as the amount of deformation in the direction of the applied force divided by the initial
length of the material. ... If a material is loaded beyond it elastic limit, the material will remain in a deformed condition after the
load is removed. This is called plastic deformation.
4. Illustrate with the aid of simple sketches a material under loading given in the above objectives.
-One material property that is widely used and recognized is the strength of a material. But what does the word "strength"
mean? "Strength" can have many meanings, so let us take a closer look at what is meant by the strength of a material. We will look
at a very easy experiment that provides lots of information about the strength or the mechanical behavior of a material, called the
tensile test.
7)Vibration
1.state the vibration is caused by the effect of a single force success in forces applied suddenly to elastic materials
-If the material is elastic, the object will return to its initial shape and size when these forces are removed. Hooke's law
states that the force should be proportional to the extension. ... In metals, the atomic lattice changes size and shape when forces
are applied
2.state the the forces causing vibration in a ship usually result from an imbalance in the machinery
-Vibration can be caused by one or more factors at any given time, the most common being imbalance, misalignment,
wear and looseness. ... Imbalance can severely reduce bearing life as well as cause undue machine vibration. Misalignment /shaft
runout - Vibration can result when machine shafts are out of line
3.describe the main sources ship vibration
-main engines, propulsion shafts, gearboxes, propellers, pumps, diesel generators- all machinery transmit vibrations. The
role of a ship designer is to first understand how each of these machinery causes vibrations and then device methods to keep them
within safe levels
4.state the ship structure and machinery are constructed largely of materials which are elastics
-Structural material in the form of a closed box, like a ship hull with a deck, resists vertical and lateral bending and twisting
all at the same time. ... Taken with a deck to which it is firmly attached, the whole forms a hollow box, a most economical and
efficient principal structural member of the hull.
5.state the vibrations that are transmitted from one elastic material or component to another
-There are actually two kinds of vibrations in isotropic elastic solids: lon- gitudinal pressure waves and transverse shear
waves. The two kinds of waves are generally transmitted with different phase velocities, because elastic solids respond differently to
pressure and shear stress.
6.state the anti-vibration materials are sometimes placed between connecting parts in order to reduce vibration
-Vibration can cause problems and damage in many industrial applications—heavy machinery, vehicles, equipment, and
tools. The repeated metal-to-metal contact in heavy machinery, for example, has the potential to damage parts and expose workers
to unsafe conditions. The vibration created by vehicle engines, buckets or blades, or by travel across uneven roadways potentially
causes circulation problems, nerve damage, and back pain for workers using industrial equipment. Extremely high-pressure
vibrations created by pneumatic hand tools can cause serious nerve and circulatory damage with prolonged use. It becomes
important, therefore, to determine the best way to reduce vibrations in the work environment to protect your equipment, workforce,
and ultimately, your profit margin
7.state if a component is vibrating a reversing stress is present in a material.
-Vibratory Stress Relief, often abbreviated VSR, is a non-thermal stress relief method used by the metal working industry
to enhance the dimensional stability and mechanical integrity of castings, forgings, and welded components, chiefly for two
categories of these metal workpieces:

 Precision components, which are machined or aligned to tight dimensional or geometric tolerances. Examples
include machine tool bases or columns, components of paper mill, mining equipment, or other large-scale
processing machinery, and centrifuge rotors.
 Heavily loaded metal workpieces, which are components designed and built with the ability to withstand heavy
loads. Examples include lifting yokes, clamshell buckets, crane bases, vibratory screening system frames, ingot
processing equipment, and rolling mill equipment

8.state that in normal working condition the stresses are due to vibration are well within the limits allowed.
-A complete assessment of exposure to vibration requires the measurement of vibration acceleration in meters per
second squared (m/s2). Vibration exposure direction is also important and is measured in defined directions. Vibration frequencies
and duration of exposure are also determined. How hard a person grips a tool affects the amount of vibrational energy entering the
hands; therefore, hand-grip force is another important factor in the exposure assessment.

9.state the vibration in a component may be from different sources,which can cause resonance and magnify the effect.
-Structural resonance refers to excessive vibrations of non-rotating components, usually machine parts or supporting
structures. Due to the complexity of these components, it is the more common resonant condition and usually occurs at or near the
rotating speed of the machine. Even slight vibratory forces from residual unbalance and misalignment effects of the machine can
excite the resonant base structure, resulting in severe vibration. A good example of this is the reed frequency vibration that often
occurs with vertical turbine pumps that have a motor mounted on top of the discharge elbow. Machine components can also be
resonant; there are many examples of two-pole electric motors where a resonant end bracket caused very high axial vibration
10.state that if vibration become excessive the stress induced can cause permanent damage.
-Vibration can cause changes in tendons, muscles, bones and joints, and can affect the nervous system. Collectively,
these effects are known as Hand-Arm Vibration Syndrome (HAVS). Workers affected by HAVS commonly report: attacks of
whitening (blanching) of one or more fingers when exposed to cold.

11. State the excessive vibration should not be allowed to continue

-Workers will not be likely to develop vibration-related injuries or disease if their exposure to vibration is maintained at
sufficiently low levels. What has been observed is that the number of affected people increases as the intensity and duration of
vibration exposure increases.
12.state when varying the rotational speed of machinery,stress may be encountered where vibrations become excessive
-usually performs efficiently if it works under “design point” conditions. However, “off-design” conditions require a
predictive model of the machine's performance. In a FCC power train system, mass flow deviation is quite common for adjusting
production capacity to meet the requirements of petrochemical product markets.