EXAMS OFFICE USE ONLY IY L00 loz \u (2015 CRILG University of the Witwatersrand, Johannesburg Course or topic No(s} CHMT 2016 / CHEM 2007 Course or topic nameis) MATERIALS SCIENCE & ENGINEERING Paper Number & ttle Examination to be held during months) of 9 NOVEMBER 2015 Year of Study (arts & Science leave blank) SECOND Degree/Diplomas for which B.Sc. (Eng.) Metallurgy and Materials Engineering this course is prescribed {85 En) shoud wich branch B.Sc. (Materials Science) Faculty/ies presenting: ENGINEERING / SCIENCE candidates Internal examiner(s) Dr LH Chown: and telephone extension number(s) bed Extemal exarnineris) Mr R. Couperthwaite Special materials required (oraphimusicidrawing paper) Calculator, ruler, per ‘maps, diagrams, tables, ‘computer cards, etc. Time allowance Course | | CHMT2016/ Nos. | CHEM2007 | Hours 7 Instructions to candidates Ane Gee (Examiners may wish to use this space to indicate, inter alia, ‘Student number to go on FIRST page of the contribution made by this ‘Question Paper and HAND IT IN ‘examination or test towards TOTAL MARKS = 130 the year mark, if appropriate) Internal Examiners or Heads of Department are requested to sign the declaration overleaf.CHMT2016 / CHEM2007 Materials Science and Engineering QUESTION 1 (30 marks) 1.1. Draw the following on the answer sheet given at the back of the question paper: a). Planes (0.11) and (02 0). Give the vector coordinates [x, y, z] of the direction of the intersection line between the 2 planes. (5) b) Plane (3 3 3) . Give the coordinates of 2 other planes that are parallel to this plane. What are the Miller indices of this family of planes? 6] ¢) The direction that starts at (+ ,0,0) and ends at (1,1,> ) . Give the vector coordinates of the direction, Now draw another direction line parallel to the first, listing its start and end pr coordinates. 5] d) Five direction lines in the close packed directions of the FCC unit cell. Label the directions with their vector coordinates. 5] 1.2 Agold sample diffracted X-rays of an unknown wavelength. The 20 angle was 64.582° for the (220) plane. What is the wavelength of the X-rays used? [Assume first-order diffraction. ‘The atomic radius of gold = 0.144 nm. Diffraction of gold also occurred for the (111), (200), (311) and (222) planes}. a0) QUESTION 2 (20 marks) 2.1 Amaterial has a fracture toughness of 3.0 MPa Vim. If the largest internal crack that this material can support without fracturing is 0.436mm, what should its design stress be? 4) 2.2 At Medupi power station one of the supporting beams is to be made as a wide plate. It will be fabricated from 1045 steel that has a plane strain fracture toughness of 77.0 MPaym and a yield strength of 1400 MPa. The design stress is one half of the yield strength. The flaw detection equipment that is to be used can only detect flaws of 4.1 mm and larger. Will a critical flaw be detected in this beam? 4) 2.3 _ Ina fatigue test, the mean stress was 45 MPa and the stress amplitude was 270 MPa. Draw a labelled diagram showing the important stress values. Then calculate the following: a). The maximum and minimum stress levels. b). The stress ratio ¢). The magnitude of the stress range. [22]QUESTION 3 (20 marks) 3.1 What is the difference between true stress and engineering stress? Discuss in terms of the testing procedure and the stress-strain equation. 5] 3.2 cylindrical tensile specimen has the following dimensions: gauge length Scm, diameter 10mm. ‘After tensile testing to failure the specimen dimensions are: gauge length 9cm, with a diameter of 2mm at the point of break. a). Determine the percentage total elongation. 2) b). Determine the percentage reduction in area. 2] ). Is this material ductile or brittle? Justify your answer. 21 3.3 Figure 1a & b show an engineering stress-strain curve for a steel: (b) is a zoomed section of (a). Find the following: (9) Ultimate tensile strength (and associated strain) |. Elastic limit (and associated strain) ). Yield stress iv). Stress at fracture v). Total elongation in % vi). Young’s modulus 350 7 I+ ] | | { 300 } MT | Si | 250 -— eee | 280 & 200 1 | 200 8 | 2 | 150 % 2 € | | 100 —}+-—} 3 jest % | | 50 E x0 ! | ° 5 a | © 005 01 015 02 025 03 oO 2 4 6 8 10 12 14 16 18 ahha! Engineering strain (%) Figure 1QUESTION 4 (20 marks) (On the temperature (°C) - toughness graph below (Figure 2): 4.1 Label the axes, lower shelf and upper shelf. (4) 4.2 Determine the 50% ductile to brittle transition toughness value and the DBTT temperature and show these on the graph. 4) 4.3 What crystal structure do you expect this metal to have? Give a reason. 2 4.4 Based on these results, would you recommend this metal for outdoor use as an advertisement billboard tower in Durban or in Johannesburg? Explain your answer. re) 45 Describe 2 main types of wear, and give 2 examples of beneficial wear. (4 46 Describe the stages of brittle failure. fa) 90 80 70 60 50 Billboard tower 40 30 20 10 Figure 2QUESTION 5 (40 marks) Use the Pt-Sn phase diagram (Figure 4) to answer the following questions. BA 52 53 54 Label all the two-phase regions ON the diagram. (8) 2) What is the maximum amount (wt%) of Sn that is soluble in single phase platinum? Q b) How much platinum (wt%) is soluble in single phase (BSn)? ty) ©) What is the range of platinum (at.%) soluble in PtSn? p) In Table 4, give details of all the invariant reactions ON COOLING: (8) Use the column format to describe the cooling of a 20 wt% Sn alloy from 1500°C to just below 1070°C including faa) ‘© Temperature in °C ‘© Name invariant reactions © Phases present ‘© Chemical composition of each phase ‘* Amount of each phase ‘© Sketch the microstructure 5.5 Inthe Fe-C system (Figure 3 below), what are the common names for the following: a) FesC, a-iron and y-iron. The invariant reaction at 0.80 wt% C. pl b) _Fe-C alloys with the amount of C < 0.8 wt%. Sketch the microstructure with labels. fa) ©) Fe-Calloys with 0.8 - 1.7 wt% carbon: Sketch the microstructure with labels. p ‘ ‘auld foeciron 1 | | Jf ‘aves a +o i c ce . thy ge + tered Meola Sexoie seco} S44 of =| yb 00 (ora Becton a fa Fes OOS Os 20 7s 3 as O35 80 fe wee Figure 3CHMT2016/CHEM2007 STUDENT NUMBER: Question 1 aa a) b)CHMT2016/CHEM2007 STUDENT NUMBER: Atomic Percent Tin ow 70 30 1900. 1100. 800: Temperature °C 1700: 600. 300: 3 a wo 40 80 Cy 70 Ey 90 ‘ido Pt Weight Percent Tin Sn Figure 4 - QUESTION 5 Table 1 - QUESTION 5.3 ‘Temperature Type of reaction Equation of the reaction