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Student Name: _____________________________________

Student Number: ____________________________________

MME 9602 Term Test

Module I: Metals
(SOLUTIONS)
October 19, 2017

This is a 1.5 hour test

Answer all seven questions in the space provided.

You are allowed the use of a calculator, with no text display capability, and one
Letter size (8.5”x11”) sheet of equations and information.

The mark value of each question is shown below.

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1) Pure copper (Cu) has the physical parameters listed in the table below:

Calculate the size of the critical radius, r*, and the number Cu atoms in this critical
nucleus when solid Cu nucleates during an undercooling of T = 236 K. (8 mark)

Crystal structure FCC

Atomic Radius 128 x 10-12 m

Atomic weight 63.55 g/mole

Heat of fusion, Hf 1628 J/cm3

Solid/Liquid 177x10-7 J/cm2

interfacial surface
energy, sl

Ideal melting 1358 K

temperature, Tm

Volume of a 𝟒 𝟑
𝑽𝒔𝒑𝒉𝒆𝒓𝒆 = 𝝅𝒓
sphere 𝟑

Avogadro’s 6.022x1023 mole-1

Number, NA

𝟐𝝈𝑺𝑳 𝑻𝒎 𝟐(𝟏𝟕𝟕𝒙𝟏𝟎−𝟕 )(𝟏𝟑𝟓𝟖)

𝒓∗ = = = 𝟏. 𝟐𝟓𝒙𝟏𝟎−𝟕 𝒄𝒎
∆𝑯𝑭 ∆𝑻 𝟏𝟔𝟐𝟖(𝟐𝟑𝟔)

𝟒 𝟒
𝑽𝒔𝒑𝒉𝒆𝒓𝒆 = 𝝅𝒓∗𝟑 = 𝝅(𝟏. 𝟐𝟓𝒙𝟏𝟎−𝟕 )𝟑 = 𝟖. 𝟐𝟎𝟓𝒙𝟏𝟎−𝟐𝟏 𝒄𝒎𝟑
𝟑 𝟑
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𝟑 𝟑
𝑽𝑪𝒖 𝒖𝒏𝒊𝒕 𝒄𝒆𝒍𝒍 = (𝒂𝑪𝒖 )𝟑 = [𝟐√𝟐𝑹𝑪𝒖 ] = [𝟐√𝟐(𝟏𝟐𝟖𝒙𝟏𝟎−𝟏𝟎 )]

𝑽𝑪𝒖 𝒖𝒏𝒊𝒕 𝒄𝒆𝒍𝒍 = 𝟒. 𝟕𝟓𝒙𝟏𝟎−𝟐𝟑 𝒄𝒎𝟑

We therefore have

𝑽𝒔𝒑𝒉𝒆𝒓𝒆 𝟖. 𝟐𝟎𝟓𝒙𝟏𝟎−𝟐𝟏
=
𝑽𝑪𝒖 𝒖𝒏𝒊𝒕 𝒄𝒆𝒍𝒍 𝟒. 𝟕𝟓𝒙𝟏𝟎−𝟐𝟑
= 𝟏𝟕𝟑 𝑪𝒖 𝒖𝒏𝒊𝒕 𝒄𝒆𝒍𝒍𝒔 𝒊𝒏 𝒕𝒉𝒆 𝒔𝒑𝒉𝒆𝒓𝒆 𝒐𝒇 𝒓𝒂𝒅𝒊𝒖𝒔 𝒓∗

Each FCC Cu unit cells has 4 atoms therefore we have 4 x 173 = 692 Cu atoms in
the sphere of radius r*.
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2. A certain metal has a critical stress intensity factor of KIC =135 𝑀𝑃𝑎√𝑚 and
an ultimate tensile stress of 1050 MPa calculate the largest possible surface
crack length (f = 1) that this material can endure and still fail at a tensile
stress of 1050 MPa. (4 marks)

𝐾𝐼𝐶 = 𝜎𝑓 𝑓 √𝜋𝑎
2
1 𝐾𝐼𝐶
𝑎= [ ]
𝜋 𝜎𝑓 𝑓

1 𝐾𝐼𝐶 2
𝜎𝑓 = 1050𝑀𝑃𝑎 [ ]
𝜋 𝑓

𝐾𝐼𝐶 = 135𝑀𝑃𝑎√𝑚

𝑓=1

1 135 2
𝑎= [ ]
𝜋 1050(1)

𝑎 = 0.00526𝑚 = 5.26𝑚𝑚
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3. In our lectures we considered the solidification process in metals to occur

by either “planar growth” or “Dendritic Growth”. Describe these two
processes and point out how they differ.

(6 marks)

The growth of the solid phase can occur by two mechanisms:

Planar growth: When Hf is removed by conduction through the solid

phase. This occurs when the undercooling T is small.

Planar growth of the solid phase occurs in molten metals that contain a
uniform distribution of small particles.

These particles provide sites for easy nucleation of the solid phase at low
T.

The solid phase grows uniformly and allows a path for thermal diffusion of
the latent heat of formation, Hf.

Dendritic growth: When Hf is removed by conduction through the liquid

phase. This occurs when the undercooling T is large.

Dendritic growth occurs when not many “easy” solidification sites exist in
the molten metal.

Solidification occurs then only when T is high.

In this case there is not a homogeneous solidification front so the latent

heat of formation, Hf can’t diffuse through the solid phase.

Instead it is transferred to the liquid phase. This reduces the T in the

regions between the dendrite arms.

The dendrites arms grow only from their ends because these regions have
higher T.
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Planar growth Dendritic Growth

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4. The Magnesium - Aluminum binary phase diagram is shown below.

a) Sketch the microstructure of a Mg – 35 atomic % Al alloy that was
slowly cooled from 6000C to 00C. Be sure to label each phase in the
microstructure. (6 marks)
b) Calculate the amount and composition of each phase present in this
alloy at 0oC. (4 marks)

Pro-eutectic  phase

Eutectic parallel plates of  and  phases

b) Composition of the  phase is 100% Mg and 0% Al.

Composition of the  phase is about 42% Al 58% Mg.

Amount of the  phase = ((42-35)/(42-0))100 = 16.7%

Amount of the  phase = 100-16.7 = 83.3%

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5. The TTT diagram of a eutectoid steel is shown below.

a) Prescribe an effective isothermal heat treatment to marquench this steel.

(2 marks)

b) Describe the microstructural changes that occur in the metal during

marquenching of a steel such as this and describe also how marquenching
improves the mechanical properties of the steel. (6 marks)

A – Austenite
B – Bainite
P – Pearlite
M - Martensite

a) An effective isothermal heat treatment for marquenching this eutectoid

steel is as shown in red on the TTT diagram above: Heat to about 750oC
and hold for a long time (several hours) to ensure the entire sample
transforms to Austenite. Quench as quickly as possible to about 250oC and
hold at that temperature for about 100 seconds. This allows the entire
sample to reach 250oC. Then quench rapidly to room temperature to
transform all the austenite to martensite. The result will be a 100%
martensite microstructure.
b) When this eutectoid steel is quenched from 750oC to 250oC the steel
microstructure is 100% unstable austenite however the temperature of the
steel sample will be considerably higher in the center than at the edges. If
the steel would be then immediately quenched from 250oC to room
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temperature the regions near the outer surfaces would drop in

temperature across the Mstart temperature and transform to martensite.
The shell of hard martensite around the outer surfaces would then
constrain the interior of the sample making it impossible for the interior
austenite to transform to martensite. This “retained” austenite is
problematic because, if the hard shell of the surrounding martensite cracks
during service the constraint will be lost causing the austenite to transform
to martensite. The resulting volume change will be significant and may
cause further cracking of the sample. To avoid the formation of retained
austenite we do the marquenching operation that simply allows the
temperature of the sample to equilibrate in the 100% austenite region of
the TTT diagram just above the Mstart temperature. Once the temperature is
constant, at 250oC for this eutectoid steel, the sample is quenched through
the Mstart and Mfinish temperatures resulting in a 100% martensite
microstructure with no retained austenite. This material is much more
stable and resistant to unexpected cracking.
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6. Iron alloys are often carburized in order to increase the carbon content
along their outer surface and thus increase their surface hardness. The
carburization process involves packing the steel piece in carbon powder and then
heated in an oxygen free atmosphere for a prescribed time at an elevated
temperature to promote carbon diffusion into the steel.

A) Calculate the length of time necessary to carburize, at T = 700oC, a

piece of low carbon (0.1 wt% C) steel until the carbon content at a
distance 1 mm into the steel is 0.77%. (6 marks)
B) Draw the slowly cooled microstructure present in this steel at a
distance of 1 mm from the carburized surface before- and after- this
carburizing process. (6 marks)
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D ≈ 5x10-11m2/s

C 0
 0.001 C s
 1.00 C x ,t
 0.0077 x  1mm  0.001m
D  4 x10 11 m 2 / sec
C Cx ,t 0  x
 1  erf 


C C s 0  2 Dt 

0.0077  0.001  x 
 0.0067  1  erf  
1.00  0.001  2 Dt 

 x 
erf    0.993
 2 Dt 
From Table 5.3 (above) :

x
 2  Dt  x  t 
0.001m 42  1250sec  0.35hrs
2 Dt 5 x10 11 m 2 / s
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Part B:

Before the carburization the microstructure of the material would be one of a 0.1% Carbon steel as
shown below

The microstructure will consist of pro-eutectoid ferrite  and a

very small amount of pearlite ( + Fe3C parallel plates).

The amount of  is:

Pro-eutectoid
(6.7 − 0.1)
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝛼 = 𝑥100 = 99%  grains
(6.7 − 0)

𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐹𝑒3 𝐶 = 100 − 99 = 1%

Small
amount of
 + Fe3C
along grain
boundaries

After carburization to a carbon content of 0.77 %, at a distance of 1mm into the sample, the amount of
Fe3C will be increased and will grow by expansion (thickening) of the pre-existing Fe3C plates. The pro-
eutectoid grain size will also have grown considerably because of spending 0.35 hours at 700oC.

The microstructure will consist of pro-eutectoid ferrite  and a

larger amount of Fe3C.

The amount of  is:

(6.7 − 0.77)
𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝛼 = 𝑥100 = 89% Pro-eutectoid
(6.7 − 0)  grains

𝐴𝑚𝑜𝑢𝑛𝑡 𝑜𝑓 𝐹𝑒3 𝐶 = 100 − 89 = 11%

Larger
amounts of
Fe3C along
grain
boundaries
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7. Describe the microstructural differences between White Cast Iron and

Malleable Cast Iron.

How is malleable cast iron created? (6 marks)

White cast iron is an iron alloy containing between 2.5 to 4.0% Carbon and about
1.0% Silicon. This amount of Si is just barely enough to destabilize the cementite
phase resulting in the precipitation of graphite instead of Fe3C. In fact graphite
flakes only form when this alloy is cooled very slowly. If it is cooled quickly Fe3C
will form. Therefore, when white cast iron is cooled quickly it is very hard and
brittle because Fe3C forms instead of graphite. White cast iron is used when
castings require a hard surface layer with a soft interior.

Malleable cast iron is white cast iron that has been re-heated at 800oC to 900oC
for a long time (~40 hrs) to transform the Fe3C into clusters of graphite. Malleable
cast iron has similar strength and ductility to nodular cast iron. Its final
microstructure is clusters of graphite in a matrix of:

- pearlite (air cool) or

-  ferrite (slow cool).