Description of coursework briefs for module 20MTRN04C

S1 Academic year 2020/2021

Programme: Mechatronics Engineering

Module Title: Materials Engineering

Module Code: 20MTRN04C

Exam/
Exam
ILOs Written
Assessment Focus Weight % Assessment Type Seme
Assessed Coursework
ster
Length
2 in-class 20% Class test a1, a2, 50 min each
Assessments b1, b2

Designed to be based on
open resources on- or off-
campus.

Group laboratory 20% Coursework b2, b3, 5000 words

report (10%) and c1, d2 and 20 min
individual discussion discussion
(10%)

Unseen written exam 60% Final exam a1, a2, 2 hrs

b1, c2,
d1

• Resit assessments might be different to accommodate the Summer Period but

will assess the same ILOs

Assignment Title: Coursework lab report based on attending four lab sessions
Type: 10% Group with 10% for individual performance.
Weight: 20%
Assessing ILOs:

Subject Specific Cognitive Skills

b2. identify the different types of structures found in engineering materials and relate
them to material behaviour;
b3. Produce data from different material sources to obtain information to assisting in
materials selection;

Subject Specific Practical Skills

c1. Conduct experiments on engineering materials to determine their properties;

Transferable Skills
d2. Appreciate how to use lab experiments to assess material properties.
 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

Lab Report (based on attendance)

Due week 10
Weight 20% (10% for group work and 10% for individual work)

For each lab please add

Group
Bay No.
Name Matric No

Lab Result

GROUP NUMBER :___________________________

STUDENT NAME :___________________________
ID :___________________________
NAME OF EXPERIMENT :___________________________
DATE OF EXPERIMENT :___________________________
FINAL SCORE : _______ x ______ % = _______

Evaluator Signature: Date: ……………………….

…………………………………………………….. Name:

LAB (1)
LAB (1A): Micro-specimen preparation and use of the metallurgical microscope
(10 marks)
1- Sketch and label the microstructure of each of the samples examined,
indicating etchant and total magnification. Identify on your sketches the
micro-constituents present and any significant features observed.
2- Define metallographic examination and state the steps followed in the lab to
prepare the sample.
3- Explain why grain boundaries are the first to be visualized on a specimen of
properly polished and etched metal under the optical microscope.

LAB (1B): The Hardness Test (10 marks)

 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

1- Produce a simple sketch for the hardness testing device in the lab indicating
its main parts and functions. What is the type of this hardness machine?

2- For the same sample you used for microstructure examination. Report the
hardness value with its proper designation, and hence answer the following:
a- Describe the shape of the indenter.
b- Describe the shape of the indentation.
c- According to the hardness reading is this material hard or soft?
d- Compare the hardness with the microstructure of the part.

LAB (2)
LAB (2A): Impact Test (10 marks)
1. Study the machine in the lab, draw a schematic of the machine and add the
function of each of its parts. Write the machine model and specifications.

2. Draw the specimen with dimensions.

Specimen Material Dimensions Notch

no. Specifications
W H L

3. Note the rupture energy of each specimen.

Specimen Rupture Energy

4. Study the features and draw the texture of the fractured surface of each
specimen.

Specimen Illustration Comments

5. Comment on the results.

 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

6. Discuss the significance and advantages of impact tests in comparison with

static tests.

7. What physical property of a material is determined by means of an impact

test?

8. Why are Charpy impact specimens notched?

9. Discuss the effect of the following factors upon the results of impact tests:
(i) Characteristics of the notch
(ii) Speed of the hammer
(iii) Temperature of the specimen

LAB (2B): Tension Test) (10 marks)

Complete the following table for the sample that your group tested in the
laboratory:
Load (kg) Extension (ΔL) Stress (F/AInitial) Strain (ΔL/L)
0 0 0 0

Plot the stress-strain diagram for your specimen material, and indicate the
0.2 % yield stress, ultimate tensile strength, the % elongation, % reduction in
area, modulus of elasticity,. Use ordinary millimeter graph paper.

After finishing answer the following questions.

1. Calculate the values of % elongation and % reduction in area and indicate
their significance?
2. Calculate the elastic modulus using the slope of the linear portion of the
curve.
3. Determine the 0.2 % yield stress.
4. What property does the area under the stress-strain define?
5. Compare the stress-strain curves for the cold-rolled and annealed steel and
the aluminum specimens shown hereunder, your answer should include some
discussion in addition to describing the behaviour.
 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

Stress-strain diagram

Cold rolled steel

Annealed steel

Aluminum alloy

LAB (3): NDT Methods (20 marks)

In certain applications, the evaluation of engineering materials or structures without

impairing their properties is especially important, such as the quality control of the
products, failure analysis or prevention of the engineered systems in service. This
kind of evaluations can be carried out with Nondestructive test (NDT) methods. It is
possible to inspect and/or measure the materials or structures without destroying their
surface texture, product integrity and future usefulness. The field of NDT is a very
broad, interdisciplinary field that plays a critical role in inspecting that structural
component and systems perform their function in a reliable fashion. Certain standards
has been also implemented to assure the reliability of the NDT tests and prevent
certain errors due to either the fault in the equipment used, the miss-application of the
methods or the skill and the knowledge of the inspectors. Successful NDT tests allow
locating and characterizing material conditions and flaws that might otherwise cause
planes to crash, reactors to fail, trains to derail, pipelines to burst, and variety of less
visible, but equally troubling events. However, these techniques generally require
considerable operator skill and interpreting test results accurately may be difficult
because the results can be subjective. These methods can be performed on metals,
plastics, ceramics, composites, and coatings in order to detect cracks, internal voids,
surface cavities, delamination, incomplete defective welds and any type of flaw that
could lead to premature failure.

Requirements

You are supposed to prepare a test report for this experiment obeying the report
preparation rules. Therefore, your report should contain experimental procedures,
results, discussion, conclusion and references. The advantages and disadvantages of
each NDT method must be stated precisely in your reports.

LAB (4) Manufacturing & Processing Lab

 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

SHEET METAL FORMING

RESULT

1. Your finished products will be evaluated by your instructor.

QUESTION**

1. In your own words, give the definition of the terms below. You may also include figures to explain:

a. Bending
b. Shearing
c. Punching
d. Cutoff

2. Describe the process of bending a sheet metal.

3. What is seam? Describe the different types of seams.

DISCUSSION**

(Describe what have you observed and understand during conducting experiment.
Comment about the results, and also give your reason and opinion to this experiment)

12. CONCLUSION**
(Based on the data and discussion, make your overall conclusion)

Individual discussion (10%)

The group will agree on assigning each member to answer one of the below questions.
This question will be the individual work for each student.

QUESTION (1)
The following data were collected from a test specimen of cold-rolled and
annealed brass. The specimen had an initial gage length l0 of 35 mm and an initial
cross-sectional area A0 of 10.5 mm2.

Load, N Elongation, mm Load, N Elongation l, mm

0 0.0000 1350 5.55
66 0.0112 1720 8.15
177 0.0157 2220 13.07
327 0.0199 2690 (maximum 22.77
load)
462 0.0240 2410 25.25 (fracture)
797 1.72
 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

(a) Plot the engineering stress–strain curve and the true stress–strain curve. Use a
software graphing
Package.
(b) Calculate the 0.2% offset yield strength; Calculate the tensile strength; Calculate
the elastic modulus using a linear fit to the appropriate data.
(c) Can you use the equations that calculate the true stresses and true strains beyond
the ultimate tensile strength? Why? If the true stress–strain data were known past the
point of necking, what might the curve look like?

QUESTION (2)
The following data were obtained from a series of Charpy impact tests performed on
four ductile cast irons, each having a different silicon content. Plot the data and
determine
(a) the transition temperature of each (defined by the mean of the absorbed energies in
the ductile and brittle regions) and
(b) the transition temperature of each (defined as the temperature that provides 10 J of
absorbed energy).
Plot the transition temperature versus silicon content and discuss the effect of silicon
on the toughness of the cast iron. What is the maximum silicon allowed in the cast
iron if a part is to be used at 25°C?

Test Temperature Impact Energy (J)

(°C)
2.55% Si 2.85% Si 3.25% Si 3.63% Si
-50 2.5 2.5 2 2
-5 3 2.5 2 2
0 6 5 3 2.5
25 13 10 7 4
50 17 14 12 8
75 19 16 16 13
100 19 16 16 16
125 19 16 16 16

QUESTION (3)
(a) Describe a test that you would use and the data you expect to obtain if you wanted
to measure the toughness of welded steel samples under impact conditions at
Room Temperature of 25C, would you expect the results to be valid if the steel
operates at -40C.
(b) If it is required to calculate the maximum load that may be applied to a piece of
material without causing plastic deformation, which of the following values would
you use for your calculations knowing that the material has an offset yield
strength of 345 MPa, ultimate tensile strength of 420 MPa, and Young’s Modulus
E= 103 GPa. Define what is meant by each of these values.

QUESTION (4)
(a) A catalyst is a substance that speeds up the rate of a chemical reaction without
participating in the reaction itself (i.e., it is not consumed). One important use
of catalysts is in catalytic converters on automobiles, which reduce the
emission of exhaust gas pollutants such as carbon monoxide (CO), nitrogen
oxides (NOx, where x is variable), and unburned hydrocarbons. Search
 Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021

literature and use proper citation to explain the adsorption sites on a catalyst
and their relation to surface defects.
(b) The grain size is often determined when the properties of a polycrystalline
material are under consideration. In this regard, there exist several techniques
by which size is specified in terms of average grain volume, diameter, or area.
Probably the most common method, however, is that devised by the American
Society for Testing and Materials (ASTM). The ASTM has prepared several
standard comparison charts, all having different average grain sizes. To each is
assigned a number ranging from 1 to 10, which is termed the grain size
number. A specimen must be properly prepared to reveal the grain structure,
which is photographed at a magnification of 100X. Grain size is expressed as
the grain size number of the chart that most nearly matches the grains in the
micrograph. You are asked to 1) Determine the ASTM grain size number of a
metal specimen if 45 grains per square inch are measured at a magnification of
100X. 2) For this same specimen, how many grains per square inch will there
be at a magnification of 85X?

QUESTION (5)
(a) Using the given Fe – Fe3C phase diagram, identify the different solid phases that
exist as a result of dissolving C in Fe. List some differences between these
phases. Accordingly define the types of carbon steels relevant to their C content.
(b) Why are carbon steels more prone to corrosion than austenitic stainless steels?
Would corrosion initiate at the ferrite or pearlite? What is the product form as a
result of corrosion of carbon steels?
(c) A steel specimen from a pipe was studied for microstructure after a failure case.
The microstructure showed 62.5 % Ferrite and 37.5 % Pearlite. Predict the C %
in this steel. From the given data, sketch this microstructure.
(d) Suggest a quick method in the workshop to distinguish between two pieces of
material that you have mixed up accidently in the lab, knowing that one of them
represents stock material of low C steel, and the other represents stock material
of 0.8% C steel.
Description of coursework briefs for module 20MTRN04C
S1 Academic year 2020/2021