NATIONAL INSTITUTE OF TECHNOLOGY,

JAMSHEDPUR
End Semester Examination (December 2021)
Class: 5th Sem, Session: Autumn (2021-22)
Branch: Metallurgical & Materials Engineering Full Marks: 50,
Time: 3 hrs [8.30AM to 11.30 AM] Date: 03/12/2021 [Friday-A shift]
Subject: Extractive Metallurgy of Non-Ferrous Metals [MM1501]
Instruction:
• Attempt all questions.
• Marks of the questions and part thereof are indicated in the right hand margin.
………………………………………………………………………………………………………
1. Answer in brief
(a) Factor affecting Bayer process. 4
(b) Factor Influencing Electrolysis process. 4

2. Write short note (any Four) (4x5=20)

(a) Worcra process of Cu Extraction.
(b) Fire Refining process of “Sn” (flow diagram).
(c) Production of Uranium (flow diagram).
(d) Flow sheets of Gold Extraction (kolar Gold field).
(e) Flow sheet of Nickel Extraction process (INCO process).
(f) Flow sheet of Hydrometallurgical Zinc Extraction Process.

3. Answer any one in brief

(a) Production Process of “Aluminium, Explain in Brief. 10
(b) Conventional process of “Pb” production and its Refining. 10

4. Write short note (any Four) (4X3=12)

(a) Write ores and uses of Aluminium.
(b) Write ores and uses of Copper.
(c) Write ores and uses of Tin.
(d) Write ores and uses of Titanium.
(e) Write ores and uses of Zinc.
(f) Write ores and uses of Lead.
(g) Write ores and uses of Uranium.
(h) Write ores and uses of Nickel.

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 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR
MID SEMESTER

CLASS: B.Tech.(Hons), 5th TIME – 2 hr

Sem
BRANCH: MME FULL MARKS: 30
SUB: Manufacturing Process in Metallurgy (Sub Code: MM1502)
1. Attempt all questions.
2. Marks of question and part thereof are indicated in the right hand
margin.

1. (a) What is weldability. Explain the different types of welding defects. 5

(b) Discuss the welding metallurgy in steels. 5

2. (a) Explain the growth of pure solid. 5

(b) Explain the solidification in single phase alloy.

5

3. Write the short notes on the following 5 x 2=10

(a) Segregation in ingots
(b) Sensitization in Austenitic stainless steel
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR

Department of Metallurgical and Materials Engineering

Autumn End Semester Examination, December 2021

B. E. (3rd Year Year): 5th Semester Course Code: 1503

(Metallurgical and Materials Engineering) Course Name: Deformation

Processing and Forming
Technology
Date of Exam : 08.12.2021

Time: 3 Hours, M. Marks: 50 Name of Faculty:Prof. BB Jha

Note: Answer all questions. Lengthy answers must be avoided.

Answers to the questions need be crisp, precise and to the point.
Missing data , if any, may be assumed appropriately.

Question 1: 3+3+4

i) Define what is thermal number and how is it expressed. What is

its physical significance with respect to temperature in machining
process?
ii) Define continuous, Buildup edge and Discontinuous chip with the
help of the diagram. Under what conditions, these verities of chips
are formed.
iii) For machining of Iron, it is given that:
Specific heat = 0.45J / gram.degree C Density = 7.8 gm/cc
Specific cutting energy = 4GJ/m3
Undeformed chip thickness =0.2 mm, chip width =5 mm
Chip speed = 1.1 m/s
Calculate: Cutting force, Metal removal rate and Temperature at
the chip-job interface at a very high cutting speed.
Question 2: 5+3+2

i) Draw the typical curve for forging load vs forging stroke for
closed die forging operation and explain:
a. Why it does not start from origin
b. Why rate of increase of load is initially high then reaches
almost a constant value and further increases at the end of the
forging operation.
ii) Explain what would be the effect of section thickness ‘h’ on the
forging load if the friction is reduced to zero.
iii) Compare the average pressure needed to compress a cylinder of
one inch in thickness and 5 inch in diameter with 1/8 inch in
thickness and 5 inch in diameter.
Question 3: 3+3+4
i) Define separating force. No-slip point, specific roll pressure, angle
of bite and relative spread.
ii) Establish a relationship between angle of bite, draft and roll
radious.
iii) Determine the maximum reduction possible in 300 mm steel plate
during cold rolling when µ =0.07 and also during hot rolling when
µ =0.7 ; Roll Radius being 500 mm. Also calculate the angle of
bite in both cases.
Question 4: 4+2+2+2

i) Name three alloys which could be strengthen by cold rolling

operation, and draw the relevant portion of their phase diagram
and explain why could they be strengthen only through cold
rolling operation.

ii) Explain with diagram the effect of front and back strip tension on
the distribution of roll pressure over length of contact.

iii) What will be the value of forward slip (Sf) when neutral point
coincides with exit plane?

iv) If, Initial and final height of the job is 10 and 8 mm, angle of bite
is 30 degree and coefficient of friction is 0.1 , Calculate the
forward slip during rolling process.
Question 5: 3+2+2+3

i) Explain drawing flow curve the term dynamic recovery and

dynamic recrystallization during hot working process.
ii) What is the role of stacking fault energy during these phenomena?
iii) Name two metals/alloys which can be hot worked by dynamic
recovery and other two metals/alloys which can be hot worked by
dynamic recrystallization.
iv) Explain the roll defects- Waviness and Edge cracking with the
help of diagrams. What are the reasons of occurrence of these
defects during rolling and what are their remedial measures

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 NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR

Department of Metallurgical & Materials Engineering

MID-Semester EXAMINATION on 08 OCT-2O21

Class : B.Tech (Hons ),5th SEMESTER Full Marks : 30

Subject : IRON MAKING (MT1505) Time :2hrs

ALL QUESTIONS ARE COMPULSORY

1. Explain with a neat & clean diagram of IRON-Blast furnace with diff reactions
occurring at different temperatures. 10

2. Why do you prefer SINTER then Pellets applications in Blast Furnaces,

explain this by supporting reduction Kinetics of Iron ores in Sinter. 10

3.”INDIA imports COKING Coals from AUSTRALIA & lime stones from
NEWZEALAND,, for Blast Furnaces .Justify your answer by suitable technical &
economic reasons . 10

BEST OF LUCK
 NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR

Department of Metallurgical & Materials Engineering

END-Semester EXAMINATION on 13.12.2O21

Class : B.Tech (Hons ),5th SEMESTER Full Marks : 50

Mode of Examinations : ON-LINE Time :3hrs

Subject : IRON MAKING TECHNOLOGY (MM1505)

Instructions :

1.AnswerAny FIVE questions only ,

2.Answers must be to the point .

1.Explain with a neat & Clean diagram,the kinetics of Direct reduction of Iron
ores by SL-RN /Solid routes & Method of manufacture of Sponge Iron.10

2.. Explain with a neat & clean diagram of IRON-Blast furnace with diff
reactions occurring at different temperatures.Why do you prefer SINTER then
Pellets applications in Blast Furnaces . Explain by supporting reduction Kinetics
of Iron ores in Sinter. 10

3.”INDIA imports COKING Coals from AUSTRALIA & Dolomites from

NEWZEALAND,, for Blast Furnaces .Justify your answer by suitable technical &
economic reasons . 10

4.Explain with a neat & Clean diagram,Compositions of Blast Furnace Gas ,the
thermodynamic criteria with a high Enthalpy of Blast to reduce the oxides at
low coke rates . 7+3=10

5.’’INDIA is top ranker after MEXICO IN sponge iron technology ,, . Justify your
answer by status of availability of Ores ,lime & Non-coking coals . 10

6. Write short notes : 2.5 X 4=10

1.Desulphurisation in Blast Furnaces, 2.HBI / Pellets in B/Fcs , 3.Coal

Injection, 4.High Top Pressures in B/Fcs .

BEST OF LUCK
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR

Department of Metallurgical and Materials Engineering

Autumn Mid Semester Examination, October, 2021

B. E. (3rd Year Year): 5th Semester Course Code: 1503

(Metallurgical and Materials Engineering) Course Name: Deformation

Processing and Forming
Technology
Date of Exam : 06.10.2021

Time: 2 Hours, M. Marks: 30 aName of Faculty:Prof. BB Jha

Note: Lengthy answers must be avoided. Answers to the questions

need be crisp, precise and to the point. Missing data , if any, may be
assumed appropriately.

Question 1: 2+2+3+3

i) Show that maximum load in tension test starts when true strain
(€) equals to strain hardening exponent (n).
ii) Derive the equation to prove that smaller is the gauge length (L0),
higher will be the total elongation up to the point of fracture.
iii) Derive the equation to establish that specimen strain rate during
tensile testing depends upon the stiffness of the machine. Which
kind of machine is suitable to study the yielding behaviour and
why?
iv) Write the equation relating flow stress with strain rate and strain
rate sensitivity (m). If m=0.05, what would be the percentage
change in flow stress in case the strain rate is increased by a factor
of AB (AB is the last two digits of your mobile number ).

Question 2: 3+3+4

i) Define the strain rate sensitivity (m), Strain hardening coefficient

( n), Strength Coefficient ( K ) and Inverse strain rate sensitivity
( m’).Using the data obtained through tensile test, depict
through diagram , how these parameters could be determined.
 ii) Depict the behaviour of superplastic material, clearly showing
the three regions, drawing the log-log plot of true stress vs true
strain rate as well as m vs log of true strain rate. Also show that
how these curves are affected by variation of grain size and
temperature. Why the m- value varies at three different stages.

iii) Based on the data as given below:

Crosshead speed -1mm/min Crosshead speed -2 mm/min

Load (kg) Dia ( mm) Load (kg) Dia ( mm
0.00 10.20 0.00 10.2
1720 10.00 1800 10.0
1835 9.50 1850 9.50
1855 9.0 1900 9.0
1860 8.0 1920 8.0
1775 7.0 1855 7.0
1440 6.2 1540 6.2

Draw the true stress-true strain curve and calculate the value of
n, K, m and m’
Question 3: 3+3+2+2
i) Explain how hot working range of deformation process is affected
by temperature, deformation pressure and strain rate. Which are
the two important factors which inhibit the upper limit of the
working temperature.
ii) Express the equation to define the deformation efficiency and
draw the curve showing dependence of frictional, ideal, redundant
and total deformation in drawing process with respect to semi-die
angle.
iii) The following equation expresses the pressure for the extrusion
of the Aluminium bar:

P = б0 ( 0.47+1.2ln R)e4µL/D
Billets of 8 inch in dia and 16 inch long are extruded into ¾
inch dia bars. In order to increase the length of product by 10
feet, would it be economical in terms of pressure to increase the
billet length or diameter. ( Take µ = 0.10 and б0 = 30000 psi )

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 NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

Course Name: Powder Metallurgy and Ceramics (PMC); Course Code: MM1504

Maximum Marks: 30; Duration: 2 hrs; Instructor: Dr. S.K. Vajpai

Note: Attempt All Questions. Elaborate your answers with necessary schematic
diagrams, wherever necessary.

1. Discuss the rationale and relevance of selection of various powder processing methods

with respect to the co-relation of characteristics of powders with the nature of intended

product development. Elaborate with suitable examples. [10]

2. Water Atomized Plain-carbon steel powders (0.8%C) are consolidated by conventional

press-sinter method, conventional hot pressing, as well as Vacuum Spark plasma

sintering method. The sintering was carried out in austenitic region. Explain the major

differences expected in these sintered compacts, in terms of sinter-ability, overall

densification, and microstructural evolution. [10]

3. Compare the pressure-less sintering and pressure assisted sintering in terms of

underlying mechanism, process, resulting microstructure, and applications. [10]

 NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING
Course Name: Powder Metallurgy and Ceramics (PMC); Course Code: MM1504

Maximum Marks: 50; Duration: 3 hrs; Instructor: Dr. S.K. Vajpai

Note: Attempt All Questions. Elaborate your answers with necessary schematic diagrams, wherever
necessary. Answer all parts of a question together at one place. Marks will be deducted for scattered
answers. Please keep your answers precise and to-the-point.

1. (i) Explain the differences in the size, morphology, and microstructure of the powders obtained by

Inert Gas and Water Atomizing mediums. Also explain the reasons for the same. [07]

(ii) Why does water atomization need much higher compression pressure than gas atomization to

achieve same intensity of disintegration of liquid stream during the process. [03]

2. (i) How do the particle shape, surface roughness, size, and size distribution affect the flowability and

apparent density of powders? [07]

(ii) Explain the technical implications of apparent density and flow rate of a powder. [03]

3. (i) Discuss the adverse effect of the density distribution in a green compact and measures required to

minimize it. [05]

(ii) Discuss the effects of air entrapment into the green and sintered compacts, and steps required to

avoid such situations. [05]

4. Discuss the importance of liquid phase sintering in the development of new materials and products,

with suitable examples. Also elaborate the disadvantages and limitations of the liquid phase sintering

citing specific examples. [10]

5. (i) Why Spherical shapes powders are preferred for making metallic filters? [02]

(ii) Describe briefly the technology of making cemented carbide products starting from the production

of carbide powders. [04]

(iii) Elaborate the advantages and limitations of Injection Moulding process over conventional

powder metallurgy process. Discuss with reference to both metallic as well as ceramic

materials. [04]
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR
END SEMESTER

CLASS: B.Tech.(Hons), 5th TIME – 3 hr

Sem
BRANCH: MME FULL MARKS: 50
SUB: Manufacturing Process in Metallurgy (Sub Code: MM1502)
1. Attempt all questions.
2. Marks of question and part thereof are indicated in the right hand
margin.

1. (a) Briefly explain the gating system. Write down the differences between 5
pressurized and non-pressurized gating system.
(b) A disk 30 cm in diameter and 5 cm thick is to be casted of pure aluminum
in an open mold operation. The melting temperature of aluminum = 5
660°C and the pouring temperature will be 800°C. Assume that the
amount of aluminum heated will be 5% more than needed to fill the mold
cavity. Compute the amount of heat that must be added to the metal to
heat it to the pouring temperature, starting from a room temperature of
25°C. The heat of fusion of aluminum = 389.3 J/g. density = 2.7 g/cm3
and specific heat C = 0.88 J/g-°C. Assume the specific heat has the same
value for solid and molten aluminum.
2. (a) Discuss the welding defects. 5

(b) Draw the schematic diagram of electron beam welding process and
5
explain it.

3. Write the short notes on the following 5 x 2=10

(a) Sand Casting
(b) Heat effected zone

4 Explain the Arc welding process. 10

1
5 (a) Discuss eutectic solidification. 5

(b) Estimate the number of crystal-like clusters in 1 mm3 of copper at its

melting point for spherical clusters containing (a) 10 atoms. (b) 60 atoms. 5
What volume of liquid copper is likely to contain one cluster of 100
atoms? The atomic volume of liquid copper is 1.6 x m3, ysl is 0.177 J m-2,
k = 1.38 x10-23 JK-1, Tm = 1356 K.

2
NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR
MID Term(October 2021)

Class: 5th Sem. Date:-04/10/21Monday} Session: Autumn

Branch: Metallurgical & Materials Engineering Full Marks: 30,
Time: 2 hrs. Subject: MM1501:Extractive Metallurgy of Non- Ferrous Metals.
Instruction:
• Attempt Two questions.
• Marks of the questions and part their of are indicated in the right hand margin.
……………………………………………………………………………………
1. (a) Write ores, occurrences and uses of Aluminium, Zinc & Copper. 5

(b) Draw Flow sheet of Conventional Process of Copper extraction. 5

(c) Draw a diagram and flow sheet of any one Newer process of Copper Extraction. 5

2. a) Write ores and uses of Zinc. 5

b) Draw Flow sheet of extraction process of Zinc. 5

c) Discuss the Bayer process with the help of Flow sheet. 5

3. a) Draw Flow sheet of synthesis of Cryolite. 5

b) Discuss Hall Heroult process with figure in brief. 10