= Practie- Fine -bwhons Important Notes (please read carefully) . Answer all the questions on the exam paper supplied. Not all questions are of equal marks. Where appropriate draw a sketch to support your calculations. Underline your final answer and make sure you provide proper steps and correct units. . Formula sheet is provided at the start of part C as well as at the last page of the exam paper. You can remove required PART A Multiple Choices (1.5x22=33_ marks) Note: 1. There are twenty two (22) questions in this part B 2, Each correct answer carries 1.5 marks. Cirele the one best answer provided on this exam paper for each question. 1. Annealing is a heat treatment technique which will: a, Harden material. (B)Soften material. . Strengthen material. d. Have no effect on the material. 2. Quenching hardens most of the steels and tempering: (@ Increases toughness. b. Increases strength. c. Decreases toughness. d. Decreases ductility. 3. Impact testing is: a, Can’t be used to evaluate the brittleness of material. b. Impact toughness which is always related to tensile toughness. c. Ductile to brittle transition temperature which can’t be obtained from impact testing. (QNotch sensitivity can be obtained from impact testing. pg. 1 UNIVERSITY4. Which of the following statement is true for brass? a. Copper - Nickel alloy. b. Copper - Tin alloy. c. Copper - Aluminium alloy. @ Copper - Zine alloy. 5. Hardenability of material is defined as: a,)It describes the ease with which steels can form martensite. b. It measures the resistance to penetration of the surface of a material by a hard object. c, It describes the difficulty with which steels can be hardened. d. It measures the ease of penetration of the surface of a material by a hard object. 6, What is the full form of TTT diagram? a, Temperature -Transition-Time diagram. b. Temperature -Time -Transmission diagram. c. Time -Transition -Transformation diagram. @Time -Temperature Transformation diagram. 7. Martensite forms: a, When cementite is rapidly cooled to room temperature. (B)Nearly instantaneously when required temperature is reached. ¢. Asa result of the atom diffusion. d. Depending on the temperature and time. 8. In the context of corrosion, which reaction happens at the cathode? a. Oxidation reaction. (Reduction reaction. c. Electrolysis. d. Oxidation and reduction reactions. pg. 2 ® RMIT ‘UNIVERSITY9. Young’s modulus of a material is defined as: Is the tangent of the point drawn at the stress-strain curve. Is also called modulus of toughness. c. Linear portion of the stress-strain curve. d. Ductility of the material. 10.For some materials the transition from elastic to plastic flow is abrupt. This transition is referred as: a. Necking phenomenon. b, Fatigue failure. c. Rupture. (Oviela point phenomenon. 11. True stress is defined as: a. The correct stress. b. The engineering stress. \The stress at actual area where the force is applied. @. Calculated as force over original area. 12. Hooke’s law is defined as: . It is the maximum force per unit area. ¢. It is calculated as the force over area d. The area contained under the elastic portion of a stress strain curve. 13. Creep is defined as: lure of a material due to cyclic, repeated loading at stress levels well below a. that of the yield strength. [ai deformation of a material at high temperatures even though the applied (ress is less than the yield strength at that temperature. c. Resistance of a material to indentation. 4. Resistance of a material to quasi-static loading. pg. 3 ® RMIT UNIVERSITY14. Which statement is ineorreet regarding polymers/elastomers? a. Thermosets are highly cross-linked polymer chains that form a three- dimensional network structure. b. In Thermosets, cross linking is not reversible; once formed, the thermosets cannot be refused or conveniently recycled. ‘ulcanization is a process which uses nitrogen atoms to link polymer chains in Tubber. d. Thermoplastics such as polyethylene has a flexible linear chain structure (straight or branched). 15.Which of the following statements where B and C scales are commonly used about Rockwell hardness testing is correct? a. B scale and C scale are not inter convertible. b. B scale uses diamond indenter, while C scale uses metal ball indenter. c. B scale uses 150 kg load while C scale uses 100 kg load for testing. @B scale for relatively soft materials, while C scale for relatively hard materials. 16.Fatigue is defined as: a. Failure of a material due to loading under high temperature. <0) Failure of a material due to cyclic, repeated loading at stress levels well below that of the yield strength. c. Failure of a material due to application of a unidirectional load. d. Resistance of a material to indentation. 17. What is a composite material? ‘hen two or more materials or phases are used together to give a combination ‘properties that cannot be attained otherwise. b. Materials containing particulates. c. Materials that contain fibers. d. All of the above (a, b & c). pg. 4 ® RMIT UNIVERSITY u18. Galvanic corrosion is: a, When a metal loses an electron. b. Corrosion occurring at the anode. When corrosion occurs due to a difference in potential energy between two Thetals. d. Corrosion occurring at high temperatures. 19. Which one of the following is used to predict the properties of composite materials? a. Hooke’s Law. b. The slope under the stress-strain curve. ORule of mixtures. d. None of above. 20.In the designation of the wrought alloys, e.g, 3XXX , what does the first digit (3) refer to? @ The main alloying element. b. Carbon percentage of the alloy. c. Whether it is an ingot or a billet. d. Specific alloy heat treatment, 21. What does the term “Monel” refer to: {@)Roughly 60% nickel and 40% copper alloy. B. A specific composite material. c. Materials that conduct electricity but not heat. d. Materials which can resist corrosion. 22. Properties that differ according to the direction of measurement are referred as: a. Isotropic b. Aspect ratio c. Viscoelastic (@anisotropic pg.5 ® RMIT UNIVERSITYPart B Short Answer Questions (18 marks) It is helpful to support your discussion with a diagram where appropriate. 1. What are the components of an electrochemical cell? Draw a diagram to illustrate the components and the functions of each component, _(4 marks) Spe. votes 2. Explain any three (3) techniques to control corrosion in brief. (3 marks) soe slrles. pg. 6 ® RMIT UNIVERSITY3. State any two (2) non-destructive testing methods that are commonly used in industry. A brief description of each method should be mentioned and your answer should discuss any limitations of the method. (4 marks) see sloles. 4, Briefly describe the advantage and disadvantage of a long, unidirectional arrangements of fibres in comparison with the short, randomly oriented fibres in composite materials (3 marks) yee slules, pg.7 UNIVERSITY,5. Explain which of the following Aluminium alloy is stronger, the 2024-T9 or the 2024-T6 alloy? You need to use the temper designations for aluminium alloys shown below for your explanation (4 marks) TABLE 14-4 I Temper designations fr aluminum alloys ‘As fabricated (hot worked, forged, cat, et.) ‘Annealed (in the softest possible condition) Cold- worked Hix—cold-worked only (refers to the amount of cold work and strengthening} Hi12—cold work that gives tensile strength midway between the O and H14 tempers. H4—cold work that gives 2 tensile strength midway between the O and H18 tempers. H16—cold work that gies a tensile strength midway between the H14 and H18 tempers, H18—cold work that gives about 75% reduction. H19—cold work that gies tensile strength greater than 2000 pst ofthat obtained by the HB temper, H2x-—cold worked and party annealed. H3scold worked and stabilized a a low temperature to prevent age hardening ofthe structure, Solution treated ‘Age hardened T1—coold from the fabrication temperature and naturally age. ‘T2—cooled from the fatrcaton temperature, cold worked, and naturally aged T3soluton teated, cold worked, and naturally aged. ‘T4soluton treated and naturally aged. ‘T5-cooled from the fabrication temperature and artficialy aged, T6—soluton veated and arifiially aged. ‘T7—soluton veated and stabilized by overaging. ‘T8—soluton veated, cold worked, and artificially aged, ‘T3—soluton treated, artifcily aged, and cold worked. "T10—coole from the fabrication temperature, cold worked, and artificially aged ® RMIT UNIVERSITYPart C Numerical problems (49 marks) Following list of formulas may be used to solve questions in part C. Stress o ="; Strain ¢ = 94 A L Rule of mixtures for density: p, = 394-0, where p, is the density of the composite, p, is the density of each constituent in the composite, f, are the volume fraction of each constituent and » is the number of constituents in the composite. Young’s modulus of Fiber Reinforced Composite in the longitudinal direction: By =f,-E;+ fy Eqs Where subscripts f stands for fiber, m stands for matrix. Young’s modulus of Fiber Reinforced Composite in the perpendicular direction: Ey Eu B-potS Ey Sut Ew Sy Density of Fiber Reinforced Composite p. = f+; + Sy-Px For fatigue testing, the maximum stress acting on the cantilever is: o = 5.09% = d where F is the load, L is the distance between the bending force and the support, d is, the diameter of the cross section of the cylindrical testing cantilever. Brinell Hardness (HB) is given by: HB= 2F nD[D — V(D? — D?)] Where: F- Applied load in Kg D - dia of the indentor in mm Di - dia. of the impression in mm. ® RMIT UNIVERSITY pg.91. A landing gear must be capable of supporting one third of an aircraft that weighs 250,000 kg. In aerospace industry, the factor of safety is taken as 2, which mean we would like the landing gear to be able to support twice its load, Determine the minimum cross-sectional area of the landing gear if it is made of heat treated steel having yield strength of 860 MPa and a tensile strength of 900 MPa. ¢=9.88%, (5 marks) total (oa of te ref = 2Yo wo X ae = 2+tso kw Lock loading) par takes = = = 3/60 with Safely foots . enh (wn, ger shold fe cble to sushi leae{: 1633,333,.3 N 5 shes 6 = £ Ae fo |, 633, 333.3. 5 abe xlo® fa [877.2 mm pg. 10 ® RMIT ‘UNIVERSITY2, The following data were collected from a test specimen of cold-rolled and annealed brass. The specimen had an initial gage length lp of 35 mm and initial cross sectional area Ag of 10.5 mm” Load (N) aL (mm) 0 0.0000 66 0.0112 177 0.0157 327 0.0199 462 0.0240 797 172 1350 5.55 1720 8.15 2220 13.07 2690 22.77 (maximum load) 2410 25.25 (fracture) (17 marks) a. Prepare a table containing the values for engineering stress and strain and true stress and strain. (5 marks) cells with correct values for engineering stress and strain respectively. State correct units used clearly vtbe ts the tutor Ssbabion. NOTE: Since the table is already prepared, you can simply fill in the blank ® RMIT ‘UNIVERSITY Load (N) aL (mm) Stress(_) | Strain( +) 0 0.0000 6 | oollas| 177 0.0157 327 0.0199 462 0.0240 797 Ln? 1350 5.55 1720 8.15 2220 13.07 2690 22.77 (maximum load) 2410 25.25 (fracture) pg. 11b. Plot the engineering stress - strain curve (use the graph paper template below) (5 marks) NOTE: 2 graph papers templates are provided. Only use the second one if you make mistake on the first one. Graph paper template 1: {tt oA | | L | ECE [ | | i t t Eo Lo 1 tT | es eet f Tt TI L * a ‘UNIVERSITYGraph paper template 2: pg. 13 ® RMIT ‘UNIVERSITY,c. The 0.2% offset yield strength (3 marks) d. The tensile strength (2 marks) e. The modulus of elasticity (2 marks) pg. 14 UNIVERSITY3. A cylindrical tool steel specit imen that is 6 inch long and 0.25 inch in diameter rotates as a cantilever beam and is to be designed so that fatigue failure never occurs. Assuming that the maximum tensile and compressive stresses are equal, determine the maximui im load that can be applied to the end of the beam. Please refer to the graph below. (5 marks) ‘Tool steel Applied stress (ksi) s T 100,000 cycle fatigue life at 90,000 psi applied stress Endurance limit = 60,000 psi ool 40 Aluminum alloy 20- gh 108 105 106 107 108 G = 5ef x 2 When He Number of cycles FL fotrpe forlure never occurs the opr shes shauldnt be move than tHe Endurance c= ® RMIT ‘UNIVERSITY Limit of this mszyecimen = bo, ave fi. es aK Sh, boxes 504x L SotX 6 - 30.7 Wb. pg. 154. A Brinell hardness measurement, using a 10mm-diameter indenter and a 500 kg load, produces an indentation of 4.5 mm on an aluminium plate. Determine the Brinell hardness number (HB) of the metal. (5 marks) 2F Ht= = —————_. no Lo-Jpr~ pr) J = 2X ko Lx bl b-~J pots = 248 ®RMIT “ UNIVERSITY5. Boron coated with SiC (Borsic) reinforced aluminium containing 40 vol % fibers is an important high-temperature, light weight composite material. Estimate the density (3 marks), modulus of elasticity (2 marks), and tensile strength parallel to the fibre axis (2 marks). Also calculate the modulus of elasticity perpendicular to the fibres (3 marks). (10 marks) Material Density Modulus of | Tensile (g/em’) Elasticity strength (GPa) (MPa) Fibers 2.36 379 2760 ‘Aluminium 2.70 69 35 | ny C= tet #8 = 4% x 2.364 bok ¥ 4) > 1.54 Hem? Medals of Elashrat Ey - helt fe En ae. 5m 4 OL HET = 13 GR u Fe, = fe be 504 Eg-tat Emel 319K 6% ¢ bax = 2. b Gry. pg.17 ® RMIT UNIVERSITY6. Glass fibers in Nylon provide reinforcement. Young’s modulus of glass fiber is 72.4GPa; Young’s modulus of Nylon is 2.8GPa. If the Nylon contains 30 % by volume glass fibers, what fraction of the force applied parallel to the fiber axis is carried by the glass fiber? (Assume the bonding between glass fiber and Nylon is strong enough to transfer the load, so «, =, =«, applies) (7 marks) yer te the romp Question tn He/ slales. pg. 18 UNIVERSITYFollowing list of formulas may be used to solve questions in part C. Percentage Reduction in Cross Sectional Are: «100 Rule of mixtures for density: p.-°/;-, where p, is the density of the composite, p, is the density of each constituent in the composite, f, are the volume fraction of each constituent and n is the number of constituents in the composite. Young’s modulus of Fiber Reinforced Composite in the longitudinal direction: E, = fy By +f+Bqs Where subscripts f stands for fiber, m stands for matrix. Young’s modulus of Fiber Reinforced Composite in the perpendicular direction: Density of Fiber Reinforced Composite p. = f, +P, + Sy*Pw For fatigue testing, the maximum stress acting on the cantilever is: « =5 09.5 where F is the load, L is the distance between the bending force and the support, d is the diameter of the cross section of the cylindrical testing cantilever. Brinell Hardness (HB) is given by: FE HB= : nD[D — V(b? - D?)) Where: F- Applied load in Kg D- dia of the indentor in mm. Di - dia. of the impression in mm. pg. 19 ® RMIT ‘UNIVERSITYEND pg. 20 RMIT UNIVERSITY