UNIVERSITEIT VAN JOHANNESBURG/

UNIVERSITY OF JOHANNESBURG

TOETS 1 / TEST 1

4 Maart 2010 / 4 March 2010

KURSUS/ : INGENIEURSWESE

COURSE : ENGINEERING TYD/TIME : 2 ure/hours

VAK/ : MATERIAALKUNDE 3A

SUBJECT : SCIENCE OF MATERIAL 3A PUNTE/MARKS: 90

Eksaminator/ : N Janse van Rensburg

Examiner

Hierdie vraestel bestaan uit 5 bladsye. / This paper consists of 5 pages.

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Benodigdhede : Sakrekenaar
Requirements : Calculator

Hierdie eksamen is toeboek.

This examination is closed book.

Beantwoord alle vrae.

Answer all questions.

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Page 1 of 5
 Section A

QUESTION 1 [17]

1.1. Schematically illustrate and explain the key production stages in an integrated
steelworks, identifying the input and output materials at each stage. (9)

1.2. Speciality steels are often subjected to special refining processes that are
intended to modify the chemical composition and/or to remove impurities.
Discuss and illustrate two (2) special refining processes, indicating the types of
alloys that it is applied to. (8)

Section B

QUESTION 2 [23]

2.1. Indicate whether the following statements are true or false. Correct the
statement if it is false: (3)

2.1.1. Chevron marks and dimples are associated with brittle fracture.
2.1.2. Cleavage crack propagation corresponds to the successive braking of
atomic bonds along specific crystallographic planes.
2.1.3. Intergranular fractures are ductile in nature, and crack propagation is
along grain boundaries.

2.2. Given the fracture surfaces in Figure 1 (a) and (b), discuss the characteristics
of the mode of fracture and comment on the type of load that is associated
with each surface. (5)

Figure 1—Fracture surfaces as a result of different types of applied loads.

Page 2 of 5
2.3. The following data were obtained from a series of Charpy impact tests
performed on three ductile cast irons, each having a different silicon content.

2.3.1. Determine the transition temperature defined by the mean of the

absorbed energies in the ductile and brittle regions. (3)
2.3.2. Plot the transition temperature versus silicon content and discuss the
effect of silicon on the toughness of cast iron (6)

Impact Energy vs. Temperature

17
16
15
14
13
12
11
Impact Energy [J]

10
9
8 2.85% Si
7 3.25% Si
6 3.63% Si
5
4
3
2
1
0
-50 -25 0 25 50 75 100 125

Temperature [°C]

Impact Energy (J)

Test Temperature 2.85% Si 3.25% Si 3.63% Si
-50 2.5 2 2
-25 2.5 2 2
0 5 3 2.5
25 10 7 4
50 14 12 8
75 16 16 13
100 16 16 16
125 16 16 16

Page 3 of 5
2.4. List the capabilities and limitations of the following non-destructive testing
techniques (6)

2.4.1. Dye penetrant

2.4.2. Eddy current
2.4.3. Magnetic particle

QUESTION 3 [16]

3.1. The fatigue behaviour for 1045 steel and 2014-T6 aluminium alloy is shown in
Figure 2.

3.1.1. Identify the curve which represents 2014-T6 aluminium alloy and
motivate your answer. (2)
3.1.2. What is the fatigue limit of 1045 steel? (1)

3.2. A cylindrical 1045 steel bar is subjected to repeated compression-tension

stress cycling along its axis. If the load amplitude is 23,000 N, calculate the
minimum allowable bar diameter (in mm) to ensure that fatigue failure will not
occur. Assume a factor of safety of 1.0. The S-versus-N fatigue behaviour for
this alloy is shown in Figure 2. (8)

A A A

A A B

Figure 2—Stress amplitude S versus the number of cycles N

3.3. List 5 measures that can be taken to extend fatigue life of a component. (5)

Page 4 of 5
QUESTION 4 [16]

4.1. Explain the difference between wear and erosion by defining the two terms.
(6)

4.2. What is cavitation and how does it form? (4)

4.3. In most designs there are a number of factors that the designer can control to
minimise wear. Discuss 3 design guidelines to minimize surface fatigue. (6)

QUESTION 5 [18]

5.1. What are the basic requirements for electrochemical corrosion of metals? (6)

5.2. Many factors can control the tendency for a material to corrode. Discuss the
effect of material properties and the environment when considering corrosion.
(12)

Formula sheet

Page 5 of 5