Second Grade Engineer's Certificate of Competency (Steam) Part B — Paper Il (June 2009) estion 1 Write an essay on the following treatment processes and their effects on the a) Annealing [$marks] b) Normalizing [3marks] c) Tempering [3 marks] Ansiwer- ‘ann 1 ‘erowitee co a5 ae Tia 1 ue Te ceva eo Handenability and Quenching Diagram a) Annealing — Is 2 hest treatment wherein a material is altered, causing changes in its ‘properties such as strength and hardness. It is a process that produces conditions by ‘heating to above the re-crystallization temperature and maintaining a suitable ‘temperature, and then cooling Annealing is used to induce ductility, soften material, relieve intemal stresses, refine the structure by making it homogeneous, and improves cold working properies and the ‘temperamre rane for process annealing ranzes from 260 °C to 760 °C. devendine on the ‘ype: of alloys. Commonly urilized during fabrication rrocedures and the annealing process comsist of ‘three srages: a. Heating to a desire temperature. ‘>. Holding or “soaking” at that temperarure. c Cooling to room temperature. ») Normalizing — 1 an annealing process in which a men is cooled in air ater heating. steel Ir involves heating the steel to just above its upper critical point. Itis soaked for a short period then allowed to cool in air. Small grains are formed which give a mmch ‘harder and tougher metal with normal tensile strength and not the maximum ductility achieved by annealing.‘The heating temperarure for the nocmalizing process is approximately 55°C to 85°C above: the upper critical temperarure. ‘Tempering — Is a process to “toughen” the metal by transferming brine martensite ina bainite or a combination of ferrite and cementite Precipitation hardenine alloys, Eke ‘many grades of aluminum and superalloys, are tempered to precipitate intermetallic particles which strenthen the metal. Tempering is accomplished by a controlled ‘ebeating of the work piece to a temperature below its lower critical temperature (150°C- 260°C and 370°C-650°C). ‘The brittle martensite becomes strong and ductile after it is tempered. Carbon atoms were ‘tapped in the mustenite when itwas rapidly cooled, typically by oil or water quenching, forming the martensite. The martensite becomes strong after being tempered because ‘when rebented, the microstructure can rearrange and the carbon atoms Can diffuse out of the distorted structure,$3 typioa tee! have yield strength’ of 250 MPa and tensile strength of 400 MPa. a) What will happen if a specimen of the material is applied a load gradually to a maximum value of 230 MPa and then the laad is released? Briefly explain the physical changes to the specimen. [2 marks] (ultimate tensile strenzth) = 400 MPa. ‘Ee he ales iad O55 NDS) oes an he pd soength (50 MP, wo thar ‘bo physical change for this material (no elangation and no deformation). it is no plastic deformation after the test oad is released. b) What will happen if a specimen of the material is applied with a load gradually to a maximum value of 300 MPa and then the load is released? Briefly explain the physical changes to the specimen. [3 marks] ‘The test load (300 MPa) is bevond the yield strength (250 MPa), therefore a permanent set or deformation occurs in the material. At this poimt. if the load is, ‘elensed, the test material is longer than the original len L - d= Onginallengh in |= Instantaneous length, in. c) What will happen if a specimen of the material is applied with a load gradually o.2 maximum value of 400 MPa? Briefly explain the physical Please sketch the stress-strain” diagr| | | “are at as tee ee stan ‘Suess-Srain Diagram ‘If the loading test is increase up to the ultimate tensile strength (400 MPa), the test matenal ‘will be broken into rwo pieces and the elongation process is illustrated in the figure below. oe ' | 1 (Stal cing) Sal iy Srmion (6) Cosme oats oma ck) ‘rack propagation (¢) Final shear fractureQuestion 3 ‘Gas Tungsten Arc Welding (GTAW) is also known as Tungsten Inert Gas (TIG) welding. Give brief explanation about GTAW with regards to:- 3) Definition [2 4 marks] b) Benefit 12 % marks] c) Hlustration 4 marks} 1) Application 24 marks] Answer a) Definition -is an arc weldinz process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmespheric contamination by a shielding gas (usually an inert gas such as argon), anda filler metal is normally used, though some welds, known as mumagenous welds, do not require i b) Benefits - = Most commonly used to weld thin sections of sminless steel and light metals suchas alumimm, magesum, and copper alloys. = Make high quality welds in almost all metals and alloys. = No slag. smoke and suitable for all positions. c) Linstration- @) Application (Gas tumgsten arc welding is most commonly used to weld stainless steel and nonferrous materials, such as alumizum and magnesium. bur it can be applied to pearly all menls, with notable exceptions being lead and zinc. Is applications involving carbon steels are limited not because of process restrictions, but because of the euistence ef more economical steel welding techmiques, such as gas metal arc ‘welding and shielded metal arc welding. Furthermore, GTAW can be periormed ina ‘variery of other-than-flat positions, depending on the skill of the welder and the materials being welded. ‘Question 4 a) Explain steps used in Dye Penetrant Testing (DPI, [5 marks] ‘Main steps of Liquid Penetrant Inspection1) Pre-cleaning - The test surface is claned to remove any dit, paint, oil, erease ar amy loose scale that could either keep penetrant out of a defect, or cause imelevant or false indications. 2) Application of Penetrant - The penetrant is then applied to the surface of the item. being tested. The penetrant is allowed time to soak into any flaws (generally 5 to ‘30 minutes). The dwell time mainly depends upon the penetrant being ured, material being testing and the size of flaws sought. As expected, smaller flaws require a longer penetration time. Due to their incompatible nature one must be ‘careful not to apply solvent-based penetrant to a surface which is to be inspected with a water-washable penetrant. 3) Excess Penetrant Removal - The excess penetrant is then removed from the surface Removal method is comolled by the rype of penetrant used. This process ust be perfommed under controlled conditions so that all penetant on the surface is removed (background noise), but penetrant trapped in real defects remains in 4) Application: — After excess penetant has been removed a white developer is applied to the sample, Several developer types are available, ‘DOD-agueOUs Wet ‘dry powder. water suspendible and water water-soluble or suspendable developer with water-washable penetrant), and by inspection conditions. ‘The developer draws penetrant from defects out onto the suréace to form a visible indication, a process similar to the action of bloning paper. Any colored stains indicate the positions and types of defects on the surface under inspection. 3) Inspection - The inspector will use visible light with adequate for visible dye penetrant, Inspection of the test surface should mke place after a 10 minute Sovlopmen: ts. Ths tne deny allows tha Vonag sedan te occur The inspector may observe the sample for indication formation when using viable dye. ‘Also of concer. if one waits too long after development the indications may *pleed out” such that interpretation is hindeved. 6) Post Cleaning — The test surface is often cleaned afer inspection and recording of defects, especially if post-inspection coating processes are scheduled. Name five characteristics ideal for dye penetrant used in Dye Penetrant Testing. [5 marks] 1) Fluid dye penetrant can penetrates into clean and dry surface-breaking discontimaities. 2) Ths developer wo dow penevant ou of he aw where a isl incon 3 Dye penatant fuid is solvent-removal. 3) Only can be used for nonporous materialsQuestion 5 a} What are the four (4) factors that initiate corrosion? marks] ‘The relative acidity of the water (boiler water). ‘The presence of dissolved oxygen in water (boiler water). Elecrolytic’ action. ‘Damage the passivation layer (magnetite) ar coating. b) Briefly explain about corrosion inhibitors. [6 marks] (Corresion Inhibitor isa chemical compound that, when added its will decreases the corrosion rate of a metal or an alloy. The effectiveness of a corrosion inhibitor is a fiction of mary factrs lke: Suid composition, quantity af water, dow rezinie and tc. Ifthe correct inhibitor and quantity is selected than is possible tw achieve 90-90%, efficiency. Some of the mechanisms of its effect are formation of a passivation layer, it isa thin film on the surface of the material that stops access of the corrosive substance to the metal. PE ee Question 6 a) What does it mean by fatigue of metals and list the three stages of metal fatigue process? marks] ‘Fatigue is the phenomenon of a metal experiencing fracture under repeated or ‘actuating stresses having a maximum value less than the ultimate strength of oaterial leading, one oz more properties of the stress state need to be considered, such as sess amplitude, mean stess, bi-rsiality. in-phase or out-of-phase shear svess, and load sequence i. Geometry —Notches and variation in cross section throucheut a part lead to stress concentrations where fatigue cracks initite. iii, Surface qualiny - Surface roushness cause microscopic stress concentrations dato a Sig ma iv, ‘Maer ype Fatigue ifs wll she behavior ding cyclic loading ‘aries widely for diferent materials. v. Residual stresses - Welding. curing. casting. and other manufacturing processes involving heat of deformation can pradace hizh levels ef tensile residual stress, which decreases the fatigue strength, vi Size-and distrbation of intemal defects — Casting defects such as gas porosity, non-metallic inclusions and shrinkage voids can significantly reduce fatigue amength