1 Chapter Engg Matls

Chapter 1
Engineering Materials
Objectives: At the end of this chapter, the students/ readers should be able to:
1. Define engineering materials;

2. Classify different types of engineering materials; and
3. Practice exam in the multiple choice test to master the usual questions and problems in the licensure examination.
Metallic Non-Metallic
Ferrous Non-Ferrous
Thermosetting Thermoplastic
Plastic
tT
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Metallic Materials are classified as ferrous and nonferrous. It plays the most significant role in the in industrial operations with which the engineer is
concerned.
Ferrous Materials are those materials containing iron as principal constituent.
Example of Ferrous Materials:

1. Steel 4. Wrought iron
2. Cast iron 5. Malleable cast iron
3. Stainless steel 6. Tool and die steels
Nonferrous Materials are those materials, which do not contain iron as principal constituent.
Example of Nonferrous Materials

1. Copper 5. Aluminum
2. Tin 6. Magnesium
3. Zinc 7. Titanium
4. Tungsten 8. Others
Nonmetallic Materials are of great importance in engineering applications.
Examples of Nonmetals
1. Wood 5. Stone
2. Brick 6. Cement
3. Concrete 7. Resins and
4. Rubber
Thermosetting plastics are soft and pliable during one stage of chemical transition only.
Examples of Thermosetting Plastics

1. Phenol formaldehyde 5. Alkyds
2. Urea aldehyde 6. Polyamides
3. Melamine 7. Allyls
4. Aldehyde 8. Etc.
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Thermoplastics include those materials that become soft and pliable when heated to moderate temperature.
Examples of Thermoplastics
1. Casein 4. Vinyl plastic
2. Cellulose nitrate 5. Acrylic plastic
3. Cellulose acetate 6. Polystyrene
The Scope of Engineering Materials
Properties of
Mechanical Physical
Properties Properties
Chemical Dimensional
Properties Properties
Mechanical Properties
Strength Formability
Rigidity Durability Toughness
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A. Mechanical Properties
The properties of materials which describe the behavior under the application of force.
Strength is the stress at which material rupture or fails. It is measured by the tensile sensible strength.
Formability is usually used for sheet forming in which the forces applied are primarily tensile stresses.
Rigidity is important where deflections are limited by service requirements.
Durability refers to the quality of the components, materials strength, consistency and resistance to stress.
Toughness is the ability to withstand high unit stress along with great unit deformation without complete fracture.
Example of Mechanical Properties of Metals

1. Tensile properties 4. Fatigue
2. Toughness 5. Hardness
3. Ductility 6. Creep
Tensile Properties is the peak stress-strain curve is considered the ultimate tensile strength.
Toughness is the capacity of material to withstand a shock load without breaking.
Ductility is the property that permits permanent deformation before fracture in tension.
Fatigue is the failure of material by cracking resulting from repeated or cyclic stress.
Hardness is the property of metal, which makes a metal capable of resisting surface penetration by other metals.
Creep is the term used in referring to the continuous increase in the strain, or deformation of any material subjected to stress.
Example of mechanical Properties of plastics

1. Tensile 4. PV limit
2. Heat distortion 5. Toughness
3. Compression strength 6. Etc.
Example of Mechanical Properties of Ceramics

1. Tensile properties 3. Fracture toughness
2. Compression strength 4. Hardness
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Example of Mechanical Properties of Composites
1. Tensile properties 3. Fracture toughness
2. Compression strength 4. Creep resistance
Example of Strength
1. Tensile 5. Shear
2. Yield 6. Creep
3. Compression 7. Stress rupture
4. Flexural 8. Etc.
Example of Formability
1. % elongation 3. Bend radius
2. % reduction in area 4. Etc.
Example of Rigidity
1. Modulus of elasticity
2. Flexural modulus
Example of Toughness
1. Impact strength 3. Critical stress
2. Notch sensitivity 4. Intensity
Example of Durability
1. Hardness
2. Wear resistance
3. Fatigue
B. Physical Properties
The characteristics which are used to describe a substance in the absence of external forces.
Example of Physical Properties

1. Specific heat 7. Electrical resistivity
2. Thermal conductivity 8. Melting point
3. Coefficient 9. Magnetic
4. Color 10. Optical
5. Reflective index 11. Acoustic
6. Density and 12. Gravimetric
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C. Chemical Properties
The characteristics of a material that relate to its behavior in chemical reactions.
1. Composition is the elemental or chemical components that make up a material and their relative proportions.
2. Microstructure is the structure of polished and etched materials as revealed by microscope magnifications greater than ten diameters;
structure includes the phases present, the morphology of the phases, and their volume fractions.
3. Crystal structure is the ordered, repeating arrangement of atoms or molecules in a material.
4. Stereospecificity is a tendency for polymers amd molecular materials to form with a n ordered spatial three-dimensional arrangement of
monomer molecules.
5. Corrosion resistance is the ability of a material to resist deterioration by chemical or electrochemical reaction with its environment.
Example of Chemical Properties of Metals
1. Alloying 5. Phases
2. Compound formation 6. Grain size
3. Composition 7. Corrosion resistance
4. Microstructure 8. Inclusions
Example of Chemical Properties of Plastics
1. Composition 5. Flammability
2. Fillers 6. Spatial configuration
3. Crystallinity 7. Chemical resistance
4. Molecular weight
Example of chemical properties of Ceramics

1. Composition 4. Binder
2. Porosity 5. Corrosion resistance
3. Grain size
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Example of Chemical Properties of Composites
1. Composition
2. Matrix/reinforcement bond
3. Volume fraction reinforcement
4. Reinforcement nature
5. Corrosion resistance
D. Dimensional Properties
The properties of materials which considers the most important factors in designing such as sizes, shape, finish and tolerances.
1. Roughness is the surface irregularities, the height, width, and direction of which establish a definite surface pattern.
2. Waiveness is a waivelike variation from a perfect surface; generally much wider in spacing and higher in amplitude than surface roughness.
3. Lay is the direction of a predominating surface pattern, usually after a machine operation.
4. Camber is the deviation from edge straighten; usually the maximum deviation of an edge from a straight line of given length.
5. Surface finish is the microscopic and macroscopic characteristics that describe a surface.
Properties of Metals
1. Malleability is the property of metal on account of which it can be extended in all directions by hammering or rolling,
Example: Lead, Tin
Order of Malleability
1. Copper 4. Lead
2. Aluminum 5. Iron
3. Tin 6. Zinc
2. Machinabiltity is the property of metal due to which a metal can

easy be cut by cutting tools to obtain a desired finished on its surface. Example: Mild Steel, Brass
3. Hardness is the property of metal which makes a metal capable of resisting surface penetration by other metals. Example: High Carbon Steel,
High Speed Steel.
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Moh’s Scale of Hardness
1. Talc 6. Feldspar
2. Gypsum 7. Quartz
3. Calcite 8. Topaz
4. Fluorite 9. Ruby
5. Apatite 10. Diamond
4. Toughness is the property of metal due to which a metal is able to withstand bending or torsion without fracture. Example: Wrought Iron, Mild
Steel
5. Ductility is the property of metal to which a metal can be drawn into the form of wires without rupture at the same time retaining enough
strength.
Order of Ductility
1. Copper 4. Zinc
2. Iron 5. Tin
3. Aluminum 6. Lead
6. Fusibility is the property of metal due to which a metal becomes

fluid when it is heated.
7. Stiffness is the property of metal due to which a metal is capable of resisting deflection due to an externally applied load.
Steel is the most extensively used material for machine components. It contains Carbon up to 1.5%. It is generally produced open heart, Bessemer
converter, crucible furnace or electric furnace. It is tough and malleable. It can be forged. It is more tensile strength.
Classification of Steels
1. Plain carbon steels
2. Alloy steels
3. Special-Purpose Steel
Plain Carbon Steels

It is the amount of impurities present generally falls within the following range.
Sulfur..................................0.02 to 0.05%
Phosphorous......................0.02 to 0.05%
Silicon.................................0.05 to 0.20%
Manganese.........................0.30 to 1.50%
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Carbon Steel is the combination of iron and carbon. It is easily rusted.
It is malleable. It can not be hardened uniformly. It can easily be machined. It is magnetic.
Classification of Plain Carbon Steels

1. Low Carbon Steels.............less than 0.30%
2. Medium Carbon Steels......0.3% to 0.5%
3. High Carbon Steels............above 0.05%
Carbon effect on the Properties of Steel

1. When carbon content is higher, melting point is lower.
2. When carbon percentage is lower, it is easy for forging.
3. When carbon percentage is higher, the degree of hardness is more
4. When carbon percentage is lower, it is easy for forge welding.
Alloy Steels are steels added by some alloying elements to increase its hardenability. It is the combination of iron and carbon and other alloying
elements. It is rust proof. It is harder and tougher. It can be hardened uniformly. It is hard for machining. It is nonmagnetic.
Alloying Elements & Their Effects On The Properties of Steel

1. Chromium gives greater hardness, resistance to forging, drawing and corrosion.
2. Cobalt improves the cutting quality and gives excellent magnetic property in the steel.
3. Manganese is an active deoxidizer and has fewer tendency to segregate within the ingot than most common elements.
4. Molybdenum gives greater hardness and resistance to forging and drawing.
5. Nickel raises the tensile strength, protects from corrosion and improves wearing property.
6. Phosphorus is considered undesirable because of its embrittling effect. It increases yield strength and reduces ductility.
7. Sulphur an element is considered to be an undesirable impurity in steel
8. Tellurium is the addition of about 0.05% tellurium to leaded steel improves machinability over the leaded-only steels.
9. Titanium an alloy is added to 18-8 stainless steels to make them immune to harmful carbide precipitation.
10. Tungsten gives greater hardness cutting toughness and fine grain structure.
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11. Vanadium gives greater hardness, cutting toughness and resistance to wear and tear.
Effects of Various Elements in Steels
1. Boron improves hardenability, without the loss of machinability and formability.
2. Calcium deoxidizes steels, improves toughness, and may improve formability anfd machinability.
3. Carbon improves the hardenability, strength, hardness and wears resistance; it reduces ductility, weldability and toughness.
4. Cerium controls the shape of inclusions and improve toughness in high-strength, low-alloy steels; it deoxidizes steels.
5. Chromium improves toughness, hardenability, wear and corrosion resistance, high-temperature strength; it increases the depth of hardness
penetration resulting from heat treatment, by promoting carburization.
6. Cobalt improves strength and hardness at elevated temperatures.
7. Copper improves resistance to atmospheric corrosion and, to a lesser extent, increases strength, with little loss in ductility; it adversely affects
hot working characteristics and surface quality.
8. Lead improves machinability; it causes liquid-metal embrittlement.
9. Magnesium has the same effect as cerium.
10. Manganese improves hardenability, strength, abrasion resistance, and mahinability; it deoxidizes the molten steel and reduces hot shortness;
and it decreases weldability.
11. Molybdenum improves hardenability, wear resistance, toughness, elevated-temperature strength, creep resistance, and hardness; it minimizes
temper embrittlement.
12. Nickel improves strength, toughness and corrosion resistance; it improves hardenability.
13. Niobium imparts fitness of grain size and improves strength and impact toughness; it lower transition temperature; and it may decrease
hardenability.
14. Phosphorous improves strength, harenability, corrosion resistance and machinability; it severely reduces ductility and toughness.
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15. Selenium improves machinability.
16. Silicon improves strength, hardness, corrosion resistance and electrical conductivity; it decreases magnetic hysteresis loss, machinability and cold
formability.
17. Sulfur improves machinability when combined with manganese; it lowers impact strength and ductility; it impairs surface quality and weldability.
18. Tantalum effects similar to those of niobium.
19. Tellurium improves machinability, formability and toughness.
20. Titanium improves hardenability; it deoxidizes steels.
21. Tungsten has the same effect of cobalt.
22. Vanadium improves strength, toughness, abrasion resistance, and hardness at elevated temperatures; it inhibits grain growth during heat
treatment.
23. Zirconium has the same effects as cerium.
Nickel Alloys
These are alloys used in variety of structural applications that usually require specific corrosion resistance and strength and toughness at temperature
extremes as great as 2000°F and as low as -400°F.
Residual Elements in Steels

1. Antimony 4.Oxygen
2. Arsenic 5. Tin
3. Nitrogen 6. etc.
Titanium Alloys
These are non magnetic and extremely corrosion resistance alloys. These have low thermal conductivity and outstanding strength in to weight ratios.
Zinc Alloys
These are alloys whose melting temperatures are low. Its abundance made it more economical.
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Uses of Alloy Steels
AISI 2330.................bolts, studs, tubing subjected to torsional stresses.
AISI 2340.................quenched and tempered shafting connecting rods, very highly stresses bolts, forgings.
AISI 2350.................high capacity gears, shafts, heavy ductile machine parts.
AISI 3130.................shafts, bolts, steering knuckles.
AISI 3140.................air craft and truck-engine crank-shafts, axles, earth moving equipment.
AISI 3150.................wear-resisting parts in excavating and farm machinery, gears and forgings.
AISI 3240.................shafts, highly stressed pins and keys, gears.
AISI 3300 series.......for heavy parts requiring deep penetrating of the heat treatment and high fatigue strength per unit weight.
AISI 4063.................leaf and coil springs.
AISI 4130, 4140.......automobile connecting rods and axles, air craft parts and tubing.
AISI 4340.................cranks shafts, axles, gears, landing gear parts.
AISI 4640.................gears, splined shafts, hand tools miscellaneous heavy duty machine parts.
AISI 8630.................connecting rods, bolts shapes, air hardens after welding.
AISI 8640,8740...,,,..gears, propeller-shafts, knuckles shapes.
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Copper Alloy
Brasses Bronzes
Copper-Zinc Copper-Tin
Phosphor
Bronze
Leaded Brass
Leaded
Phosphor
Tin Brass
Aluminum
Bronze
Red Brass
Silicon Bronze
Copper Nickels Copper, Nickel,

Zinc Alloys
Cupro nickel
Nickel Silver
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Low Melting Alloy
1. Lead has properties of high density, resistance to corrosion, softness, low strength, ductility and good workability. Lead is used for damping
sound and vibrations, in radiation shielding against X-rays, in ammunition, as weights and in the chemical industry.
2. Zinc is the metal fourth most utilized industrially, coming after iron, aluminium and copper. It has two major uses: for galvanizing iron, steel sheet,
and wire; and as an alloy base for casting.
3. Tin is an alloying element for dental alloys and for bronze, titanium and zirconium alloy. An ancient metal used in canning due to its resistance to
rust and other corrosion.
Refractory Metals and Alloy

1. Molybdenum is a silver-white metal, was discovered in the 18th centuries. It has high melting point, a high modulus of elasticity, good resistance
to thermal shock, and good electrical and thermal conductivity. The typical applications of molybdenum are in solid propellant rockets, jet
engines, honeycomb structures, electronic components, heating elements and dies for casting.
2. Niobium (Columbium) possesses good ductility and formability, and it has greater oxidation resistance than other refractory metals. They are
used in rockets and missiles and in nuclear, chemical and superconductor applications.
3. Tungsten is the most plentiful of all the refractory metals. It ha the highest melting point of any metal and characterized by high strength at
elevated temperatures. It has high density, it is brittle at low temperatures and offers poor resistance to oxidation. The typical applications are
for nozzle throat liners in missiles and in the hottest parts of jet and rocket engines, circuit breakers, welding electrode and spark-plug
electrodes.
4. Tantalum is characterized by high melting point, good ductility, and resistance to corrosion. It is used as an alloying element, electrolytic
capacitors and various components in the electrical, electronic and chemical industries; for thermal applications such as in furnaces and in acid-
resistant heat exchangers.
Special-Purpose of Steels
The material produced to meet certain special conditions in fabrication or in use such as free machining,, heat resistance, corrosion resistance, impact
resistance and too steel.
HSLA Steels (High Strength Low Alloy)

A class of relatively low cost steels providing much of the advantage or more costly regular alloy steels.
Case Hardening Steels

A steel hardening which is usually done in the material surface. It s accomplished by carburizing, cyaniding, nitriding, induction hardening or flame
hardening.
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High Speed Steel
It is an alloy of tungsten, chromium, vanadium and carbon. Most common composition is 18% tungsten, 4% chromium, 1% vanadium and 0.70%
carbon. Sometimes cobalt up to 4% is added to improve its high speed quality. It is generally used for lathe, shaper, planer tools, drills and milling
cutters.
Bright Steel
The main constituents of bright steel are 0.05 to 0.45% carbons and up to 0.20% lead. It is generally used for making bolts, set screws, pin etc.
which are to be used for a long time for highly loaded parts.
Mild Steel
It contains 0.05% to 0.25% carbon. It is ductile, malleable, and easy for forging and welding and can be case hardened. It is used for general purposes
to make wires, rods, sheets, flats, round angles, channels and other structural works.
High Carbon Steels

It contains 0.70 to 1.5% carbon. It is harder, stronger and less ductile and can be hardened and tempered. It is used for making tools such as chisels,
taps, dies, files drills, blades and hammers.
Stainless Steels
A kind of steel that contains a minimum of 10.5% chromium. Alloy steel which contains mainly chromium and nickel. A stainless steel contains 18%
chromium, 8% nickel is mostly used. Another type of stainless steel containing 12 to 20% chromium, 8 to 12% nickel 1% manganese added with 1% of
carbon steel. It is used for measuring and surgical instruments.
The Stainless Steel Family
Stainless Steel
Ferritic Martensic
Austenitic PH
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Ferritic Applications
1. Atmospheric Corrosion 3.Decorative
2. Elevated temperatures
Martensic Applications
1. Structural components 3. Tools
2. Cutting devices
Austenitc applications
1. Chemical resistance 3. Piping
2. Tanks
PH Applications
1. Structural members 2. Springs
Cast Iron
The most abundant and cheapest material. It has four element alloys containing iron, carbon, silicon and manganese. A type of iron in which contains
3 to 3.5% carbon either in combined form or in free state. Generally cupola furnace is used for the manufacturing of cast iron.
Properties of Cast Iron

1. Gray cast iron has gray structure
2. White cast iron has silver white structure
3. It cannot be forged, bent or twisted
4. It can be easily cast into different shapes
5. Gray cast iron can easily be machined
6. It is heat resisting and sensitive to shock
7. It has high compressive strength
Gray Iron
A kind of iron primed from carbon that is precipitated in the form of graphite flakes. It contains 2.5 to 3% carbon in combined form. It is very hard and
brittle and difficult to be machined.
Ductile Iron (Nodular Iron)

It is an iron alloyed with magnesium which causes the excess carbon to precipitate in the form of small spheres or nodules.
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White Iron
An iron produced in outer portion of gray and ductile iron casting by chilling selected surfaces of the mold, thereby denying time for carbon
precipitation. It contains 2.5 to 3% carbon in combined form. It is very hard and brittle and difficult to be machined.
Malleable Iron
An iron made from iron by a two-stage heat treating process. The structure promotes ductility, strength and shock resistance.
Compacted-Graphite Iron
The graphite in this structure is in the form of short, thick and interconnected flakes having undulating surfaces and rounded extremities.
Polymeric Materials
Plastics Elastomers
Vulcanized Thermoplastic Thermoplastic Thermosetting

s
Plastics are one of numerous polymeric materials and have extremely large molecules.
Elastomer is capable of covering substantially in shape and size after the load has been removed.
Thermosetting Plastics are soft and pliable during one stage of chemical transition only. They can be molded by a variety of method but they
undergo a setting process at this temperature and once they set they cannot again be softened by reheating.
Examples of Thermosetting Plastics

1. Phenol formaldehyde 7. Unsaturated polyesters
2. Urea aldehyde 8. Polyurethane’s
3. Alkydes 9. Melamines
4. Polyamides 10. Silicones
5. Alloys 11. Exposides
6. Phenolics 12. Others
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Thermoplastics include those materials that become soft and pliable when heated to moderate temperature. These plastics can be molded or
extruded or rolled into sheets and retain their shapes when cooled. If again heated they soften as before, and they can be heated and reworked over
and over again.
Examples of Thermoplastics
1. Casein 8. Nylons
2. Cellulose Plastic 9. Acetals
3. Polysterene 10. Polycarbonates
4. Polyethylene 11. Fluorocarbons
5. Polyvinyl chloride 12. Polyamides
6. Polystyrene 13. Polysulfones
7. Polypropylene 14. Others
Table1. Density for Various Metals, Polymers and Ceramics
Materials Density
Metals Kg/m3
Aluminium and its Alloys 2.7x103
Aluminum tin 3.1x103
Babbitt lead-based white metal 10.1x103
Babbitt, tin-based white metal 7.4x103
Brasses 8.6x103
Bronze, aluminium 7.5x103
Bronze, leaded 8.9x103
Bronze, phosphor 8.7x103
Bronze porous 6.4x103
Copper 8.9x103
Copper lead 9.5x103
Iron, cast 7.4x103
Iron porous 6.1x103
Iron, wrought 7.8x103
Magnesium alloys 1.8x103
Steels 7.8x103
Zinc alloys 6.7x103
Polymers Kg/m3
Acetal (polyformaldehyde) 1.4x103
Nylons (polyamides) 1.14x103
Polyethylene, high density 0.95x103
Phenol formaldehyde 1.3x103
Rubber, natural 1.0x103
Rubber, silicone 1.8x103
Ceramics Kg/m3
Alumina 3.9x103
Graphite, high strength 1.7x103
Silicon, carbide 2.9x103
Silicon Nitride 3.2x103
Table2. Modulus of Elasticity for Various Metals, Polymers & Ceramics
Materials Modulus of Elasticity

Metals
Aluminum 62 GPa
Aluminum and its alloys 70 GPa
Aluminum tin 63 GPa
Babbitt lead-based white metal 29 GPa
Babbitt, tin-based white metal 52 GPa
Brasses 100 GPa
Bronze, aluminium 117 GPa
Bronze, leaded 97 GPa
Bronze, phosphor 110 GPa
Bronze porous 60 GPa
Copper 124 GPa
Iron, gray cast 109 GPa
Iron, malleable cast 170 GPa
Iron porous 80 GPa
Iron, spheroidal graphite 159 GPa
Iron, wrought 170 GPa
Magnesium alloys 41 GPa
Steels, low alloys 196 GPa
Steel, medium and high alloys 200 GPa
Steel, stainless 193 GPa
Steel, high speed 212 GPa
Zinc alloys 50 GPa
Polymers Modulus of Elasticity
Acetal (polyformaldehyde) 2.7 GPa
Nylons (polyamides) 1.9 GPa
Polyethylene, high density 0.9 GPa
Phenol formaldehyde 7 GPa
Rubber, natural 0.004 GPa
Ceramics Modulus of Elasticity
Alumina 390 GPa
Graphite 27 GPa
Cemented carbide 450 GPa
Silicon, carbide 450 GPa
Silicon Nitride 314 GPa
Table3. Linear Thermal Expansion Coefficient for Various Metals, Polymers and Ceramics
Materials
Metals Linear Thermal Expansion
Aluminum 23x10−6
Aluminum and its alloys 24x10−6
Aluminum tin 24x10−6
Babbitt lead-based white metal 20x10−6
Babbitt, tin-based white metal 23x10−6
Brasses 19x10−6
Bronzes 18x10−6
Copper 18x10−6
Copper lead 18x10−6
Iron, cast 11x10−6
Iron, wrought 12x10−6
Iron porous 12x10−6
Magnesium alloys 27x10−6
Steels, alloys 11x10−6
𝟏𝟎−𝟔 Steel, stainless 17x10−6
Steel, high speed 11x10−6
Zinc alloys 27x10−6
Polymers Linear Thermal Expansion
Acetal (polyformaldehyde) 90x10−6
Nylons (polyamides) 100x10−6
Polyethylene, high density 126x10−6
Phenol formaldehyde 25 − 40x10 −6
Rubber, natural 80 − 120x10 −6
Rubber, nitrile 34x10−6
Rubber silicone 57x10−6
Thermoplastics 60 − 100x10 −6
Thermosets 10 − 80x10 −6
Ceramics Linear Thermal Expansion
Alumina 5x10−6
Graphite 1.4 − 4x10−6
Silicon, carbide 4.3x10−6
Silicon Nitride 3.2x10−6
Table4. Alloy Groups

Alloy Groups AISI Numbering System
AISI 10XX Plain Carbon Steel
AISI 11XX Free-Cutting Steel (0.10% Sulfur Content)
AISI 12XX Free-Cutting Steel
AISI 13XX Manganese Cutting Steel
AISI 15XX Carbon Steel
AISI 23XX Nickel Steel (3.5% Nickel)
AISI 25XX Nickel Steel (5% Nickel)
AISI 31XX Nickel-chromium-steel (1.25%Ni;0.65% Cr)
AISI 33XX Nickel-chromium-steel (3.5%Ni;1.5% Cr)
AISI 40XX Molybdenum Steel (0.25%Mo)
AISI 41XX Chromium-Molybdenum Steel
AISI 43XX Nickel-Chromium-Molybdenum Steel
AISI 44XX Molybdenum Steel (0.50%Mo)
AISI 46XX Nickel-Molybdenum Steel (1.8% Ni; 0.25% Mo)
AISI 48XX Nickel-Molybdenum Steel (3.5% Ni; 0.25% Mo)
AISI 5XXX Chromium Steel (0.8%Cr)
AISI 51XX Chromium Steel (0.8%Cr)
AISI 51100 Chromium Steel (91% Cr; 1%C)
AISI 52100 Chromium Steel (1.45%; 1%C)
AISI 61XX Chromium-Vanadium Steel
AISI 86XX Nickel Chromium-Molybdenum Steel
AISI 92XX Silicon Steel
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AISI and SAE Designation of Steels
The first digit indicates the Class of Steel

1: used to indicate carbon steels
2: for Nickel Steels
3: for Chrome-Nickel Steels
4: for Molybdenum Steels
5: for Chromium Steels
6: for Chrome-Vanadium Steels
7: for Tungsten Steels
8: for the National emergency Steels
9: for Silicon-Manganese Steels
The second digit indicates the approximate percentage of the principal alloying element present in the steel.
The remaining two (sometimes three) digits represent a number 100 times the approximate percentage of carbon present in the steel.
In the AISI system, a one or two-letter prefix (usually one letter) is added to the above four or five digits to indicate the method of producing the steel.
A: for basic open hearth alloy steels

B: for acid Bessemer carbon steels
C: for basic open hearth carbon steels
D: for acid open hearth carbon steels
E: for electric furnace steels
NE: for the national emergency steels
The AISI DESIGNATION SYSTEM
The AISI uses a four-digit designation system for carbon and alloy steel as shown in the illustration below. The first two digits indicate the specific alloy
group that identifies the primary alloying elements other than carbon in the steel. The last two digits indicate the amount of carbon in the steel.
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General Form of Designation
AISI X X XX
Carbon content
Specific alloy in the group
Alloy group: indicate major alloying elements
Alloy Groups in the SAE Numbering System
10XX Plain carbon steel

11XX Free-cutting steel
12XX Free-cutting steel
13XX Manganese
14XX Boron
2XXX Nickel
3XXX Nickel-chromium
303XX Nickel-chromium
4XXX Molybdenum
41XX Molybdenum chromium
43XX Molybdenum
46XX Molybdenum-nickel
47XX Molybdenum-chromium-nickel steel
48XX Molybdenum Nickel
5XXX Chromium
514XX Heat and corrosion resistant
515XX Heat and corrosion resistant
6XXX Chromium- vanadium
8XXX Nickel-chromium-molybdenum
92XX Silicon-manganese
9XXX Nickel-Chromium-molybdenum
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Precious Metals
1. Gold is soft and ductile, and it has good corrosion resistance at any temperature. It is the most malleable metal with enormous commercial value.
used in trade jewelry, reflectors, coinage, good leaf for decorative purposes, dental work, electroplating and electrical contacts and terminals.
2. Silver is a ductile metal and it has the highest electrical and thermal conductivity of any metal. The typical applications for silver include tableware,
jewelry, coinage, electroplating, photographic film, electrical contacts, solders, bearing linings and food and chemical equipment.
3. Platinum is a soft, ductile, grayish-white metal that has good corrosion resistance even at elevated temperature. Platinum alloys are used as
electrical contacts, for spark-plug electrodes, as catalyst for automobile pollution-control devices, in filaments, in nozzles in dies for extruding glass
fibers, thermocouples, in the electrochemical industry, as jewelry and inn dental work.
Heat Treatment of Ferrous Alloys

1. Pearlite 4. Retained Ausenite
2. Spherodite 5. Tempered Martensite
3. Bainite 6. Martensite
Heat Treatment of Metals

1. Annealing consists of heating the metal to a temperature slightly above the critical temperature and then cooing slowly, usually in the furnace,
to produce an even grain structure, reduce the hardness and increase the ductility usually at a reduction of strength.
2. Normalizing is a form of annealing (cooling in air) used to remove the effects of any previous heat treatment and to produce a uniform grain
structure before other heat treatments are applied to develop particular properties of metal.
3. Quenching is a rapid cooling from above the critical temperature by immersion in cold water or other cooling medium.
4. Tempering or drawing consists of reheating the quenched metal below critical temperature to restore some of the ductility and reduce the
brittleness.
5. Casehardening or carburizing is a process of hardening the outer portion of the metal by prolonged heating free from contact with air while
the metal is packed in carbon in the form of bone char, leather or charcoal.
6. Cyaniding is casehardening with powdered potassium cyanide or potassium ferrocyanide mixed with potassium bichromate substituted for the
carbon.
7. Nitriding is a surface hardening accomplished by heating certain steel alloys immersed in ammonia fumes
25
Test 1
Instruction: Choose the correct answer in the questions below and check your answers whether you PASS the TEST or NOT and then answer it
again until you master it.
1. Which of the following materials that improves red hardness?

A. Boron
B. Chromium
C. Cobalt
D. Columbium
2. What SAE number of Manganese Steel?

A. 11XX
B. 12XX
C. 13XX
D. 14XX
3. What is the major component of stainless steel?

A. Chromium
B. Copper
C. Nickel
D. Vanadium
4. What is the major components of bronze?

A. Antimony
B. Babbitt
C. Copper
D. Tin
5. What is the major component of steel?

A. Chromium
B. Copper
C. Iron
D. Lead
26
6. What is the composition of brass?
A. Copper and chromium
B. Copper and nickel
C. Copper and tin
D. Copper and zinc
7. What is the composition of a muntz metal?

A. Copper and chromium
B. Copper and nickel
C. Copper and tin
D. Copper and zinc
8. What is the function of alloying elements in steel?

A. To increase hardenability
B. To increase resistance to softening on tempering
C. To increase resistance to corrosion
D. All of the above
9. What type of bond which consists of a sharing of electrons between the atoms to make a molecule?
A. Atomic bond
B. Covalent bond
C. Ionic bond
D. Metallic bond
10. The ability of a substance to exist in more than one lattice form.
A. Allotropy
B. Amorphology
C. Crystallization
D. Isotropy
11. A combination of elements which possesses metallic properties is referred to as

A. Alloy
B. Compound
C. Mixture
D. Heterogenous
26
12. Nodular cast iron is also called
A. Ductile cast iron
B. Gray iron
C. Malleable cast iron
D. White cast iron
13. The permanent elongation of a component under a static load maintained for a period of time.
A. Creep
B. Elasticity
C. Fatigue
D. Plasticity
14. Which of the following is not an example of hexagonal closed-packed?

A. Alpha titanium
B. Nickel
C. Zinc
D. Zirconium
15. The effect of an increase in shear stress that causes an increase in the overall strength of the metal is known as
A. Case hardening
B. Strain hardening
C. Work hardening
D. A and C
16. The process in which, at a certain temperature range, new equiaxed and strain-free grains are formed replacing the older grains, is called
A. Recrystallization
B. Recovery
C. Polyrization
D. None of the above
17. The ratio of stress to strain in the elastic region is known as

A. Modulus of elasticity
B. Modulus of rigidity
C. Young modulus
D. A and B
27
18. Which of the following materials that causes to improve strength?
A. Carbon
B. Cobalt
C. Vanadium
D. All of the above
19. Which of the following materials that causes to improve machinability?

A. Lead
B. Sulfur
C. Tellurium
D. All of the above
20. What materials that improves hardenabiltiy, without the loss of machinability and formability?
A. Boron
B. Cerium
C. Cobalt
D. Copper
21. What material that improve hardenabilty?

A. Titanium
B. Phosphorous
C. Manganese
D. All of the above
22. Which of the following is the lightest engineering metal?

A. Magnesium
B. Lead
C. Copper
D. Brass
23. What is the purpose of surface treatment?

A. Control friction
B. Improve resistance to wear
C. Reduce adhesion
D. All of the above
28
24. The minimum chromium content in a stainless steel should be
A. 6 to 8%
B. 8 to 10%
C. 10 to 12%
D. 12 to 16%
25. It is known as commercially pure alumminum.

A. 1XXX
B. 2XXX
C. 3XXX
D. 4XXX
29
Answer to Test 1 Performance Performance Status Remarks
Score Rating
1. C Cobalt
2. C 13XX 21-25 Above 83% Topnotchers Very good
3. A Chromium
18-20 70 to 83% Passers Good
4. C Copper
5. C Iron 13-17 50 to 69% Qualifiers Poor
6. D Copper and Zinc
12-below 49% below Failed Very poor
7. D Copper and Zinc
8. D all of the above
9. B Covalent Bond
10. A Allotropy
11. A Alloy
12. A Ductile cast iron
13. A Creep
14. B Nickel
15. D A and C
16. A Recrystallization
17. D A and B
18. D All of the above
20. A Boron
21. A Titanium
22. A Magnesium
23. D all of the above
24. C 10 to 12%
25. A 1XXX
30
Test 2
1. A crystalline form of carbon having a layered structure with basal planes or sheets of close-packed atoms.
A. Graphite
B. Lampblack
C. Black soot
2. Increases the strength without sacrificing the ductility of the carbon steels
A. Nickel
B. Chromium
C. Vanadium
D. Molybdenum
3. Increases the atmospheric corrosion resistance and strength of steel.

A. Aluminum
B. Copper
C. Nickel
D. Chromium
4. The lightest metals used in machine construction.

A. Aluminum
B. Cast iron
C. Copper
D. Wrought iron
5. Materials containing iron as principal constituent.

A. Ferrous
B. Non-ferrous
C. Non-metallic
D. No one of the above
31
6. A material recovers its original dimensions, when the load is removed, is called
A. Elastic
B. Plastic
C. Phenolic
D. Thermoplastic
7. Fatigue failure occurs when a work piece is subjected to

A. Fluctuating stress
B. Residual stress
C. Torsional stress
D. Flexural stress
8. The ability of a material to absorb energy when deformed elastically and return it when unloaded is known as
A. Stiffness
B. Toughness
C. Resilience
D. Hardness
9. The hardness of steel increases if it contains

A. Austenite
B. Bainite
C. Pearlite
D. Martensite
10. The most important element that controls the physical properties of steel is
A. Carbon
B. Chromium
C. Nickel
D. Iron
11. The ability to absorb energy up to fracture.

A. Toughness
B. Resilience
C. Stiffness
D. Hardness
32
12. The polymers without cross-links.
A. Thermoplastics
B. Thermostats
C. Phenolics
D. Nylons
13. The absolute vale of ratio of transverse to axial strain.

A. Modulus of rigidity
B. Modulus of elasticity
C. Bulk modulus
D. Poison’s ratio
14. The polymers with intermediate amount of cross-linking.

A. Thermosets
B. Thermoplastics
C. Nylons
D. Elastomers
15. Properties are independent of orientation or direction.

A. Isotropic
B. Anisotropic
C. Orthotropic
D. Composites
16. The most abundant material on earth.

A. Cast iron
B. Copper
C. Lead
D. Sulfur
17. The main alloying element in high speed steel is

A. Chromium
B. Nickel
C. Tungsten
D. Vanadium
33
18. Which of the following is the lightest material?
A. Aluminium
B. Cast iron
C. G.I. sheet
D. Lead
19. Fixture clamps are generally made of

A. Alloy steel
B. Case hardened mild steel
C. High carbon steel
D. High speed steel
20. A product of blast furnace.

A. Cast iron
B. Pig iron
C. Wrought iron
D. White iron
21. It is the property of metal on account of which it can be extended in all directions by hammering or rolling
A. Machinability
B. Malleability
C. Ductility
D. Fusibility
22. It is the property of metal which a metal capable of resisting surface penetration by other metals.
A. Toughness
B. Stiffness
C. Hardness
D. Resilience
23. A product of pudling furnace.

A. Pig iron
B. Wrought iron
C. Cast iron
D. Nodular iron
24. A material commonly used for shielding or screening magnetism is
34
A. Aluminium
B. Brass
C. Copper
D. Soft iron
25. The purpose of tempering is to make a metal

A. Harder
B. Less brittle
C. More brittle
D. Softer
35
Answer to Test 2
1. A Graphite Performance Status Remarks
Performance
2. A Nickel Rating
Score
3. B Copper
4. A Aluminum
21-25 Above 83% Topnotchers Very good
5. A Ferrous
6. A Elastic 18-20 70 to 83% Passers Good
7. A Fluctuating stress
8. C Resilience 13-17 50 to 69% Qualifiers Poor
9. D Martensite 49% below Failed Very poor
12-below
10. A Carbon
11. A Toughness
12. A Thermoplastic
13. D Poisson’s ratio
14. D Elastomers
15. A isotropic
16. A Cast iron
17. C Tungsten
18. A Aluminum
19. B Case hardened mild steel
20. B Pig Iron
21. B Malleability
22. C Hardness
23. B Wrought Iron
24. D Soft Iron
25. B less brittle
36
Test 3
Instruction: Choose the correct answer of the questions below.
1. Which of the following material has the maximum ductility?

A. Aluminum
B. Copper
C. Mild Steel
D. Zinc
2. Steel containing up to 0.15% carbon, is known as

A. Dead mild steel
B. High carbon steel
C. Medium carbon steel
D. Mild steel
3. The material commonly used for machine tool bodies is

A. Aluminum
B. Cast iron
C. Copper
D. Mild steel
4. The material commonly used for crane hook is

A. Aluminum
B. Cast iron
C. Mid steel
D. Wrought iron
5. Shock resistance of steel is increased by adding

A. Chromium
B. Cobalt and molybdenum
C. Nickel
D. Nickel and chromium
37
6. The steel widely used for motor car crankshaft i
A. Chrome steel
B. Nickel-chrome steel
C. Nickel steel
D. Silicon steel
7. A steel with 0.80 percent carbon is known as

A. Eutectoid steel
B. Hyper eutectoid steel
C. Hypoeutectoid steel
D. Hypocytectoid
8. An 18/8 steel contains

A. 18 percent chromium and 8 percent nickel
B. 18 percent nickel and 8 percent chromium
C. 18 percent nickel and 8 percent vanadium
D. 18 percent vanadium and 8 percent nickel
9. The process which involves the machinability of steels but lower the hardness and tensile strength is
A. Full annealing
B. Normalizing
C. Process annealing
D. Spherodizing
10. The metal suitable for bearings subjected to heavy loads is

A. Monel metal
B. Phosphor bronze
C. Silicon bronze
D. White metal
11. The metal suitable for bearings subjected to light loads is

A. Monel metal
B. Phosphor bronze
C. Silicon bronze
D. White metal
38
12. Thermoplastic materials are those materials which
A. Are formed into shape under heat and pressure and results in a permanently hard product
B. Are flexible and can withstand considerable wear under suitable conditions
C. Are used as friction lining for clutches and brakes
D. Do not become hard with the application of heat and pressure and no chemical change occurs
13. The castings produced by forcing molten metal under pressure into a permanent metal mould is known as
A. Centrifugal casting
B. Die casting
C. Permanent mould casting
D. Slush casting
14. The metal is subjected to mechanical working for

A. Controlling the direction of flow lines
B. Reining grain size
C. Reducing original block into desired shape
D. All of the above
15. The temperature cut which the new grains are formed in the metal is called
A. Eutectic temperature
B. Lower critical temperature
C. Upper critical temperature
D. Recrystallization temperature
16. The hot working metal is carried out

A. At any temperature
B. At the recrystallization temperature
C. Above the recrystallization temperature
D. Below the recrystallization temperature
17. During hot working of metals

A. Porosity of the metal is largely eliminated
B. Mechanical properties are improved due to refinement of grains
C. Grain structure of the metal is refined
D. All of the above
39
18. The parts of circular cross-section which are symmetrical about the axis of rotation are made by
A. Hot drawing
B. Hot extrusion
C. Hot forging
D. Hot spinning
19. The cold working metals is carried out _____________ the

Recrystallization temperature.
A. Above
B. Average
C. Below
D. The peak
20. The process extensively used for making bolts and nuts is
A. Cold heading
B. Cold peening
C. Extrusion
D. Hot peening
21. In a unilateral system of tolerance, the tolerance is allowed on

A. Both sides of actual size
B. Both sides of the nominal size
C. One side of the actual size
D. One side of the nominal size
22. A basic whole is one whose

A. Lower and upper deviations are zero
B. Lower deviations is zero
C. Upper deviation is zero
23. Ball bearing are, usually made from

A. High carbon steel
B. High speed steel
C. Low carbon steel
D. Medium carbon steel
40
24. Rankine’s theory is used for
A. Brittle materials
B. Ductile materials
C. Elastic materials
D. Plastic materials
25. The surface finish factor for a mirror polished material is

A. 0.45
B. 0.65
C. 0.85
D. 1.00
41
Answer to Test 3
1. C Mild steel Performance Performance Status Remarks
2. A Dead mild steel Score Rating
3. B Cast iron
4. D Wrought iron
5. D Nickel and chromium 18-20 70 to 83% Passers Good
6. A Chrome steel
7. A eutectoid steel 13-17 50 to 69% Qualifiers Poor
8. A 18 percent chromium and 8 percent nickel 12-below 49% below Failed Very poor
9. D Spherodizing
10. D White metals
11. B Phosphor bronze
12. D Do not become hard with the application of heat
and pressure and no chemical change occurs
13. B Die casting
15. D Recrystallization temperature
16. C Above the recrystallization temperature
18. D Hot spinning
19. C Below
20. A Cold heading
21. D One side of the nominal size
22. B Lower deviations is zero
23. D Medium carbon steel
24. A Brittle materials
25. D 1.00
42
Test4
1. Transforming gaseous, liquid and solid elements by chemical and physical means where atoms or molecules are combined to form solid materials.
A. Analysis
B. Processing
C. Synthesis
D. Wroughting
2. Control of structure at higher levels of aggregation to yield bulk materials

A. Analysis
B. Processing
C. Synthesis
D. Wroughting
3. Composites produced with innovative process that yield high strength and stiffness plus weight reduction
A. Advanced composites
B. Fiberglass
C. Hydrocarbons
D. Reinforced concrete
4. Manufacturing engineering has evolved to a sophisticated field of study. Which two aspects of fabricating products and systems contribute most to
the new approaches of this field?
A. Automation
B. Chemistry
C. Mathematics
D. Systems approach
5. What approach to design reflects a new concern for disposing of products after their useful life?
A. CIM
B. Design for assembly
C. Design for disassembly
D. JIT
43
6. Which is not an obstacle to acceptance of new engineering materials and processes?
A. Lack of experience by designers and fabricators
B. Concern for safety with new techniques
C. Need for compromise between favourable properties and cost
D. Concern for keeping up with one’s competition
7. What factor in materials selection usually dominates the final choice?

A. Cost
B. Processibility
C. Recyclability
D. Weight
8. Which term describes well-defined methods for solving specific problems, such as those used to develop an approach to materials selection?
A. Algorithm
B. CIM
C. Design
D. JIT
9. Which of the following best fits the category of a material system?

A. Battery
B. Gold
C. Plastic spoon
D. Titanium
10. The largest consumer of electricity in the United States is the refining of the metal?
A. Aluminum
B. Brass
C. Copper
D. Steel
11. A ______ is a substance that cannot be broken down any further by chemical reaction.
A. Atom
B. Compound
C. Element
D. Molecule
44
12. A compound is a substance that can be broken down by chemical reactions into
A. Atom
B. Compound
C. Element
D. Molecule
13. Proton and neutrons are known as

A. Electrons
B. Neutrinos
C. Nucleons
D. Quarks
14. Another name for an electron shell is

A. energy state
B. Ion
C. Principal energy level
D. Quantum
15. Two electrons can exist in the same orbital if they have
A. Opposite spins
B. The same energy
C. The same polarity
D. The same spins
16. The maximum number of electrons in the L, or second energy level is

A. 2
B. 4
C. 8
D. 18
17. Inert gases can also be called

A. Active
B. Group 5 elements
C. Noble gases
D. Stable
45
18. The core electrons in neon (Ne) number
A. 2
B. 6
C. 10
D. 18
19. Horizontal rows in the periodic table are called

A. Groups
B. Metals
C. Periods
D. Transition elements
20. Metalloids consist of how many elements?

A. 3
B. 5
C. 7
D. 10
21. The electronegativity of iron (Fe) is

A. 1.83
B. 3.98
C. 5.98
D. 7.98
22. A distinction that sets intelligent structure apart from other advanced materials is:
A. Cost per volume is often higher than traditional materials
B. Ability to adapt to changes in environment
C. Requires more processing
D. Benefits from superior properties offset material cost
23. What type dendrites form in thixotropic metals?

A. BCC
B. FCC
C. Spheroidal
D. Tree-like
46
24. What advantage comes from equiaxed grains?
A. Directional strength
B. Lower processing cots
C. Reduced density
D. Uniform strength
25. Characterization technique involving instruments and methods such as Aluminum

A. Artificial
B. Nanoscale
C. Qualitative
D. Quantitative
47
Answer to Test 4
Performance Performance Status Remarks
1. C Synthesis Score Rating
2. B Processing
3. A Advanced composites 21-25 Above 83% Topnotchers Very good
4. A Automation 18-20 70 to 83% Passers Good
5. C Design for disassembly
6. D concern for keeping up with one’s competition 13-17 50 to 69% Qualifiers Poor
7. A cost 49% below Failed Very poor
12-below
8. A algorithm
9. D Titanium
10. A Aluminum
11. C Element
12. C Element
13. C Nucleons
14. C Principal energy levels
15. A Opposite spins
16. C 8
17. D stable
18. C 10
19. C Periods
20. C 7
21. B 3.98
22. A Cost per volume is often higher than traditional
materials
23. D Tree-like
24. D Uniform Strength
25. A Artificial
48
Test 5
1. ME Board Oct 1999

What is the lightest known metal?
A. Aluminum
B. Chromium
C. Mercury
D. Steel

Material having high electrical resistance and should not be used as conductor of electrical current.
A. Copper
B. Iron
C. Magnesium
D. Nickel

The property that characterizes a materials ability to be drawn into a wire is known as
A. Ductility
B. Elasticity
C. Plasticity
D. Utility

Stress relieving is also ____________ for the purpose of reducing the internal stress of steel material / metal.
A. Drawing
B. Normalizing
C. Quenching
D. Tempering
49
5. ME Board April 1998
A carbon content in the range of _________ in steel readily
responds to heat treatment.
A. 0.35 to 0.40% C
B. 0.28 to 0.30% C
C. 0.18 to 0.25% C
D. 0.12 to 0.15% C

It indicates how many times a volume of material is heavier than an equal volume of water.
A. Specific density
B. Specific gravity
C. Specific volume
D. Specific weight

Nickel-Chromium-Molybdenum steel designation SAE ______.
A. 63XX
B. 74XX
C. 81XX
D. 94XX

Moment of inertia is called
A. Modulus of elasticity
B. Radius of gyration
C. Weep strength

It is hardening treatment whereby a cast metal is being heated to a very high temperature then suddenly to rapid cooling to improve hardenability
of wear resistance is called
A. Annealing
B. Normalizing
C. Quenching
D. Tempering
50
A good general purpose deoxidizer and promotes fine grain in steel
A. Copper
B. Magnesium
C. Molybdenum
D. Silicon

Treatment process that produces a residual compressive stress at the surface and residual tension on the inside that results in considerable
increase in fatigue strength for members on torsion / bending is known as
A. Heavy oil quenching
B. Partial quenching
C. Quenching
D. Shallow quenching

The flux that should be rovided in sodering electrical connection or commutator wires as it tends to corrode the connections
A. Acid fluxes
B. Sal ammoniac
C. Stearin
D. Zinc chloride

The characteristics of tool steel sustain shocks and impacts is due to its
A. Ductility
B. Machinability
C. Stiffness
D. Toughness

The application of electrical current to the corrosion circuit to counter the corrosion reaction is called
A. Cathodic protection
B. Chemical corrosion process
C. Galvanic action
D. Sacrificial anodes method
51
A major component of cast steel is
A. Chromium
B. Iron
C. Manganese
D. Silicon

Normally cast iron contain 2% carbon or more and silicon in the range of _________ %.
A. 1 to 3
B. 1 to 4
C. 1 to 6
D. 2 to 3

The material for engine radiation is usually made of
A. Admiralty brass
B. Navy brass
C. Silicon brass
D. Yellow brass

A problem by – product used as an electrodes in an electric arc furnace melting operation called
A. Anthracite coke
B. Bituminous coke
C. Foundry coke
D. Graphite electrodes

Which of the following does not affect the tensile strength of steel?
A. Boron
B. Cobalt
C. Phosphorous
D. Sulfur
52
Alloy steel axle under repeated load / stress will eventually fail if the load / stress are above the endurance for the steel under consideration. The
endurance limit of the steel is
A. Equal to 80% of the elastic limit
B. Equal to half of the ultimate strength
C. Equal to module of elasticity
D. Equal to the allowable stress of the module of elasticity

Mirror finish has fitness of ______ rms
A. 1
B. 1 to 3
C. 2 to 5
D. 2 to 8

Chromium steel includes heat and corridor resistant designation
A. SAE 9XX
B. SAE 56XX
C. SAE 61XX
D. SAE 514XX

Non – metallic material of high melting temperature being used as furnace lining is called is called
A. Dolomite clay bricks
B. Quartz bricks
C. Refractories
D. Silica sand

In greater quantity, this element is harmful to the molten ferrous metal.
A. Aluminium
B. Oxides
C. Siicon
D. Sulfur
Silicon – manganese steel designation, SAE _______.
A. 9XX
B. 40XX
C. 72XX
D. 92XX 53
Answer to Test 5
1. A Aluminum Performance Performance Status Remarks
2. B Iron Score Rating
3. A Ductility
4. C Quenching 21-25 Above 83% Topnotchers Very good
5. A 0.35 to 0.40% C 18-20 70 to 83% Passers Good
6. B Specific gravity
7. D 94XX 13-17 50 to 69% Qualifiers Poor
8. D None of these
9. C Quenching
10. D Silicon
11. D Shallow quenching
12. A Acid fluxes
13. D Toughness
14. A Cathodic protection
15. B iron
16. A 1 to 3
17. D Yellow brass
18. D Graphite electrodes
19. A Boron
20. B equal to half of the ultimate strength
21. A 1
22. D SAE 514XX
23. C Refractories
24. D Sulfur
25. D 92XX
54
Test 6

Cold drawing is also called
A. Cold lap strap
B. Hard drawn
C. Oxidized steel
D. Strain hardening

The brittleness in steel at elevated temperature is known as
A. Hard drawn
B. cold lap
C. Red shortness
D. Residual stresses

Material may be stretched and still return to its former form / condition upon release of force is called
A. Ductility
B. Elastic limit
C. Moduluss of elasticity
D. Plasticity

What is the SAE specification number of molybdenum – chromium –nickel?
A. 48XX
B. 47XX
C. 46XX
D. 45XX
55
5. ME Board Oct 1997, ME Board April 1992
Galvanized iron is term referring to iron-coated with
A. Aluminum
B. Manganese
C. Tin
D. Zinc

A metal, which has a high electrical conductivity but should not be used for high temperature is known as
A. Carbide
B. Chrome alloy
C. Silicon
D. Zinc

It improves red hardness of steel.
A. Boron
B. Chromium
C. Cobalt
D. Lead

What is the SAE specification number of molybdenum?
A. SAE 2XXX
B. SAE 3XXX
C. SAE 4XXX
D. SAE 5XXX

Which does not belong to the group?
A. AISI
B. ASTM
C. SAE
D. SEA

It is the ability of the material to resist deformation under stress.
A. Hardness
B. Plasticity
56
C. Stiffness
D. Toughness
11. ME Board April 1997, ME Board April 1996

Which of the following is not a structural class of steel?
A. High carbon
B. High speed steel
C. Low carbon
D. Tool and die
12. ME Board April 1997, ME Board April 1996

Continuous stretching under load even if the stress is less than the yields point known as
A. Plasticity
B. Elasticity
C. Ductility
D. Creep
13. ME Board Oct 1996, ME Board Oct 1944

Killed steel is always associated with
A. Silicon
B. Manganese
C. Phosphorus
D. Sulfur
14. ME board Oct 1996

The good deoxidizer in steel melting is called
A. Aluminum
B. Manganese
C. Silicon
D. All of the above

Good stabilizer in stainless steel is
A. Columbium
B. Tantalum
C. Titanium
D. All of the above
57
Metals are conductive because
A. Having characteristics luster
B. The electrons are loosely bound to the nuclei and therefore mobile
C. They are on the left side of the periodic table
D. They have extra electrons as exhibited by normally possible balance state

The yield strength of a rectangular yellow brass 65 to 70% Cu, 20 to 35% Zn can be increased / improved by __________.
A. Tempering
B. Hell casting
C. Heat treatment
D. Cold working

Used in as cast condition steel casting with carbon content less than __________ % C.
A. 0.15 to 0.18
B. 0.20
C. 0.25
D. 0.26

Liners are normally made of
A. Alloyed aluminum
B. Alloyed bronze
C. Alloyed steel
D. Cast iron

A furnace used in melting non – ferrous metals called
A. Crucible furnace
B. Cupola furnace
C. Induction furnace
D. Tempering furnace
58
A furnace used in melting ferrous metals
A. Annealing furnace
B. Induction furnace
C. Normalizing
D. Tempering furnace

All are associated with standard material specified except ________.
A. American Iron and Steel Institute
B. American Society for Testing Materials
C. Society of Automotive Engineers
D. Southeast Asia Iron and Steel Institute

The ability of a metal to be deformed considerably without rupture is called
A. Ductility
B. Elasticity
C. Malleability
D. Plasticity

Permanent deformation or strain may occur without fracture is called
A. Ductility
B. Elasticity
C. Malleability
D. Plasticity

Alloy that improves strength of steel at high temperature application is known as
A. Tungsten
B. Molybdenum
C. Chromium
D. All of the above
59
Answer to Test 6
1. B Hard drawn Score Rating
2. C red shortness
3. B Elastic limit
4. B 47XX 18-20 70 to 83% Passers Good
5. D Zinc
6. D Zinc 13-17 50 to 69% Qualifiers Poor
7. C Cobalt 12-below 49% below Failed Very poor
8. C SAE 4XXX
9. D SEA
10. C Stiffness
11. D Tool die
12. D Creep
13. A Silicon
16. B the electron are loosely bound to the nuclei and
therefore mobile
17. D cold working
18. B 0.20
19. D cast iron
20. A Crucible furnace
21. B Induction furnace
22. D Southeast Asia Iron and Steel Institute
23. D Plasticity
24. D Plasticity
25. D All of the Above
60
Test 7

Metal that assists lubrication or lubricant in itself
A. Antimony
B. Babbitt
C. Lead
D. Zinc

The smallest area at the point of rupture of a tensile specimen divided by the original area is called
A. Charpy test
B. Izod test
C. Percentage elongation
D. Percentage reduction of area

All are associated with the grade of steel except
A. SAE 10XX
B. SAE 13XX
C. SAE 43XX
D. SAE 74XX

Cold working of steel plates make the metal
A. Harder
B. More detail
C. More malleable
D. Tougher
61
The property that characteristics a material ability to be drawn into a wire called
A. Ductility
B. Endurance limit
C. Thermal conductivity
D. Tensile strength

Normal stress relieving temperature for cast steel is
A. 200 to 350 °F
B. 300 to 400 °F
C. 400 to 500 °F
D. 450 to 550 °F

Most effective alloying element for reducing brittleness of steel at very low temperature is known as
A. Manganese
B. Molybdenum
C. Nickel
D. Silicon

Ordinary steel begins to lose strength and elasticity significantly of about
A. 900 – 1000 °F
B. 800 – 900 °F
C. 700 – 850 °F
D. 600 – 700 °F

For a high corrosion resistant stainless steel what minimum chromium content is required?
A. 1.1%
B. 4.3%
C. 5.8%
D. 8%
62
A material that should be avoided in constructing wood pattern
A. Sap wood
B. Kiln dried wood
C. Heart wood
D. Core portion of wood

The gradual chemical resection by other substance such that the metal is converted to an oxide or other compounds is termed as
A. Cheeping
B. Corrosion
C. Rusting
D. Weathering

What is the property of a material, which resists forces to pull the material apart?
A. Compression
B. Shear strength
C. Tensile strength
D. Torsional strength

What is the difference between brass and bronze?
A. Brass is composed of copper and zinc while bronze is basically copper and tin plus non-ferrous alloy such as manganese, aluminium and
chromium
B. Brass is composed of copper and zinc while bronze is composed of copper and tin
C. Bronze is mostly an alloy of copper and tin while brass is a mixture of copper and antimony
D. Bronze is reddish in color while brass is a mixture of copper and antimony

Liquid metal is called ___________.
A. Aluminum
B. Lead
C. Mercury
D. Zinc
63
Which of the following elements
A. Aluminum
B. Silicon
C. Sulfur
D. Zinc

It has molybdenum alloy except __________.
A. SAE 43XX
B. SAE 41XX
C. SAE 6XXX
D. SAE 5XXX

Cast alloy steel for very high temperature application
A. Manganese – nickel steel casting
B. High chrome steel casting
C. High manganese casting
D. Chrome – nickel steel casting

What heat treatment process can cast steel materials of high chrome high manganese etc. Type steel is subjected for the prpose of machining
process?
A. Annealing
B. Normalizing
C. Quenching
D. Tempering

Galvanized steel plate is
A. Aluminium
B. Manganese
C. Tin
D. Zinc
64
20. ME Board April 1995, ME Board Oct 1994
Major component of bronze casting is
A. Copper
B. Lead
C. Manganese
D. Zinc

Alloy steel known for its resistance to corrosion, abrasion and wear that are usually ideal for mill grinding of ore in cement and concentrator
application. It is usually combined with molybdenum to increase the depth hardening.
A. Chrome – moly steel
B. Chromium – nickel – moly steel
C. Manganese – moly steel
D. Manganese chromium steel

Commonly utilized / cheapest shaft material available in the market with carbon content of 0.28 to 0.34?
A. SAE 1030
B. SAE 4130
C. SAE 4132
D. SAE 4320

Heating of metal above the critical temperature and then cooling slowly usually in the furnace to reduce thehardness and improve the
machinability is called
A. Annealing
B. Normalizing
C. Quenching
D. Tempering

It is hardening treatment whereby a cast metal is being heated to a very high temperature then suddenly subjected to rapid cooling to improve
hardenability or wear resistance is called
A. Annealing
B. Normalizing
C. Quenching
D. Tempering
65
SAE steel that responds to heat treatment
A. SAE 1117
B. SAE 1060
C. SAE 1030
D. SAE 1020
66
Answer to Test 7
1. B Babbitt Rating
Score
2. D Percentage reduction of the area
3. D 74XX 21-25 Above 83% Topnotchers Very good
4. A harder
18-20 70 to 83% Passers Good
5. A Ductility
6. D 450 to 550 °F 13-17 50 to 69% Qualifiers Poor
7. C Nickel
8. D 600-700 °F
9. D 8%
10. A Sap wood
11. B Corrosion
12. C Tensile strength
13. B Brass is composed of copper and zinc while
bronze is composed of copper and tin
14. C mercury
15. C Sulfur
16. D SAE 5XXX
17. D Chrome-nickel steel casting
18. A Annealing
19. D Zinc
20. A Copper
21. A Chrome-moly steel
22. A SAE 1030
23. A Annealing
24. C Quenching
25. A SAE 1117
67
Test 8

A form of correction that develop on a highly localized area on a metal surfaces is called
A. Crevice
B. Erosion
C. Galvanic
D. Splitting

The deterioration of organic coating characterized as completely ______________.
A. Chalking
B. Checking
C. Fritting
D. Rusting

The temperature above, which the alloy is liquid and will run is known as
A. Flow point
B. Liquids
C. Melting point
D. Pour point

It refers to any layer or deposit of extraneous material on the heat – transfer surface.
A. Fouling
B. Low line
C. Pressure drop
D. Scaling
68
Steel containing large amounts of mild nickel and chromium is
A. Alloy steel
B. Carbon steel
C. Cast steel
D. Stainless steel

The corrosion of iron – base alloys.
A. Chalking
B. Crazing
C. Fritting
D. Rusting

The corrosion occurs within or adjacent to a crevice formed by contact with another piece of the same or another material
A. Pitting
B. Galvanic
C. Erosion
D. Crevice

An alloy of tin, copper, antimony or sometimes lead is known as
A. Gold
B. Cast iron
C. Babbitt
D. Aluminum

The cheapest and most abundant engineering material is
A. Aluminum
B. Babbitt
C. Cast iron
D. Steel
69

1 Chapter Engg Matls

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1 Chapter Engg Matls

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Chapter 1

1. Define engineering materials;

Ferrous Materials are those materials containing iron as principal constituent.

Example of Ferrous Materials:

Example of Nonferrous Materials

Nonmetallic Materials are of great importance in engineering applications.

Examples of Thermosetting Plastics

The Scope of Engineering Materials

Rigidity Durability Toughness

Rigidity is important where deflections are limited by service requirements.

Example of Mechanical Properties of Metals

Toughness is the capacity of material to withstand a shock load without breaking.

Example of mechanical Properties of plastics

Example of Mechanical Properties of Ceramics

Example of Physical Properties

3. Crystal structure is the ordered, repeating arrangement of atoms or molecules in a material.

Example of Chemical Properties of Metals

Example of Chemical Properties of Plastics

Example of chemical properties of Ceramics

2. Machinabiltity is the property of metal due to which a metal can

6. Fusibility is the property of metal due to which a metal becomes

Plain Carbon Steels

Classification of Plain Carbon Steels

Carbon effect on the Properties of Steel

Alloying Elements & Their Effects On The Properties of Steel

4. Molybdenum gives greater hardness and resistance to forging and drawing.

7. Sulphur an element is considered to be an undesirable impurity in steel

Effects of Various Elements in Steels

1. Boron improves hardenability, without the loss of machinability and formability.

6. Cobalt improves strength and hardness at elevated temperatures.

8. Lead improves machinability; it causes liquid-metal embrittlement.

9. Magnesium has the same effect as cerium.

18. Tantalum effects similar to those of niobium.

19. Tellurium improves machinability, formability and toughness.

20. Titanium improves hardenability; it deoxidizes steels.

21. Tungsten has the same effect of cobalt.

23. Zirconium has the same effects as cerium.

Residual Elements in Steels

Copper Nickels Copper, Nickel,

Refractory Metals and Alloy

HSLA Steels (High Strength Low Alloy)

Case Hardening Steels

High Carbon Steels

The Stainless Steel Family

Properties of Cast Iron

Ductile Iron (Nodular Iron)

Vulcanized Thermoplastic Thermoplastic Thermosetting

Examples of Thermosetting Plastics

Table2. Modulus of Elasticity for Various Metals, Polymers & Ceramics

Materials Modulus of Elasticity

Table4. Alloy Groups

The first digit indicates the Class of Steel

A: for basic open hearth alloy steels

The AISI DESIGNATION SYSTEM

Specific alloy in the group

Alloy group: indicate major alloying elements

Alloy Groups in the SAE Numbering System

10XX Plain carbon steel

Heat Treatment of Ferrous Alloys

Heat Treatment of Metals

1. Which of the following materials that improves red hardness?

2. What SAE number of Manganese Steel?

3. What is the major component of stainless steel?

4. What is the major components of bronze?