COLLEGE OF SCIENCE AND TECHNOLOGY

SCHOOL OF ENGINEERING

P.O. Box: 3900 Kigali, Rwanda, Tel: +250 252 574696/ 574698, Fax: +250 252 571925/ 571924,
E-mail: hmee@cst.ac.rw
DEPARTMENT OF MECHANICAL AND ENERGY ENGINEERING
(Nyarugenege Campus)

ACADEMIC YEAR: 2017-2018 EXAMINATION PERIOD: JAN 2018

YEAR OF STUDY: 3 SEMESTER: I Programme: Full Time

SUBJECT CODE & NAME: MEE 3262 - ENGINEERING MATERIALS & METALLURGY

NO. OF STUDENTS: 70 DURATION:2hrs MAX. MARKS:50

DATE OF SUBMISSION:

NAME OF MODULE LEADER: MARIE AIMEE TUYIZERE FLORA

TEL: E-MAIL: +250781518944

SIGNATURE:

Enclosed with:

(i) Module Content √ (ii) Exam Questions. √ (iii) Marking scheme √

Head of Department: ERNEST MAZIMPAKA Date:

INDICATIVE CONTENT

1. Introduction to Engineering Materials

Types of materials, source of materials and their extration, crystalline and amorphous
materials. Application and selection of materials.

2. Metallic Materials
Structural aspects of solidification & solid phase transformation in binary systems,
ferrous and non - ferrous metals, steel making processes, heat treatment, TTT diagram.

3. Ceramics, Glasses & Refractory Materials

Composition, properties, structures of various non -metallic materials, application of

ceramics, glasses, refractory materials, methods of manufacture.

4. Polymers & Rubbers

Polymerization, Structural feature of polymers, thermoplastic polymers, thermosetting
polymers, additives, major mechanical properties, rubber (elastomers), synthesis of
rubber.
5. Composites
Introduction to composite materials, types of composite materials, methods of
fabrication of composite materials, property averaging and major mechanical properties
of composite materials.

6. Environmental Degradation
Metal degradation by atmosphere, aqueous & galvanic corrosion, stress corrosion
cracking, methods of corrosion prevention, behaviour of metal at elevated temperatures,
pyrometer, oxidation, scalling and creep. Chemical degradation of ceramics and
polymers, radiation damage surface. Improvement against degradation.
 COLLEGE OF SCIENCE AND TECHNOLOGY
SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL AND ENERGY ENGINEERING

(Nyarugenge Campus)

END OF SEMESTER EXAMINATION -ACADEMIC YEAR 2017-2018

YEAR: 3 SEMESTER: I GROUP: Mechanical and Energy Engineering

MODULE: MEE 3262 - ENGINEERING MATERIALS & METALLURGY

DATE: /01/2018 TIME: 2hours

MAXIMUM MARKS = 50

INSTRUCTIONS

1. This paper contains FOUR (4) questions.

2. Answer THREE (3) Questions only:
Question ONE (1) from Section “A” is Compulsory and Answer any TWO (2) from Section “B”
3. No written materials allowed.
4. Do not forget to write your Registration Number.
5. Write all your answers in the booklet provided
6. Do not write any answers on this questions paper.
7. Start each question in a NEW page
 SECTION: A

Question: 1 [20 Marks]

a) (4 Marks)
i. What is the difference between corrosion and structure failure in Engineering material?
/ 2 Marks
ii. Give four reasons why we need to understand engineering materials. / 2 Marks

Answer: (4 Marks)
i.

 Corrosion is electrochemical attack of a metal, usually starting at the surface, resulting in

loss of material. / 1 Mark
 Structure failure is a condition in which a structure or a product cannot fulfil its purpose.
/ 1 Mark

ii. Four reasons why we need to understand engineering materials: Any answer is
acceptable
/ 2 Marks: 0.5 mark each
 An understanding of material is fundamental in the study of manufacturing
processes (transformation)
 To help us select the best materials for a design
 To help us make the design right for the selected materials.
 To know available materials, the advantages and disadvantages of these
materials.
 Properties of materials, and how these can change (e.g., with time, temperature,
processing, environment, and so on…)
 A material composition, properties, structure, processing methods and cost, the
loading on the material and the environment in which the material is used
(Temperature, Chemical, Electrical, Magnetic)
b) Explain how bond rupture occur in polymers by giving one typical example and a solution to
prevent this polymer degradation phenomenon. (5 Marks)

Answer:
o Bond Rupture phenomenon in polymers:
• Rupture of covalent bonds in polymer molecules can be caused by chemical reaction,
exposure to heat or exposure to radiation. Bond rupture results in a reduction in
average molecular weight and associated changes in properties of the material.
/ 2 Marks
• The most common form of bond rupture is that caused by ultraviolet (UV) radiation in
daylight. This can cause polymers to discolour, become brittle, crack and fail. Stabilizer
additives can be added to protect polymers from radiation damage.
/ 2 Marks
• An example of bond rupture due to chemical reaction is the reaction of parts of the
polymer chains in vulcanized rubber with ozone (O3) gas in the atmosphere. This can
result in the cracking of old rubber tyres.
Or
In some polymers, elevated temperatures can result in bond rupture. An example is
poly(vinyl chloride), PVC, which will discolour and change properties at 200 0C in just a
few minutes. (Stabilizers additives can be used to reduce bond rupture due to heating).
/ 1 Mark

c) (9 Marks)
i. What is the result when the concentration of alloying elements is greater than the solubility
limit? / 2 Marks

Answer: / 2 Marks
When the concentration of alloying elements is greater than the solubility limit, there
is
 Formation of another different phase by excess atoms, which is a second phase
/ 1 Mark
 Different crystal structure and/ or different mechanical properties
 / 1 Mark

ii. With a neat and clear supporting sketch define and explain all steps of float glass process.
/7 Marks

Answer:

 Float glass process is a process through which a molten glass is floated over a bath of
molten tin, where it begins to cool to form a flat product, then is slowly cooled and cut into
the required lengths. Is used to form flat sheets of glasses, such as window glass.
/ 2 Marks

Sketch: / 7 Marks: 0.5 Marks each component and 0.5 Mark each step explanation
(note: weighing and mixing, and melting areas are counted in step exolaination)

(a) The microstructure of a Cu-Ag alloy at 775ºC (Figure 1) consists of primary α and eutectic
microstructures. If the mass fractions of these two micro-constituents are 0.73 and 0.27,
respectively, determine the alloy composition. (2 Marks)
Figure 1: Cu-Ag Phase diagram

Answer:
First, you need to realize that primary α refers to the α phase that precipitates out prior to the
eutectic reaction. Thus, the weight fraction primary α is equal to the weight fraction α just
above the eutectic temperature, 779ºC. Similarly, the weight fraction eutectic microstructure
is equal to the weight fraction L just above this temperature.

/ 2 Marks: 0.5 Mark each sequence

 SECTION: B

Question: 2 [15 Marks]

a) (5 Marks)
i. What is the main material that makes a cooking pan? What are the three advantageous
characteristics to select that material for cooking pan manufacturing?
/2 Marks
Answer: /2 Marks
The main material is Aluminium / 0.5 Mark
 The three advantageous characteristics to select that material for cooking pan
manufacturing are (any answer is acceptable): / 1.5 Mark
• Ductile and highly formable (easy to manufacture, Easily machined and cast,
weldable )
• Lightweight (Excellent Strength-to-weight ratio with TS ~ 50-800 MPa, density =
1/3 that of steel )
• High heat conduction (High Thermal Conductivity )
• Inert surface oxide (No contamination): Corrosion resistant
• Tough
• Many alloys available

ii. What are the three effects of metal plastic deformation? /3 Marks
Answer:
Plastic deformation of metals (e.g. During processing operations) can
o Change grain shape
o Cause strain hardening and
o Increase the number of dislocations

b) (5 Marks)
i. Differentiate annealing and grain growth processes? / 3 Marks
ii. What is the purpose of Hall–Petch method? / 2 Marks

Answer:

i. Differentiating annealing and grain growth processes:

Process annealing – Heat treatment of a metal to change properties, to change the

microstructure, or to relieve stresses in the material. Heat treatment to remove the effects of
cold work (that is to soften and increase the ductility of a strain-hardened material), usually
to allow further deformation of the metal without causing failure.
 / 1.5 Marks

Grain growth – The increase in size of some grains by diffusion of atoms across grain
boundaries from other grains, and decrease in size (and eventual disappearance) of other
grains. The result is an increase in average grain size and a reduction in the total number of
grains. / 1.5 Marks

ii. Hall–Petch method (or Grain-boundary strengthening) is a method of strengthening

materials by changing their average crystalline (grain) size to obtain small grains by
making the materials harder, stronger and tough.
/ 2 Marks

c) (5 Marks)

i. What structure is formed when there is a moderate cooling of austenite? / 1 Mark

ii. What is the most stronger and the most ductile among all structures formed during a certain
cooling of austenite structure. / 1 Mark

iii. A 0.45%C hypoeutectoid plain-carbon (figure 2) steel is slowly cooled from 9500C to a
temperature just slightly above 7230C. Calculate the weight percent austenite and weight percent
proeutectoid ferrite in this steel. / 3 Mark
Figure 2: Iron carbon phase diagram

Solution: (5 Marks)

i. The structure that is formed when there is a moderate cooling of austenite is Bainite
/ 1 Mark
ii. The most stronger among all structures formed during a certain cooling of austenite
structure is Martensite / 0.5 Mark
and the most ductile is spheroidite / 0.5 Mark

iii.
Autenite ( ) = = = = 57.99% or 58% / 1.5 Mark

Proeutectoid ferrite ( )= = = = 42% /1.5Mark

Question: 3 [15 Marks]

a) Differentiate crazing and strain ageing (2 Marks)

Answer: (2 Marks)

 Crazing is the formation of crazes for energy absorption to increases the fracture
toughness of the polymer. / 1 Mark

 Strain ageing is the movement (or segregation) of carbon atoms to dislocations,

thereby pinning the dislocations in place, which cause an increase in strength and
decrease in ductility. / 1 Marks

b) Describe glass transition phenomenon (3. 5 Marks)

Answer:

The glass-transition phenomenon occurs with amorphous or non-crystalline polymers that, when
cooled from a liquid melt, become rigid solids yet retain the disordered molecular structure that
is characteristic of the liquid state. ( a reversible transition in amorphous materials from a hard
and relatively brittle state into a molten or rubber-like state). This is due to a reduction in motion
of large segments of molecular chains with decreasing temperature. Upon cooling, the glass
transition corresponds to the gradual transformation from a liquid to a rubbery material and
finally to a rigid solid.

c) With a neat clear sketch explain Ironmaking process. (9.5 Marks)

Answer: a neat clear sketch explain Ironmaking process:

/3.5 Marks: 0.5 Mark each component
Explanantion of the process: / 6 Marks

 Ironmaking – The starting point for the manufacture of steel / 0.5 Mark
 Iron is One of the most abundant elements in the world (Iron makes up 5% of the earth’s
crust. Iron exists naturally as various types of iron ore (rocks containing iron oxides)
/ 0.5 Mark
 Iron is extracted from iron ore in blast furnace (a large cylinder , lined with refractory
bricks) / 0.5 Mark
 The furnace is filled layers of Iron ore, Coke which generates high temperature when
burning, Limestone (calcium Carbonate), and combines with impurities in molten Fe to
form slag that floats on the surface and can be removed. / 0.5 Mark
 Air that is preheated to around 11000C is blasted into the furnace through the nozzles
called Tuyeres. / 1 Mark
  The high temperature causes the coke to burn, and temperatures of 1650 0C are achieved.
/ 0.5 Mark
 At 16500C, Oxygen reacts with carbon (in the coke) to produce carbon monoxide gas, and
Carbon monoxide reacts with iron oxide (in the iron ore) to produce molten iron and
carbon dioxide. / 1 Mark
 Molten corrects at the bottom of the blast furnace / 0.5 Mark
 Impurities float to the top as slag and are removed / 0.5 Mark
 The molten iron is transferred into ladles (each holding up to 160 tons of iron) and
transported to steelmaking plant / 0.5 Mark

Question: 4 [15 Marks]

a) (3 Marks)
i. As a mechanical engineer, what is the best way to ensure the capability to decide on good
engineering materials? / 1 Mark

Answer:
As mechanical engineer, the best way of ensuring capability to decide on good engineering
materials is to know a little about a lot of engineering materials.
/ 1 Mark
ii. Give four among the most used ways to find information about materials when there is a need
to select a material. / 2 Marks

Answer: / 2 Marks
o Testing /0.5mark
o Material manufacturers or suppliers /0.5mark
o Standard documents /0.5mark
o Textbooks /0.5mark
 iii. State the three types of technical ceramics / 3 Marks

Answer:

The three types of technical ceramics are: / 3 Marks

 Oxide Ceramics
 Carbide ceramics
 Nitride ceramics

b) (5 Marks)

i. What is the main objective to design fiber-reinforced composites? /1 Mark

ii. Which factors influencing properties of engineering composites? / 1.5 Mark
iii. What are the general characteristics of Polymer-Matrix Composites (PMCs)? / 2.5 Marks

Answer: (5 Marks)

i. Fiber-reinforced composites are usually designed to gain a material with a high specific
strength and/or a high specific modulus. / 1 Mark
ii. Factors influencing properties of engineering composites are:
o The properties of the two phases /0.5mark

o The characteristics of the reinforcement phase (concentration, size, shape,

distribution, orientation) and /0.5mark

o The properties of the interface (bonding) between the matrix and the
reinforcement phases. /0.5mark

iii. The general characteristics of Polymer-Matrix Composites (PMCs) are:

 The most common type of composite /0.5mark

 Large number of applications /0.5mark

 Good properties /0.5mark

 Easy and cheap to manufacture /0.5mark

 Most commonly have a fibre reinforcement phase /0.5mark

c) Define a difference between cermets and Portland cement concrete (4 Marks)

Answer: (4 Marks)
 Cermets are composites of ceramic particles (strong, brittle) in a metal matrix (soft,
ductile) that enhances toughness. / 2 Marks
 Portland Cement Concrete - The ingredients for this concrete are portland cement, a fine
aggregate (sand), a coarse aggregate (gravel), and water. / 2 Marks

End!