Cover Type B

TO BE RETURNED AT THE END OF THE EXAMINATION.

THIS PAPER MUST NOT BE REMOVED FROM THE EXAM CENTRE.

SURNAME: _______________________

FIRST NAME: _______________________

STUDENT NUMBER: _______________________

COURSE: _______________________
_________________________________________________________

AUTUMN SEMESTER, 2003

60101
CHEMISTRY AND MATERIALS SCIENCE

MONDAY 16 JUNE, 2003

9.30 A.M. – 12.40 P.M.
TIME ALLOWED: 3 HOURS PLUS 10 MINUTES READING

PART A TO BE ANSWERED ON THE UNISCAN ANSWER SHEET

PROVIDED
PART B TO BE ANSWERED ON THIS EXAM PAPER

CALCULATORS MAY BE USED

 PART A
ANSWER THE FOLLOWING QUESTIONS ON THE MULTIPLE CHOICE
ANSWER SHEET PROVIDED

1. Ceramics are:
a) Predominantly covalently bonded organic materials.
b) Ionic and covalently bonded composites.
c) Non-ferrous and amorphous metals.
d) Ionic and/or covalently bonded inorganic materials.
e) Amorphous organic materials.
2. The fracture strength of ceramics are influenced by:
a) Corrosion resistance.
b) Colour.
c) Surface and volume defects.
d) Yield strength.
e) Organic additives.
3. Slip casting of clay products are carried out:
a) mixing the powder with water then pouring into a mould
b) pressing the powder with water within a mould
c) pressing the powder without water
d) extruding with water through a die
e) under high vacuum (10-5 torr) and high temperatures
(20000C)
4. Solid state sintering is accelerated with
a) large size particles
b) small size particles
c) mixed particles
d) at lower temperatures
e) all-of-the above
5. The most widely used production method for advanced ceramics is:
a) cold pressing
b) hot pressing
c) slip casting
d) extrusion
e) tape casting

1
6. What is one of the hard reasons for a new suitcase design?
a) wrong colour
b) structural integrity
c) economics
d) wrong materials
e) all of the above

7. Annealing of cold worked steels requires

a) austenitizing followed by slow cooling
b) austenitizing followed by air cooling
c) austenitizing followed by quenching
d) heating below the lower critical temperature and slow
cooling
e) heating below the lower critical temperature and fast
cooling

Partial GALVANIC Series in seawater is given as:

cathodic anodic
Gold Stainless Copper Stainless Steel Aluminium Galvanised Magnesium

Passive Active Steel

8. When a metallic coating is scratched the corrosion rate of the underlying

metal is unaffected for the system
a) galvanised iron
b) tin plated steel
c) gold plated steel
d) nickel plated steel
e) chrome plated steel

2
9. A cathodic metal and anodic metal plate are riveted together. Which
part of the joint would you paint if it is used to reduce galvanic
corrosion and minimising cost is important?
a) the anodic metal plate.
b) the cathodic metal plate
c) only the rivet
d) the anodic and the cathodic metal plates
e) two of the above

10. A ductile tough polymer is

(a) a crystalline thermoplastic.
(b) an amorphous thermoplastic
(c) a thermoset.
(d) an exception.
(e) all of the above.

11. An elastomer
(a) displays Hookian elasticity.
(b) is hard and brittle.
(c) is ductile and tough.
(d) is soft and ductile.
(e) is rubbery and brittle.

12. Which of the following is most correct for thermosets?

(a) Thermosets show Hookian elasticity.
(b) Thermosets are brittle due to 3D covalent bonding
(c) Thermosets are hard due to 3D covalent bonding.
(d) Thermosets do not plastically deform.
(e) Thermosets display all of the above.

3
13. A 1060 steel is exposed to the environment except for a few spatters
of paint. After a period of time, the exposed portion of the steel is
slightly rusted and corrosion pits are observed under the paint
spatters. The exposed portion has corroded due to:
a) Galvanic corrosion.
b) Erosion corrosion.
c) Differential aeration.
d) Uniform corrosion.
e) Stress corrosion cracking.

14. A monomer is
(a) the repeating unit in a polymer.
(b) the reactant that a polymer is synthesised from
(c) unreactive as it is not functional
(d) the mer structure of the polymer.
(e) all of the above

15. Tg is the point at which

(a) On cooling the polymer softens
(b) On cooling the polymer becomes brittle
(c) On heating the polymer becomes brittle
(d) On heating the polymer melts
(e) On heating the polymer loses its crosslinks

16. The property that defines a thermoplastic is

(a) It is soft and flexible at all temperatures
(b) It is hard and brittle at all temperatures
(c) It softens on heating
(d) It softens on cooling
(e) It hardens on heating

17. This is because:

(a) There are strong crosslinks between the chains
(b) There are only secondary bonds between the chains
(c) There is partial crosslinking between the chains
(d) They have a very low moleculare weight
(e) They have a very high molecular weight

4
18. The property that distinguishes thermosets is that
(a) It is soft and flexible at all temperatures
(b) It is hard and rigid at all temperatures
(c) It softens on heating
(d) It softens on cooling
(e) It hardens on heating

19. This is because:

(a) There are strong crosslinks between the chains
(b) There are only secondary bonds between the chains
(c) There is partial crosslinking between the chains
(d) They have a very low moleculare weight
(e) They have a very high molecular weight

20. Vulcanisation is:

(a) An operation where your ears are made pointy and your skin
green (live long and prosper!)
(b) Cross-linking rubber with sulphur to increase strength and
stiffness
(c) Cross-linking with sulphur to reduce stiffness and strength
(d) Adding sulphur as side groups to increase stiffness and
strength
(e) Adding Cl as side groups to increase stiffness and strength

5
Borsic reinforced aluminium containing 40vol% fibres is an important high
temperature, lightweight composite material. Given:
Material E Tensile
GPa Strength
MPa
Fibres 379 2760
Aluminium 69 35
Assuming a unidirectional composite, estimate the following using the rule of
mixtures

Ec = EmVm + E pV p
Em E p
Ec =
Vm E p + V p Em

21. The stiffness of the composite in the fibre direction is:

(a) 379GPa
(b) 102GPa
(c) 193GPa
(d) 255GPa
(e) 152GPa

22. The stiffness of the composite perpendicular to the fibre direction

is:
(a) 152GPa
(b) 379GPa
(c) 102GPa
(d) 193GPa
(e) 255GPa
(f) 152GPa

6
23. In order to make stiff, strong composites
(a) There should be good bonding between the fibres and the
matrix
(b) There should be poor bonding between the fibres and the
matrix
(c) Very short fibres should be used
(d) A stiff matrix should be used
(e) Weak fibres should be used

24. This because

(a) Poor bonding means that the fibres take the load and the
matrix won’t fail
(b) Strong bonding means that most of the load is transferred to
the fibres which are stiffer and stronger
(c) Short fibres are more efficient at load transfer
(d) A stiff matrix allows for decreased load transfer to fibres
(e) Weak fibres allow the matrix to take most of the load

25. Composites can be characterised by

(a) by the type of matrix
(b) by the morphology of the reinforcement
(c) by the orientation of the reinforcement
(d) all of the above
(e) only by the matrix material

26. In order to make tough composites

(a) there should be good bonding between the fibre and the matrix
(b) long fibres should be used
(c) ductile fibres should be used
(d) there should be poor bonding between the fibres and the matrix
(e) a very stiff interface between fibre and matrix should be used

7
27. This is because
(a) good bonding allows good stress transfer so ductile fibres are
useful here
(b) poor bonding allows fibre pullout, an energy absorbing process
(c) long fibres can stretch further
(d) a stiff interface provides an energy “sink”
(e) good bonding allows for energy absorption when the interface
eventually fails

28. A colleague wants to calculate the tensile strength of a composite

using the Rule of Mixtures. She is aware that you are a dynamic
materials scientist and comes seeking advice. You tell her:
(a) Today is not a good day, Mars is in Aquarius
(b) Go ahead it gives a good indication of strength
(c) Ooh, not a good idea, strength is microstructure sensitive and
the rule does not take microstructure into account
(d) Use it, but increase the matrix strength by 20%
(e) Don’t know, I slept through the lecture on that

29. Why are ceramic matrix composites made?

(a) To improve the strength of the ceramic
(b) To improve the stiffness of the ceramic
(c) To improve the toughness of the ceramic
(d) To improve the electrical conductivity of the ceramic
(e) All of the above

30. Why are metal matrix composites made?

(a) To increase the stiffness of the metal
(b) To increase the strength of the metal
(c) To control thermal expansion properties
(d) To control electrical properties
(e) All of the above
31. The boundary between solid α and solid α + β is known as:
(a) the liquidus.
(b) the solidus.
(c) the eutectus.
(d) the peritectus
(e) the solvus

8
32. Which of the following is false?
(a) The phase diagram may be used to determine the composition of
each phase at a particular temperature.
(b) The phase diagram may be used to determine the composition of
each micro-constituent at a particular temperature.
(c) The phase diagram may be used to determine the composition of
each phase for non-equilibrium cooling conditions.
(d) The phase diagram is indicative of the phases produced in non-
equilibrium conditions.
(e) In non-equilibrium cooling, a non-equilibrium solidus is required to
determine the compositions of each phase.

33. Which of these alloying elements would be expected to give the

largest increase in tensile strength when a 1 at% alloy with aluminium
is prepared?

Al Li Ba Be Cd Ga
Atomic Radius 0.1432 0.1519 0.2176 0.1143 0.1490 0.1218
(nm)
Crystal structure FCC BCC BCC HCP HCP Ortho
Valance +3 +1 +2 +2 +2 +3
Electronegativity +1.61 +2.95 2.90 +1.70 +0.40 +0.52

(a) Li
(b) Ba
(c) Be
(d) Cd
(e) Ga

9
34. The 40% Ag alloy has been cooled to room temperature. Which of
the following most closely represents the origins of each phase
constituent.

(a) α and β formed by direct precipitation from the liquid melt.

(b) Primary β and secondary α formed by nucleation.
(c) Primary β, eutectic α and β, and secondary and tertiary α and β.
(d) Primary β, eutectic α and β, precipitate α from eutectic β,
precipitate β from primary α and eutectic α
(e) Primary β, eutectic α and β, and secondary α and β precipitates.

35. The "eutectic" microstructure looks like:

(a) β precipitates evenly dispersed in an α matrix
(b) α precipitates evenly dispersed in a β matrix
(c) alternating layers of α and β
(d) separate grains of α and β
(e) β lining the grain boundaries

10
 PART B

QUESTION B1 Given the Fe­C phase diagram below, answer the following
questions

100% Fe3C @ 6.37%C

11
 (i) What phases are present at Point a?
γ - austenite

(ii) What phases are present at Point b?

α + Fe3C

(iii) What is/are the composition/s of the phase/s present at Point

b?
See construction on diagram
Where the ends of the tieline cross into the next phase field, give the
compositions of the phases present.
So for ferrite (α) this gives a composition of 0.07%C
And for the cementite (Fe3C) it will be 6.67%C

(iv) What is/are the relative amount/s of the phase/s are present
at Point b?
The relative amounts are found using the lever rule. At 0.8%C there will be
more ferrite than cementite as we are closer to the 100% ferrite region
(0.07%C) than we are to the 100% cementite region (6.67%C). The
compositions from part (iii) gives us the total length of the tieline and either
side of the 0.8%C give us the two sides of the lever. So for the amount of
ferrite we take the largest side of the lever which is the right hand side.
Thus:
6.67 − 0.8 5.87
%α = × 100 = × 100 = 88.9%
6.67 − 0.07 6.6
The amount of cementite will be 100-88.9 or 11.1% but I strongly suggest
you do the lever rule calculation again for this left hand side as confirmation
of the answer you get for the right hand side

12
 (v) Two micrographs, one of the alloy at point b & another of a
0.4%C steel. Label the phases & microconstituents on both
micrographs

ferrite

ferrite

Pearlite
(α+Fe3C)
Pearlite
(α+Fe3C)

alloy:0.4%C alloy:point b (0.8%C)

(vi) Show by calculation (i.e. the lever rule) which micrograph

belongs to which alloy.
For a 0.4%C alloy we need to work out the relative amounts of the
microconstituents present. Again we need to use the Lever Rule. This time
we are interested in the amount of proeutectoid ferrite and pearlite, so the
Tie Line is drawn from the 100% regions of ferrite and pearlite, i.e. from
0.07%C to 0.8%C (see the blue line on the Fe-C diagram). Thus the lever rule
calculation will be:
0.4 − 0.07 0.33
% pearlite = × 100 = × 100 = 45%
0.8 − 0.07 0.73
The amount of proeutectoid ferrite will be 100-45 = 55%, but again do the
calculation as a check. If you consider that we are closer to the feriite rgion
than the 100% pearlite line (just!!) then you can work out why I took the left
hand side of the lever for the amount of pearlite.

13
 (vii) Alloy b is heated up to Point a, held there for 1 hour then
quenched into water. How would the hardness and impact
strength differ from that of the alloy shown in the micrograph
shown above?
This is austenitising followed by quenching. The austenitising (heating up to
point a) dissolves all the carbon. On quenching there is no time for diffusion
and the excess C is trapped causing distortion in the lattice. Dislocation
motion is thus hindered and hardness would increase but impact strength
would decrease (the steel has become more brittle)

(viii) For this quenched alloy, circle the microstructure below would
you expect to observe? What is this microstructure called?

Martensite

14
NAME: 162.5kN

250
200
Load (kN)

150
100
50
0
50 51 52 53 54
Gauge Length (mm)

QUESTION B2
For the load-extension curve provided calculate the following, given that the
specimen tested had a diameter of 25mm.
(i) the 0.2% proof stress ANSWER:331MPa
Working:
0.2% proof stress is the stress required to cause 0.2% (or 0.002) permanent strain.
First find what 0.002 strain is based on the gauge length of the sample:
0.002 X 50 = 0.1mm
Next draw a line parallel to the straight line, initial part of the curve from 0.1mm
and read off the stress where it crosses the tensile curve. In this case you will
read of the force, YOU MUST THEN CONVERT IT TO STRESS by dividing by the
cross sectional area (it does say PROOF STRESS):
CSA = πr2 = π(12.5)2 = 490.9mm2
0.2% proof stress = 162500N/490.9 mm2 = 331MPa
NOTE: use N not the kN on the scale

15
(ii) the tensile strength ANSWER:469MPa
Working:
Tensile strength is the maximum stress achieved, calculated form the maximum
load on the stress-strain curve divided by the original cross-sectional area:
230,000
= 469MPa
490.9
Note that again kN must be made into N and don’t quote the number the calculator
gives you to umpteen decimal places, such as 468.5272MPa and include the units in
your answer.

(iii) the Modulus of Elasticity ANSWER:93GPa

Working:
This is the slope of the initial part of the curve in terms of stress and strain.
σ
E=
ε
Thus if we take 2 points, say the 150kN and 50kN points we need to work out the
appropriate stress and strain at those points
Load N Stress MPa Extension mm Strain*
150,000 306 0.18 3.6 x 10-3
50,000 102 0.07 1.4 x 10-3
* extension/gauge length

thus the slope is:

306 − 102 204
−3 −3
= −3
= 92.8 x10 3 MPa = 93GPa
3.6 x10 − 1.4 x10 2.2 x10
Again, make sure your units are correct and think about the number you get, 93GPa,
this is ion the right range (40 to say 200 GPa) for a metal.

(iv) % elongation at fracture ANSWER:6.3%

Working:
This is percentage increase in the gauge length after fracture. Draw a line, parallel
to the initial part of the curve, down from the fracture point on the diagram (blue
line on the graph) and read of the final gauge length. This line is drawn as when the
specimen breaks there will be elastic recovery. A vertical line would represent the
plastic and elastic deformation. Remember this is a measure of ductility, so we are
interested in the amount of plastic deformation.
53.14 − 50
× 100 = 0.063 × 100 = 6.3%
50

16
QUESTION B3

(i) What mechanism accounts for the lower than theoretical strength
measured strength of metals and their plastic deformation?
The movement of dislocations. Less force is required to break the bonds at
dislocations than to break all the bonds along a plane at one time

(ii) Relate this mechanism to two strengthening techniques used on metals

detailing the theory behind them.
To strengthen metals you need to hinder dislocation movement. Answers
could include
1. grain size hardening where grain boundaries hinder dislocation
movement, thus the closer the grain boundaries (i.e. the smaller
the grains) the less distance the dislocations can move.
2. Work hardening where extra dislocations are generated that must
interact with each other, resulting in an increase in shear force
necessary to keep them moving
3. precipitation hardening where a fine dispersion of precipitates
cause distortion in the lattice resulting in higher shear stresses
needed for dislocations to pass them by.
4. alloying, where atoms of different size form either substitutional
or interstitial impurities resulting in distortion in the lattice and
again an increase in shear stress necessary for dislocations to get
past.

17
(iii) What mechanism accounts for deformation in polymers?
For polymers it is the uncoiling and sliding past each other of the chains

(iv) There are a number of ways in which this mechanism can be

hindered. What is the result of this hindering to the mechanical
properties of the polymer? Describe two ways in which materials
scientists can do this relating these ways to the polymer
microstructure.
By hindering interchain mevemnet we increase the stiffness and strength of
the polymer and the Tg. Again a number of ways are possible:
1. Adding large side groups or substituent groups to the polymer chain,
these interfere with groups on other chains
2. Increase crystallinity, here the secondary bonding between the chains
becomes more important, i.e. is stronger, thus more force is required
for inter-chain movement
3. Crosslink the polymer, here we place strong covalent bonds between
the chains

18
(v) Ceramics are generally strong but a brittle. List 4 reasons why and
explain their effect.
1. The covalent and ionic bonds mean dislocation movement is very
difficult (think why!!!)
2. Often there are limited slip planes, particularly in amorphous
materials, thus any slip is further restricted
3. As plastic deformation is limited, ceramics are subject to flaw
sensitivity, i.e. plastic deformation cannot occur at crack tips thus
crack growth is the only option

vi) What is sintering?

The bonding of adjacent surfaces of particles in a mass of powder or a
compact by heating. Sintering strengthens a powder mass and normally
produces densification and, in powdered metals, recrystallization. This
generally refers to sold state processes

vii) What is the driving force for densification?

The reduction in surface area ( and thus surface energy) of the material.
This is why fine powders sinter more easily, as they have greater surface
area and thus a larger driving force.

viii) Describe the mechanisms that take place.

19
Solid state diffusion between touching particles, volume diffusion, grain
boundary diffusion and surface diffusion all operate. Sintering is carried out
below the melting point.

20
QUESTION B4

a) Sketch typical curves of stress against strain obtained in tensile tests

of;

i) ductile metal;
ii) brittle ceramic;
iii) mild steel.

Label the regions which correspond to elastic and plastic strain, the
U.T.S., yield and ductility.

Brittle ceramic
UTS

elastic plastic Mild steel

Stress
Ductile metal

Yield

elastic plastic ductility

Strain

b) Sketch a typical creep curve and identify the various stages. How is
the rate of creep determined from the curve?

21
 primary
secondary
tertiary

fracture

strain

Slope= creep rate

Elastic
strain

time

22
(c) Determine the carburising time necessary to achieve a carbon
concentration of 0.30wt% at a position 4mm into an iron-carbon alloy
that initially contains 0.10wt% C. The surface concentration is to be
maintained at 0.90wt% C, and the treatment is to be conducted at
1100°C. You are given that:
D0 = 2.3 x10 −5 m 2 / s
Qd = 148kJ / mol
R = 8.13 Jmol − K

−Q  − 148,000 
D = D0 exp  D = 2.3 x10 −5 exp 
 RT   8 . 13 x1373 
D = 2.3 x10 −5 exp(− 13.2587 ) = 4.014 x10 −11 m 2 sec −1

C x − C0  x 
= 1 − erf  
C s − C0  2 Dt 

0.3 − 0.1  0.004   0.004 

= 1 − erf   0.25 = 1 − erf  
0.9 − 0.1 −11  −11 
 2 4.014 x10 t   2 4.014 x10 t 
 0.004   0.004 

0.75 = erf   
β = 
−11  , let −11 
 2 4.014 x10 t   2 4.014 x10 t 
thus
0.75 = erf (β )
from the erf table, β must be between 0.8 and 0.85 and can be calculated via this
method:

0.75 is 27% of the way between 0.7421 and 0.7071, therefore, b must be 27% of
the way between 0.8 and 0.85, i.e., 0.8135
 
 β = 0.8135 = 
0.004 315.68 
β = 0.8135 =  −11 

 2 4.014 x10 t   t 
t = 150,580 secs, or 41,8hrs

23
QUESTION B5
a) Describe the metallic bond. Explain how attraction and repulsion
combine to establish the bond.

b) Describe the bonding in ceramic structures and how it affects:

i) strength,
ii) toughness,
iii) conductivity and
iv) ductility.

24
c) Discuss three(3) defects which occur in crystalline solids. One must
be a point defect, one a line defect and one a surface defect.
point defect:

line defect:
edge dislocation

surface defect:
grain boundary

25
 e) Draw a FCC unit cell. Show on the sketch the (111) plane.
Why is it a close-packed plane?.

(111) plane
It is close packed because each atom is in
contact with 6 others

26
 DATA SHEET

C x − C0  x 
= 1 − erf  
C s − C0  2 Dt 

−Q
D = D0 exp 
 RT 

27