exam-2-may-2017-questions-and-answers

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Studocu is not sponsored or endorsed by any college or university Exam 2 May 2017, questions and answers Chemistry and Material Science (University of Technology Sydney) Studocu is not sponsored or endorsed by any college or university Exam 2 May 2017, questions and answers Chemistry and Material Science (University of Technology Sydney) Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
A. Mechanical properties The following five questions may be answered by reference to the table below. Material E, GPa Yield Strength, MPa UTS, MPa Copper 110 248 289 Al alloy 70 255 420 Steel 207 448 551 Brass alloy 101 345 420 1. A cylindrical rod with a length of 380 mm and a diameter of 10 mm is to be subjected to a tensile load of 24.5 kN. What is the cross-sectional area of this rod at zero load? A. 7.85 mm 2 B. 31.4 mm 2 C. 78.54 mm 2 D. 202.7 mm 2 E. 314.2 mm 2 2. What is the engineering stress in the rod once the above tensile load has been applied? A. 77.97 MPa B. 202.7 MPa C. 311.9 MPa D. 780.2 MPa E. 3121 MPa 3. If the rod is not to experience plastic deformation, which of the following are possible candidates? A. Al alloy B. steel C. brass alloy D. steel and brass alloy E. Al alloy, steel and brass alloy 4. Assume the most conservative case, i.e steel. What is the elastic strain in the rod (absolute units, not %) at the tensile load mentioned? Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
A. 1.51× 10 -4 B. 1.51 10 -3 C. 1.51 10 -2 D. 1.51 10 -1 E. 1.51 5. If, in addition, the rod cannot increase in length by more than 1.2 mm, what material/s would be suitable? A. copper B. Al alloy C. steel D. brass E. steel or brass Given the tensile stress-strain diagram below, answer the following questions. 6. The stiffness E, for the material is A. 85 GPa B. 190 GPa C. 80 GPa D. 96 GPa E. 75 GPa 7. The 0.2% offset proof stress is A. 600 MPa B. 900 MPa C. 795 MPa D. 1160 MPa E. 1260 MPa Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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B. Polymers 8. Crosslinks between chains in an elastomer have the effect of A. resisting permanent creep under load B. reducing the elastic modulus C. increasing crystallinity D. preventing oxidation E. making the polymer very soft 9. In a thermoplastic polymer, adjacent molecules are bonded by A. primary bonds B. secondary bonds C. covalent bonds D. ionic bonds E. crystalline bonds 10. In a thermoplastic polymer, side groups are bonded to the backbone by A. primary bonds B. secondary bonds C. covalent bonds D. ionic bonds E. crystalline bonds 11. The effect of addition of plasticiser to a thermoplastic is to A. increase the melting point B. reduce the glass transition temperature C. reduce the rate of chemical crosslinking D. increase the molecular weight Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
E. make it transparent Using the data in this table, answer the following questions Polymer T g C UTS MPa @ 25 Impact Strength J @ 25 % elongation at fracture @ 25 A -40 15 33 500 B 120 48 1 1 C 55 60 2 - D - 35 2 2 12. Which of the polymers in the table are thermoplastics? A. A, B, C, D B. A, B, D C. D D. C E. A, B, C 13. You are required to choose one of these polymers to act as a seal on an air conditioning duct that will experience temperatures as low as 5 C. Which material would you choose? A. A B. B C. C D. D E. A or D 14. You are required to choose a polymer that has a low impact strength to act as a safety pin that will fail before damage to a piece of equipment occurs. You are also required to use a polymer that could be recycled easily. Which polymer would you use? A. A or D B. B C. C D. B or C Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
C. Corrosion 15. In order for an oxide coating to be protective: A. The Pilling-Bedworth ratio must be significantly less than 1 B. The Pilling-Bedworth ratio must be approximately equal to 1 C. The Pilling-Bedworth ratio must be significantly greater than 1 D. The Pilling-Bedworth ratio does not affect the protectiveness of the coating E. The square of the Pilling-Bedworth ratio must be an imaginary number 16. When two dissimilar metals are placed in electrical contact, the type of corrosion that can occur is: A. Intergranular Corrosion B. Pitting C. Crevice Corrosion D. Galvanic Corrosion E. Stress-corrosion cracking 17. The relative sizes of the anode and cathode are important in determining the rate of corrosion. The most correct statement of the four given below is A. Small anode/large cathode produces fast corrosion rates B. Large anode/small cathode produces fast corrosion rates C. Small anode/large cathode produces slow corrosion rates D. Anodes and cathodes of the same size produce no corrosion 18. Which of the following designs would least encourage corrosion: Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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B 19. A steel bolt is undergoing uniform corrosion in a marine splash environment. The reaction that best represents the corrosion overall is: A. 4 Fe+ 3O₂ + 6 H₂O → 4 Fe(OH)₃ B. 2Fe(s) 2Fe 2+ (aq) + 4e - C. 4Fe + 3O 2 2Fe 2 O 3 D. 2Fe + 3O 2 Fe 2 O 3 E. Fe(s) + O 2 (g) + H 2 O(l) Fe(OH) 2 20. This 316 stainless steel pole and flange has been attached to the flooring surface using 316 stainless steel screws. Corrosion is evident. This type of corrosion and a remedy for it is: A. Galvanic corrosion, remove the corrosion product and replace the screws with brass ones B. Galvanic corrosion, remove the corrosion product and insulate the screws from the flange C. Crevice corrosion, remove the corrosion product and seal the crevices with an appropriate sealant D. Crevice corrosion, remove the corrosion product and insulate the screws from the flange E. Intergranular corrosion resulting from the weld, clean up the corrosion and heat treat the fixture. Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
D. Composites 21. It is desired to produce a continuous and oriented carbon fibre reinforced epoxy composite having an E of at least 83 GPa in the direction of fibre alignment. What volume fraction of fibres is required? Given, E for the fibres is 260 GPa and E for the epoxy is 2.4 GPa. A. 0.2 B. 0.31 C. 0.51 D. 0.6 E. 0.88 The following table may be used to answer the next three questions. A continuous/aligned fibre-reinforced composite is to be produced consisting of 40% volume aramid fibres and 60% volume polycarbonate. The mechanical properties of the two materials are given as follows: E (GPa) UTS (MPa) Aramid Fibre 131 3600 Polycarbonate 2.4 80 22. What is the longitudinal stiffness of the composite? A. 80 GPa B. 54 GPa C. 131 GPa D. 23 GPa E. 6 GPa 23. What is the lateral stiffness of the composite? A. 80 GPa B. 54 GPa C. 131 GPa D. 6 GPa E. 4 GPa Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
24. For the above composite, what would the stiffness be, if the same volume of fibres were used, however they were in the form of a chopped strand mat? A. 30 GPa B. 21 GPa C. 53 GPa D. 79 GPa 25. Calculate the density of a Kevlar fibre-reinforced epoxy composite, if the volume percent of fibres is 82%. The density of Kevlar is 1.44 Mg/m 3 and that of epoxy is 1.1 Mg/m 3 . A. 1.38 Mg/m 3 B. 1.16 Mg/m 3 C. 1.44 Mg/m 3 D. 1.56 Mg/m 3 E. 1.03 Mg/m 3 26. In a commercial aircraft, a total of 0.25m 3 of its exterior surface is constructed of this Kevlar/epoxy composite (from theprevious question) rather than the conventional aluminium alloy. Calculate the mass savings using the density calculated in the previous question and approximating the alloy density to that of pure aluminium, 2.7 Mg/m 3 . A. 660kg B. 345kg C. 330kg D. 290kg E. 370kg E. Cement and concrete 27. In civil engineering, the term ‘cement’ applies to A. a mixture of lime with sand, gravel and stone chips B. a finely ground mixture of calcium sulphate C. partially fused lumps made by heating limestone (CaCO 3 ) and approved minerals containing SiO 2 to 1450°C D. finely powdered CaO Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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E. A crystalline mixture of finely ground calcium silicates and other calcium compounds having hydraulic properties 28. The manufacture of cement is responsible for what proportion of human emissions of CO 2 ? A. a negligible amount B. 0.2% C. 5% D. about half E. 90% 29. Concrete continues to harden for months after setting A. True B. False 30. The compressive strength, shrinkage and permeability of concrete depends on: A. water-to-cement ratio B. cement type C. temperature of the environment D. size distribution of aggregates added E. all of the above F. Ceramics 31. The mean fracture strength of a batch of alumina components is measured to be 400 MPa. What size of defects would you expect to find in the material? (Take the fracture toughness of alumina to be 4 MPam ½ and Y to be 1.8, see Appendix for fracture toughness equation). A. 9.8 µm B. 0.98 mm Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
C. Cannot be calculated with the given data D. 3.14 µm 32. These defects would more than likely be A. Dislocations B. Porosity C. Large grains D. Grain boundaries E. B and/or C 33. Sintering is the consolidation of a powder at an elevated temperature that is below the melting point of any major phase A. true B. false 34. Ceramics, in general, are ____________than metallic materials A. More ductile B. More electrically conductive C. Tougher D. Harder E. Softer Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
35. Ceramics are generally much more brittle than metallic alloys because A. the ionic and covalent bonds of ceramics are much weaker than the metallic bond B. unlike most metals, their dislocations cannot move easily C. they have a high fracture toughness compared to metals D. their Young ’s moduli are very low compared to metals E. they have very high melting points 36. The term ‘green’ is used during the processing of ceramics to denote A. a reject item that has failed to meet basic quality control standards B. an item that has sprayed with green paint C. an item that is completed and ready for final application D. shapes that have re-entrant cavities E. a cold-pressed shape that has not yet been sintered 37. The special feature shared by refractories (e.g. MgO) and refractory elements (e.g. W) is A. their very high melting points B. their high electrical conductivity C. their resistance to corrosion D. that they are cheap E. they are most suitable for use at cryogenic (very low) temperatures G. Alloy phase diagrams The following questions refer to the Sn (tin) Pb (lead) phase diagram given below. Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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38. For an alloy of composition 25 wt . % Pb balance Sn , estimate the phase(s) present at 2 2 0°C. A. 75% phase, 25% phase B. 75% phase, 25% phase C. 39% phase and 61% liquid phase D. 61% liquid phase and 39% phase E. liquid 39. For an alloy of composition 25 wt.% Pb balance Sn, estimate the phase(s) present at a temperature just above the eutectic temperature. A. 75% phase, 25% phase Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
B. 75% phase, 25% phase C. 39% phase and 61% liquid phase D. 61% liquid phase and 39% phase E. liquid 40. For an alloy of composition 25 wt.% Pb balance Sn, estimate the phase(s) present at room temperature under equibrium conditions A. 75% phase, 25% phase B. 75% phase, 25% phase C. 39% phase and 61% liquid phase D 61% liquid phase and 39% phase E. liquid 41. Which of the following statements is correct? The first material to form from a melt of 25 wt% Pb- balance Sn is A. rich in Pb because Pb has a higher melting point than Sn B. rich in Sn because Sn has a higher melting point than Pb C. rich in Sn because the melt composition contains Sn D. rich in Sn because this composition lies on the Sn-rich side of the eutectic point E. rich in Pb because this composition lies on the Pb-rich side of the eutectic point 42. Consider a 75 wt.% Pb -25 wt.% Sn alloy held at 200 °C. The phases present under equilibrium conditions will be found to be A. = 17 wt% Sn - 83 wt% Pb; L = 55.7 wt% Pb - 44.3 wt% Sn B. L = 25 wt% Sn - 75 wt% Pb; = 25 wt% Sn - 75 wt% Pb C = 17 wt% Sn - 83 wt% Pb; = 55.7 wt% Sn - 44.3 wt% Pb D. = 18.3 wt% Sn - 81.7 wt% Pb; = 97.8 wt% Sn - 2.2 wt% Pb Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
E. = 17 wt% Sn - 83 wt% Pb; L = 55.7 wt% Sn - 44.3 wt% Pb 43. For the same alloy, what would the microstructure consist of at 1 50°C (under equilibrium conditions) ? A. 85% -15% B. 85% -15% C. martensite D. eutectoid E. bainite 44. The liquidus temperature of this alloy is approximately A. 327 °C B. 183 °C C. 2 63°C D. 200 °C E. 232 °C 45. The special composition of 61.9 wt% Sn, balance Pb is known as A. pearlite B. the eutectic composition C. the eutectoid composition D. cementite E. alpha phase 46. The maximum solubility of Sn (wt.%) in solid Pb at any temperature is about A. none B. 2 or 3% Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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C. 18 or 19% D. 62% E. close to 82 or 82 % 47. A eutectoid reaction involves which of the following phases? A. One liquid and one solid B. One liquid and two solid C. Two liquids and one solid D. Three solid s E. Three liquids H. Iron and steel 48. The amount of steel that is currently being annually produced worldwide is about A. 1.5x10 7 tons B. 1.5x10 8 tons C. 1.5x10 9 tons D. 1.5x10 10 tons E. 1.5x10 11 tons The iron (Fe)- carbon (C) phase below w ill be used diagram provided for the following eleven questions. Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
49. The eutectic point is indicated by the symbol A. A B. B C. C D. D E. E 50. The eutectoid point is indicated by the symbol A. A B. B C. C D. D E. E Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
51. The austenite phase field is indicated by the symbol A. A B. B C. C D. D E. E 52. The liquid phase is indicated by the symbol A. A B. B C. C D. D E. E 53. In the Fe-C system, the maximum solubility of C in austenite (at any temperature) is A. 0.02 wt% C B. 0.80 wt% C C. 1.68 wt% C D. 4.3 wt% C E. 6.7 wt% C 54. On being slowly cooled below 727 °C, an alloy of composition C will transform to A. ledeburite B. austenite C. cementite D. pearlite Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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E. martensite 55. On being cooled rapidly from 727 °C to room temperature (as by being quenched in a bucket of water), an alloy of composition C will transform to A. ledeburite B. austenite C. cementite D. pearlite E. martensite 56. The constituent ‘pearlite’ is actually a A. fine two-phase mixture of ferrite and cementite sheets B. a distinct phase containing about 6.7 wt.% C C. a face centred cubic form of iron D. body centred tetragonal form of iron E. a mixture of ferrite and austenite 57. Iron carbon alloys containing more than 0.8% C are generally A. very hard B. quite brittle C. very difficult to weld D. used for tooling such as dies, presses, cutters etc. E. all of the above 58. The plain Fe-C alloy containing about 0.07 to 0.09 wt% C is also colloquially known as A. cast iron B. carbon steel C. HSLA steel Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
D. mild steel E. 1040 steel The following five questions refer to the time-temperature-transformation diagram given below for a steel of American designation "1080". This diagram is of the isothermal kind, ie. read horizontally 59. A sample of this steel is heated to 800ºC and then quenched in molten salt to 650ºC and held at that temperature for 2 seconds. It is then instantaneously examined at that temperature by some kind of high temperature microscope. At that moment the microstructure of the steel consists of A. austenite B. austenite with 40% pearlite C. all pearlite D. martensite E. bainite 60. The experiment described above is repeated, except that now the sample is instantaneously examined 10 seconds after quenching to 650ºC. It will now be found to consist of Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
A. only austenite B. austenite with about 40% pearlite C. all pearlite D. mostly ferrite E. bainite 61. A fresh sample of steel is heated to 800ºC. It is quenched to 650ºC again and then held at that temperature for 1000 seconds. After that it is quenched into ice water and examined. It will be found to consist of A. a mixture of martensite and ferrite B. austenite with 40% pearlite C. all pearlite D. a mixture ferrite and pearlite E. spheroidite 62. A fresh sample of steel is heated to 800ºC, quenched in molten salt to 400ºC and then held at that temperature for 300 seconds. It is then quenched in ice water and examined. It will be found to consist of A. austenite B. ferrite C. pearlite D. martensite E. bainite 63. The horizontal line marked M s denotes A. the temperature of the quenching salt B. the temperature at which the metal melts C. the temperature at which martensite starts to form D. the maximum amount of vanadium that can dissolve in the steel E. the maximum temperature at which spheroidite can be stable I. Non-ferrous alloys and precipitation hardening Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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The following six questions may be answered with the help of the relevant portion of the Cu-Al binary phase diagram provided below. 64. Which phase in this system is the most promising-looking candidate for being a precipitation- hardenable matrix ? A. (Al) B. C. L D. the eutectic E. no phase 65. Following on from the previous question, the phase that is precipitated within the matrix will be A. (Al) B. C. L Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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D. the eutectic E. no phase 66. The composition of the Al- eutectic is A. 12.5 wt.% Cu B. 32.5 wt.% Cu C. 52.5 wt.% Cu D. 82.5 wt% Cu 67. The amount of Cu that can dissolve in Al at 500°C is about A. 0.5 wt.% B. 2 wt.% C. 4 wt.% D. 8 wt.% E. 98 wt.% 68. To what temperature should an alloy with 97%Al-3%Cu be heated in order to bring all precipitates into solution in preparation for precipitation hardening? A. around 450 to 550°C B. around 650 to 750 °C C. around 850 to 950 °C D. around 1050 °C E. at least 1250 °C 69. If we wish to subsequently precipitation-harden such an alloy then we will need to A. !! trick question !! - this composition cannot be precipitation hardened B. slow cool it back to room temperature only C. quench it to room temperature only Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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D. slow cool it back to room temperature then age it between 100 and 300°C E. quench it from the solution annealing temperature then age it between 100 and 300°C J. Metal processing 70. In the reaction a Fe 2 O 3 + b CO= c Fe+ d CO 2 , the coefficients a , b , c and d are respectively A. 3, 2, 1, 3 B. 2, 1, 3, 2 C. 1, 2, 2, 3 D. 2, 6, 4, 6 E. 1, 3, 2, 3 71. Aluminium metal is extracted commercially from its ore by ? A. reduction with hydrogen B. electrolysis of a molten salt bath using carbon anodes C. carbothermic reduction in a blast furnace D. reduction with a more active metal, such as magnesium E. electron beam evaporation 72. The forming process described in the diagram below is called ? A. rolling B. forging C. drawing D. extrusion E. casting 73. The increase in hardness that occurs during cold work of a metal alloy is accompanied by A. a decrease in strength A o A d force die blank force Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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B. a decrease in ductile-to-brittle transition temperature C. a big change in Youngs modulus D. a decrease in ductility E. an increase in toughness 74. The term ‘investment’ casting refers to? A. casting of metals for long-term financial gain B. casting of metal into a sand mould C. casting of aluminium into a steel mould D. continuous casting of steel E. casting of metals into a ceramic mould that was usually made by the lost wax process K. Welding and joining 75. The key difference between ‘brazing’ and ‘welding’ is that A. in brazing only steel fillers are used B. welding is only carried out with an electric arc C. brazing is generally stronger than welding D. welding is used for ships, brazing for bridges E. the work piece should never melt during brazing The following schematic diagram will be used to identify the important parts of a weld made by fusion welding. The next five questions refer to this diagram. Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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76. The hatched region denoted A is/was A. the weld metal or fusion zone B. the heat affected zone C. parent plate D. previously parent plate but has been melted into the weld metal E. a friction weld 77. The region denoted B and indicated with little crosses is/was A. the weld metal or fusion zone B. the heat affected zone C. parent plate D. previously parent plate but has been melted into the weld metal E. a friction weld 78. The region marked C is/was A. the weld metal or fusion zone B. the heat affected zone C. parent plate D. previously parent plate but has been melted into the weld metal E. a friction weld 79. The region marked D is/was A. the weld metal or fusion zone B. the heat affected zone C. parent plate D. previously parent plate but has been melted into the weld metal Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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E. a friction weld 80. The type of weld shown is known as a A. fillet weld B. butt weld C. V weld D. lap weld E. edge weld The End ! Please turn page over for some equations Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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Appendix Stiffness of chopped fiber composites: E=kE f V f +E m V m 2D random, k = 0.325 3D random, k = 0.2 Fracture toughness equation: K c =Y.  ( a ) Avogadro’s Number = 6.023 x 10 23 Downloaded by Julia Asfar (juliaasfar0@gmail.com) lOMoARcPSD|12214066
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