THIS PAPER MUST NOT BE REMOVED FROM THE

EXAMINATION ROOM

University of Technology,Sydney

SURNAME :____________________________

FIRST NAME :____________________________

STUDENT NO.:____________________________

COURSE :____________________________

_____________________________________________________________________________________________________

AUTUMN SEMESTER, 2004

60101
CHEMISTRY & MATERIALS SCIENCE

MONDAY 28 th JUNE, 2004

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

PART A TO BE ANSWERED ON THE ANSWER SHEET PROVIDED

PART B TO BE ANSWERED ON THIS EXAM PAPER

THIS PAPER IS DESIGNED TO BE COMPLETED IN 3 HOURS 10

MINUTES. AN EXTRA 10 MINUTES HAS BEEN ADDED TO THE TIME
ALLOWED AND IT IS RECOMMENDED THAT YOU USE THIS 10
MINUTES TO READ THE PAPER BEFORE COMMENCING TO ANSWER THE
QUESTIONS.

ALL QUESTIONS ARE TO BE ATTEMPTED.

CALCULATORS MAY BE USED

ANSWER QUESTIONS ON THE COMPUTER ANSWER SHEET PROVIDED

THIS QUESTION PAPER MUST NOT BE REMOVED FROM THE EXAMINATION

ROOM.
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ANSWER QUESTIONS ON THE COMPUTER ANSWER SHEET PROVIDED

IN MULTIPLE-CHOICE EACH QUESTION IS OF EQUAL VALUE

(1 MARK)

1. Ceramics are known to be more brittle than metals. This is mainly due to:

a) metals are cross- linked structures.

b) metallic structures are covalently bonded.
c) metallic structures have close packed planes.
d) ceramic materials are stiffer.
e) ceramics contain large grain boundaries.

2. Cold working results in:

a) increased ductility and increased hardness.

b) increased ductility and decreased hardness.
c) decreased ductility and increased hardness.
d) decreased ductility and decreased hardness.
e) decreased ductility and no effect on hardness.

3. The main aim of tempering martensite is to improve:

a) corrosion resistance.
b) colour.
c) strength.
d) hardness.
e) ductility.

4. The engineering stress is directly related to:

a) the yield stress.

b) applied force.
c) Young’s modulus.
d) deformation.
e) stress at fracture.

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5. Crosslinking in a polymer is:

a) an industrial cladding process.

b) atomic bonding where there is donation and acceptance of electrons.
c) linear chains bonded where atoms share electrons.
d) a weak secondary bond.
e) found in metals and accounts for their electrical conductivity.

6. Complete solid solubility in binary alloys partially is governed by:

a) the temperature.
b) rate of cooling.
c) atomic size.
d) vacancy defects.
e) Young's modulus.

7. Covalent and Ionic bonded materials are generally:

a) ductile and weak.

b) brittle and strong.
c) brittle and weak.
d) ductile and strong.
e) impact resistant and strong.

8. Increasing the grain size in a metal:

a) increases strength.
b) decreases strength.
c) has no effect on strength.
d) increases the number of dislocations.
e) decreases the number of vacancies.

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Questions 9-11 refer to the diagrams below

z z

B
y

A
x
x

1
C
2
y

2
x

9. The Miller Indices for Plane A are

a) (1 ∞ ∞)
b) (1, 0, 0)
c) (1 1 0)
d) (0 1 1)
e) (0, 1, 1)

10. The Miller Indices for Direction B are

a) [1,1,1]
b) (1 0 1)
c) [1 0 1]
d) [1 1 0]
e) [1,1,0]

11. The Miller Indices for Plane C are

a) (1 1 2)
b) (1, 2, 2)
c) (2, 2, 1)
d) (1 2 2)
e) (2 2 1)

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12. The mechanism of plastic deformation in crystalline metallic solids is:

a) grain growth
b) the stretching of bonds
c) the movement of atoms along slip planes
d) void formation
e) grain boundary fracture

13. Sintering of ceramics and metals involves:

a) melting and pouring into a mould

b) a decrease in slip movement
c) pressing and heating to a high temperature
d) an increase in the number of metallic bonds
e) machining with liquid lubricant

14. At room temperature, annealed ferritic iron is hardest when the ferrite grains are

a) large
b) small
c) columnar
d) equi-axed
e) pure

15. A hypo-eutectoid (low carbon) composition steel is

a) harder
b) more ductile
c) tougher
d) less ductile
e) both b) and c)
than a hyper-eutectoid (high carbon) steel
(Assume both steels to be in the annealed condition).

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16. Which type of polymer undergoes a reversible softening process on being heated and
then cooled ?

a) thermoplastic polymer
b) thermosetting polymer
c) elastomer
d) copolymer
e) at least 2 of the above

17. Corrosion occurs on a metal plate immersed in water where the solution oxygen
concentration is:

a) greatest
b) least
c) variable
d) fixed
e) none of the above

18. Galvanic corrosion is due to:

a) two different metals forming an electrochemical cell

b) variation in oxygen concentration over the metal
c) grain boundaries having a greater energy than the interior of the grain
d) a metal in an electrolyte having a stress concentration
e) oxide formation on the surface of the metal

19. Galvanising is a type of:

a) anodic protection
b) cathodic protection
c) resistive coating
d) noble coating
e) strengthening process

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20. After carburising a low carbon steel, the outer layer is :

a) hard and brittle

b) soft and ductile
c) toughest
d) most corrosion resistant
e) two of the above

21. Fine pearlite transformation involves:

a) austenitizing followed by slow cooling

b) austenitizing followed by air cooling
c) austenitizing followed by quenching
d) quenching within a molten salt and holding 30 minutes and fast cooling
e) heating below the lower critical temperature and fast cooling

22. Maximum hardness may be obtained in steels by the formation of:

a) Martensite
b) Pearlite
c) Ferrite
d) Cementite
e) Bainite

23. TTT diagrams of steels represent:

a) equilibrium phase changes

b) solid solubility
c) non-equilibrium phase changes
d) eutectic formation
e) stress-strain behaviour

24. The physical condition of a thermoplastic well below its glass transition temperature is:

a) soft and flexible

b) tough
c) extremely ductile
d) hard and brittle
e) viscous

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25. 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

26. At ambient temperature a thermoset will have

a) a greater impact than

b) a lower impact than
c) the same impact strength as
d) greater ductility than
e) a lower Young’s Modulus than
a thermoplastic above its Tg

27. 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

28. 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

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29. 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

30. Interstitial solid solutions arise when:

a) large foreign atoms take up lattice sites not normally occupied in a perfect
lattice.
b) small foreign atoms take up lattice sites not normally occupied in a perfect
lattice.
c) foreign atoms take up normal lattice sites.
d) host atoms take up normal lattice sites.
e) foreign atoms take up any site in the lattice.

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Questions 31 - 35 refer to the TTT diagram below.

Small thin pieces of thick hot rolled strips of 1080 steel (0.8 % carbon) are heat
treated for 1 hour at 850°C and then given the following treatments. Using the
isothermal transformation diagram given, determine the correct microstructures of
the samples after each treatment.

A B C

31. Treatment A Water quench to room temperature.

a) Coarse Pearlite.
b) Upper Bainite.
c) 100 % Martensite.
d) 50 % fine Pearlite / 50 % Martensite.
e) fine Pearlite.

32. Treatment B

a) Coarse Pearlite.
b) Upper Bainite.
c) 100 % Martensite.
d) 50 % Pearlite/ 50 % Martensite.
e) 70% Martensite / 30% Austenite.

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33. Treatment C

a) Coarse Pearlite.
b) Upper Bainite.
c) 100 % Martensite.
d) 50 % Pearlite/ 50 % Martensite.
e) 70% Martensite / 30% Austenite.

34. For treatments A, B & C, the resulting steels will increase in hardness in the
following order:
a) no difference
b) C then B then A
c) B then C the A
d) A then B then C
e) B then A then C

35. For treatments A, B & C, the resulting steels will increase in ductility in the
following order:
a) no difference
b) C then B then A
c) B then C the A
d) A then B then C
e) B then A then C

35. The maximum engineering stress is called:

a) The Yield stress.
b) The UTS.
c) Young’s modulus.
d) 0.2% proof stress.
e) Stress at fracture.

36. A eutectic involves:

a) A liquid going to two solids L → Sl + S 2.
b) A liquid going to a solid, L → S.
c) A solid producing two solids, S 1 → S2 + S3.
d) A liquid forming a solid and liquid, L → S1 + L.
e) A solid producing a solid and liquid, S1 → S2+ L

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37. Investigation of a brass pipe was carried out and it was found that the
composition of the pipe on the outer wall was different compared with its internal
wall. Further experimentation found that the only copper sponge like material
existed on the internal area. What has happened?

a) selective leaching.
b) intergranular corrosion.
c) pitting corrosion.
d) process fault.
e) erosion.

38. The Hume-Rothery Rules are used for:

(a) mechanical testing

(b) calculation of the amount of phases
(c) composite formation
(d) solid solution formation
(e) biomaterial compatability

39. 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

40. 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

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NAME: STUDENT #

PART B

Question B1 Given the Fe-C phase diagram below, answer the following questions

100% Fe3 C @ 6.37%C

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(i) What phases are present at Point (a)? 1 mark

(ii) What phases are present at Point (b)? 1 mark

α + Fe3 C

(iii)What is/are the composition/s of the phase/s present at Point (b)? 1 mark

α = 0.01%C
Fe3 C = 6.37%C

(iv) What is/are the relative amount/s of the phase/s is/are present at Point (b)?
2 marks
%α = (6.37−0.8)/(6.37−0.01) X100 =87.6%
%Fe3 C = 12.4%

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Ferrite + Fe3 C
ferrite
Two micrographs, one of the alloy at point (b) & another of a 0.4%C steel.
Ferrite + Fe3 C ferrite

alloy: X alloy: Y

(v) Label the phases & microconstituents on both micrographs. 2 marks

(vi) Show by calculation (i.e. the lever rule) which micrograph belongs to which alloy.
2 marks

X = 0.4%C Y= 0.8%C (Point B)

%pearlite = (0.8-0.4)/(0.8-0.01) X100 %pearlite =100%

=51%

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Question B2

A cylindrical specimen of stainless steel having a diameter of 12.8 mm and a

gauge length of 50.800mm is pulled in tension. The following results are obtained
from that tensile test.

Load STRESS Gauge length STRAIN

(N) MPa (mm)
0 50.800
12700 50.825
38100 50.876
76200 50.952
92700 51.054
107800 51.308
128300 51.816
159000 53.848
160400 54.356
124700 fracture 56.642
Draw a stress - strain curve. 5 marks
1200

0.002 proof stress = 720MPa

1000

800

Stress/ (MPa)
600

400

0.002 strain
200

0
0 0.005 0.01 0.015 0.02 0.025

Strain

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(b) What is the ultimate tensile strength? 1 mark

CSA = 128.7mm2
UTS = 160400/128.7 = 1246MPa

(c) Determine the yield strength at a strain offset of 0.002. 2 marks

See above construction on graph = 720MPa

(d). What is the modulus of elasticity? 2 marks

Slope of initial part of curve (the linear part) = 198GPa

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Question B3

Galvanic series
Pt
Cathodic
Au
Ag
316 s/steel (passive)
304 s/steel (passive)
Copper
Brass
Tin
Lead
316 s/steel (active)
304 s/steel (active)
Iron & steel
Aluminium alloys
Cadmium
Zinc Anodic
Magnesium

(a) A stainless steel handrail is fabricated on site by welding lengths of stainless steel tube
to brackets. Within a matter of weeks, corrosion of the welds takes place. It is found
that the weld metal is mild steel. What sort of corrosion is this? Describe how it takes
place and the importance of relative anode/cathode sizes. 3 marks

Galvanic corrosion, small anode large cathode bad as large cathode wants
to consume alarge # of electrons resulting in fast dissolution of the
anode

(b) A more informed fabricator uses an appropriate weld metal, but corrosion occurs next
to the weld in the heat affected zone. What is this corrosion, how does it arise and
how can it be remedied? 3 marks
Intergranular corrosion

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(c) Corrosion of some metal railing under spots of paint (from repainting the exterior of a
building) has occurred. Why has it occurred and what is the mechanism involved?
How could this be avoided? 3 marks

Differential aeration or crevice corrosion. Areas low in oxygen become

the anode as areas high on oxygen drive the cathode reaction

Remove paint spatters

(d) Categorise the following situations as acceptable or unacceptable in relation to

corrosion. Give reasons for your answers. Where undesirable corrosion is a
possibility, what steps would you take to prevent the corrosion if it is assumed that
you cannot change the metal combination. 2 marks each

i) Copper fasteners on an aluminium roof,

OK, small cathode large anode

ii) Copper roof fixed with mild steel fasteners,

NO, small anode large cathode, put insulating gaskets/washers
between the steel and the copper

iii) Lead flashing in direct contact with aluminium roofing,

OK, small cathode large anode

iv) Zinc coating is applied to a mild steel base,

OK, small cathode large anode, even when zinc coating damaged

v) Copper pipework fixed with brass fasteners.

OK, next to each other on galvanic series, little corrosion will occur

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NAME: STUDENT #

PART C

Question C1
(a) A 0.4%C steel is heated up to 860°C (see phase diagram, Question B1), held there
for 1 hour then quenched into water. For this quenched alloy, circle the
microstructure below would you expect to observe? What is this microstructure
called? 1 mark

NAME: Martensite

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(b) How would the hardness and impact strength differ from that of the 0.4%C alloy slowly
cooled from 860°C? 2 marks
Harder and more brittle (lower impact strength)

(vii) Explain this change in properties in terms of the atomic level. 2 marks
Quenching causews the C to be trapped in the lattice causing severe distortion.
This greatly hinders dislocation motion and results in higher hardness and
lower impact strength

Question C2
A piece of plain carbon steel containing 0.2 wt% carbon was case carburised to give a case
depth of 0.3mm. The carburising was done at a temperature of 10000 C. The carbon
concentration at the surface was 1.4%.
The diffusion coefficient is given by:
D= Do exp (-Q/RT)
Where Do = 9x 10-6 m2 s-1
Q= 125 kJ mol-1
R= 8.314 J mol-1 K-1

The following table gives values of the error func tion (erf):

β 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

erf β 0 0.11 0.22 0.33 0.43 0.52 0.60 0.68 0.75

β 0.9 1.0 1.1 1.2 1.3 1.4 1.5 2.8

erf β 0.8 0.84 0.88 0.91 0.93 0.95 0.97 1.00

The diffusion of carbon into the steel is described by the time-dependent diffusion (Grube)
equation :

C s − C( x, t )  x 
= erf  
C s − C0  2 Dt 

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(a) The diffusion coefficient at this temperature is: 2 marks

(b) What is the erf (β) value if the composition C (x,t) is 0.5 wt.% carbon? 2 marks

(c) What is the time required for carburization for 0.5 wt% carbon if the depth of the case
is taken to be the value of 3 x 10-4 m (0.0003 m) : 2 marks

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Question C3
(a) What mechanism accounts for plastic deformation in metals? Describe using
diagrams. 3 marks

Dislocation motion

(b) Relate this mechanism to two strengthening techniques used on metals detailing the
theory behind them. 3 marks
Hindering dislocation motion increases strength, so anythi ng that does
this will strengthen the metal:
Reducing grain size
Precipitation hardening where the precipitates distort the lattice
Solid solution strengthening (alloying) where atoms of different size
distort the lattice
Cold working which generates more dislocations which inteact and tangle
each other

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(c) What mechanism accounts for deformation in polymers? Explain. 3 marks

Interchain movement and chain uncoiling

When there are only weak secondary bonds, chains move past each other
easily, when there a strong crosslinks, interchain movement is severely
restricted

(d) 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. 3 marks

Again, hinder movement:

Large side groups, increasing crystallinity
crosslinking

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Question C4
Borsic reinforced aluminium containing 50vol% fibres is an important high temperature,
lightweight composite material. Given:

Material E Tensile Strength

GPa 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

(a) The stiffness of the composite parallel to the fibre direction 2 marks

224GPa

(b) The stiffness of the composite perpendicular to the fibre direction 2 marks

117GPa

(c) On what basis can composites be classified? Describe each classification. 5 marks

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Matrix, reinforcement shape (fibre, particle etc.), and fibre architecture

(woven, 3d palnar, 3d random etc.)

The End
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