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University of Technology,Sydney
:. _ _ _ _ _ _ __
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COURSE

AUTUMN SEMESTER, 2012

60101
CHEMISTRY & MATERIALS SCIENCE

FRIDAY 22 JUNE 2012

14.00- 17.00.
ALL QUESTIONS TO BE ANSWERED ON THE COMPUTER MARKING SHEET

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ALL QUESTIONS ARE TO BE ATTEMPTED.

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EXAMINATION ROOM.

1
2
 Mechanical Properties
1. Plastic deformation refers to

a} The deformation that occurs in polymers

b) The recoverable deformation on unloading a material

c) The permanent deformation that occurs in a material when stressed beyond yield

d) The permanent deformation that occurs before yield

2. The theoretical strength of a metal is much higher than the observed experimental

strength because:

a) Theoretical calculations take into account the presence of dislocations

b) Theoretical calculations do not take into account the presence of dislocations

c) lt is difficult to apply the stress accurately to the metal

d) Theoretical calculations assume only elastic deformation

3. Dislocations play a more important role in controlling the mechanical properties in metals

than they do in glasses because:

a) There are only edge dislocations in glasses.

b) The amorphous nature of glasses allows dislocations in glasses to move under low

shear stresses.

c) The dislocations in glasses are trapped and cannot move easily whereas in metals

dislocation movement can occur more readily.

d) There are many slip planes in glasses allowing dislocations to move easily

4. A steel cable bar 3.13cm in diameter and 1500cm long is to lift a 18,140 kg load. Given E-

207 GPa, what is the length of the cable during lifting? (assume it has a solid cross-section)

a) 1.12mm

b) 1.502m

c) 1.5002m

d) 0.1mm

e) 1.6m

3
The tensile test curves given below for Alloy A and Alloy B are used for the following seven

questions.

1000
900
8
800
700
m
Q. 600
:2:
en 500

-
en
Q.)
:loo.. 400 A
en 300
200
100
0
0 5 10 15 20 25 30
Strain,%

5. The yield strength of Alloy A is about

a) 200 MPa

b) 200 N.mm· 2

c) 400 MPa

d) 600 MPa

e) 760 MPa

6. The UTS of Alloy A is about

a) 200 MPa

b) 200 N.mm· 2

c) 400 MPa

d) 600 MPa

e) 760 MPa

4
7. The elongation to fracture of Alloy B is about

a) 0.02%

b) 0.2%

c) 2%

d) 4.7%

e) 50%

8. Which statement of the five given below is most likely to be false?

a) Alloy B is clearly the superior choice for structures like bridges

b) Alloy A is clearly the superior choice for structures like bridges

c) Alloy A is quite ductile

d) Alloy B has a relatively high strength

e) Alloy A can absorb more energy during tensile fracture than Alloy B

9. True or false? Alloy B is not as stiff as Alloy A

a) True

b) False

10. The modulus of elasticity of a material is 100 GPa. What stress do I need to apply to

deform it by 0.1%?

a) 1GPa

b) 1MPa

c) 10 MPa

d) 100 MPa

e) 1000 MPa

5
 Chemistry
11. The molecular formula of sugar is C6H12 05. If there are about 5 grams in a teaspoon of

sugar, approximately how many molecules of sugar are there in the teaspoon?

a) 180 molecules

b) 1 x 1026 molecules
22
c) 1.7 X 10 molecules

d) 6 x 1023 molecules

12. What is the total number of moles of H2S0 4 needed to prepare 5.0 litres of a 2.0 M

solution of H2S04?

a) 2.5

b) 5.0

c) 10.0

d) 20.0

13. The following data were collected at the endpoint of a titration performed to find the

molarity of an HCI solution.

Volume of acid (HCI) used = 20 ml

Volume of base (NaOH) used= 22.4 ml

Molarity of standard base (NaOH) = 0.30 M

What is the molarity of the acid solution?

a) 0.26M
b) 0.34M
c) 0.30M
d) 0.27M
14. What is the gram formula mass of K2C0 3?

a) 138 g
b) 106 g
c) 99 g
d) 67 g

6
15. When the reaction equation Cu + AgN0 3 -+Cu{N0 3}2 + Ag is properly balanced, the

number of moles of AgN0 3 will be ...

a) 2moles
b) 4moles
c) 3 moles
d) 1 mole

16. What is the formula of the compound formed between magnesium and oxygen?
a) MgO
b) Mg202
c) Mg203
d) Mg02
e) Mg20
17. When iron pyrites {FeS 2L an ore of iron, is roasted in oxygen, the following {unbalanced)
reaction occurs:
FeS2{s) + 02{g ) S0 2{g) + Fe 20 3 {s)
By balancing the equation determine the number of moles iron oxide.
a) 2
b) 1
c) 4
d) 6
18. If 10kg of FeS 2 is used, how many kilograms of iron oxide will be produced?
a) 10 kg
b) S.Okg
c) 6.7kg
d) 2.8 kg

7
 Composites
19. Calculate the modulus in the fibre direction for polyester reinforced with an unidirectional
60 vol% E glass fibres. Given E for the polyester is 6.9 GPa, and E for the glass fibre is
72GPa.
a) -72 GPa
b) 46 GPa
c) 15 GPa
d) 34 GPa
e) -7 GPa
20. Calculate the modulus perpendicular to the fibre direction for polyester reinforced with
an unidirectional 60 vol% E glass fibres.
a) -72GPa
b) 46 GPa
c) 15 GPa
d) 34 GPa
e) -7 GPa
21. If chopped strand mat (CSM) was used instead of the unidirectional fibres, what would the
modulus be?
a) -7 GPa
b) 15 GPa
c) 19 GPa
d) 46GPa
e) 160GPa
22. What is the critical fibre length?
a) The maximum length the fibre can be to ensure maximum stiffness to the
composite
b) The minimum length the fibre can be to ensure maximum stiffness to the
composite
c) The minimum length that allows for maximum stress transfer from the matrix to
the fibre
d) The minimum length that allows for maximum stress transfer from the fibre to
the matrix

8
23. For the composite above, if the critical fibre length for the system is 10mm, what would be
an approximation for the tensile strength, in the fibre direction, of the composite if aligned
fibres SOmm long (60 vol%) were used? Given the tensile strength for the polyester is 28
MPa, and the glass fibres, 3.4GPa.
a) 13 MPa
b) 2.1 GPa
c) 1850 MPa
d) 5.2 GPa

9
 Corrosion

This galvanic series is for a series of metals in rainwater from more noble to active

Stainless steel (Type 304}

Copper

Brass

Lead

Stainless steel (Type 410}

Mild Steel

Aluminium

Zinc

24. Which one of the following features least promotes corrosion?

a) Entrapment of moisture
b) Crevices
c) Shape
d) Thickness of the metal or alloy used

25. Pipes of different materials, such as copper and steels, should not be embedded in a

trench in close proximity to avoid

a) deposition of copper on steel pipe

b) depassivation of steel
c) corrosion of copper pipes
d) galvanic corrosion, in general

26. Corrosion of iron is retarded by

a) the presence of salts
b) low pH conditions
c) high pH conditions
d) both the presence of salts and high pH conditions
e) both the presence of salts and low pH conditions

10
27. A cast iron grate has been attached to a Sm length of copper pipe. From a corrosion point

of view:

a) There is no problem as the surface area of the grate is much less than the surface area

of the copper pipe.

b) The pipe will start to corrode in areas around the grate as the surface area of it is

much greater than the surface area of the bolts.

c) The grate will corrode fairly quickly as the surface area is much lower than that of the

pipe.

d) Both the grate and the pipe will corrode at the same rate.

28. What would you do in this case?

a) Nothing as there is no problem

b) Galvanise the grate

c) Electrically insulate the grate from the pipe

29. A 304 stainless steel pipe has had a flange (of the same stainless steel alloy) welded to it. A

304 stainless steel filler welding rod was used. After approximately 12 months corrosion is

noted in the pipe and the flange just either side of the weld. This is due to:

a) Galvanic corrosion

b) Uniform corrosion

c) lntergranular corrosion

d) Stress corrosion cracking

30. What could have been done to avert this problem?

a) Post-weld anneal at 750°C to relieve weld induced stresses

b) Use a stabilised grade of stainless steel

c) Use a more noble grade of stainless steel as a filler material to avoid galvanic

corrosion

d) Use a good anti-corrosion paint system to coat the pipe and flange

11
31. In comparison with ordinary structural steels, weathering steels, in the unpainted

condition, have markedly enhanced resistance to corrosion caused by changeable

atmospheric conditions. This is due to:

a) sacrificial anode protection mechanism

b) a coherent oxide coating forming on the surface

c) differential aeration

d) the steel being very noble

12
 Phase Diagrams

32. Circle the most correct statement. In general, elements or alloys with the face-
centred cubic, closest-packed structure are
a) very brittle compared to other crystal structures
b) less ductile than those with the body-centred cubic structure
c) only stable at high temperatures
d) more ductile than those with the hexagonal closest packed or body centred cubic
structures
e) ideal for structural applications such as bridges

The following twelve questions relate to the high temperature part of the Au-Ni phase
diagram:

Au-Ni
Atomic Percent Nickel

(Au.Ni)

0 10 20 30 40 50 60 70 110 90 100
Au Weight Percent Nickel Ni

33. Although this is clearly not a eutectic system, it nevertheless has a range of
composition with a lower than usual melting point. The Ni content (by weight%)
that corresponds to this liquid is about
a) 0%
b) 17%
c) 45%
d) 62%
e) 100%

13
34. The melting point of pure gold (Au) is
a) 700 2C
b) 9552C
c) 10642C
d) 12602C
e) 14552C

35. A composition consisting of 60 wt% Ni, balance Au, is weighed out, melted in a
furnace and then cooled at some industrially appropriate rate. According to the
equilibrium diagram the first signs of solid phase should appear at
a) 700 2C
b) 9552C
c) 10642C
d) 12602C
e) 14552C

36. Actually, in practice we expect that the first solid phase

a) should form a few degrees Celsius above the temperature indicated in the
previous question because of the phenomenon of supersaturation
b) should be rich in Au
c) should be pure Ni
d) should consist of equiaxed grains of ferrite
e) should form a few degrees Celsius below the temperature indicated in the
previous question because of the phenomenon of undercooling

37. The Ni content (by weight%) of this first solid phase is about
a) 0% Ni
b) 35% Ni
c) 60% Ni
d) 85% Ni
e) 100% Ni

38. The sample is allowed to cool further to 1100 2C and then examined using some
kind of high temperature microscope. At this temperature the proportion of solid
phase in the sample is about
a) A.10 to 15%
b) B. 20 to 25%
c) C. 50%
d) D. 70 to 75%
e) E. 100%

14
39. The composition of the solid phase at this temperature is (by weight%)
a) 0% Ni
b) 16% Ni
c) 38 to 39% Ni
d) 46% Ni
e) 66% Ni

40. The composition of the liquid phase at this temperature is about (by weight%)
a) 38 to 39% Ni
b) 46% Ni
c) 56% Ni
d) 66% Ni
e) 100% Au

41. The sample is then allowed to cool further until only an infinitesimal fraction of it is
liquid. The composition of this last little bit of liquid phase is (by weight%)
a) 0% Ni
b) 16% Ni
c) 32% Ni
d) 38 to 39% Ni
e) 46% Ni

42. If the sample had been cooled relatively rapidly from 1300QC, then its
microstructure at room temperature would have consisted of
a) alternating sheets of Au and Ni
b) equiaxed and chemically homogenous grains of (Au,Ni) solid solution
c) martensite
d) dendrites, which are 'cored' so that their centres are richer in Ni than their
edges.
e) eutectoid phase

43. Which of the statements comparing the 15 wt.% Ni composition to the 60 wt.%
composition is most correct?
a) The 15 wt.% Ni composition will solidify with virtually no coring, compared to the
60 wt.% Ni composition
b) The 15 wt.% Ni composition has a lower caratage of gold in it than the 60 wt.%
Ni composition
c) The 15% wt.% Ni composition will be badly cored, compared to the 60 wt.%
composition
d) The 15 wt.% Ni composition solidifies at a higher temperature than the 60 wt.%
Nione
e) There is a huge cap between solidus and liquidus in the 15 wt% Ni composition.

15
 44. A 50 weight% Ni-50 weight% Au alloy is actually 77 atomic% Ni because
a) Au is less dense than Ni
b) Au has a much bigger molar mass than Ni
c) the lattice parameter of Au is bigger
d) Au is a noble metal
e) Au is face centred cubic

Alloy phase diagrams- eutectic

45. The difference between a eutectic and a eutectoid is that

a) a eutectic has high strength, a eutectoid not
b) a eutectic forms from a liquid, a eutectoid from a solid phase
c) only the spelling is different
d) a eutectic only forms in non-ferrous systems, a eutectoid only in ferrous systems
e) a eutectic consists of two phases, a eutectoid of only one

The following fourteen questions relate to the Cd-Pb (cadmium-lead) phase diagram
provided here:
Cd-Pb
Alom JC Percent Lead
0 lO 20 30 40 s,o 60 70 80 90 100
350 ..,... ,. I

327.s·c
321.1 •c

300

u
0

250 24a•c
<lJ
I-.
;:l
--'
t'O
I-.
1))
(Pb)
c.
E 200
(U f
f-
(Cd) f

150-

0 10 20 30 40 50 60 70 eo 90 100
Cd Weight Percent Lead Pb

16
46. At 3402C the solubility of Pb in liquid Cd and vice versa is (by weight%)
a) zero
b) about 10%
c) about 50%
d) about 95%
e) unlimited

47. The eutectic in this system is obtained at a composition of (by weight%)

a) trick question: there is no eutectic
b) 8.3 wt% Pb
c) 83 wt.% Pb
d) 96 wt% Pb
e) 100 wt% Pb

48. The melting points of the elemental components of the Cd-Pb system are
(respectively)
a) cannot be determined because they form a solid solution
b) 328 and 3212C
c) greater than 3502C
d) both 2482C
e) 321 and 328 2(

49. How much lower is the melting point of the eutectic composition than that of the
elemental components?
a) there is no difference
b) about 752C
c) depends on the how much Pb there is
d) by definition a eutectic does not have a defined melting point
e) 2482C

50. The maximum amount of Cd that can dissolve in the Pb-rich solid phase (by weight
%) is about
a) none
b) 4% Cd
c) 17% Cd
d) 83% Cd
e) 96% Cd

17
51. The solubility of Pb in solid Cd is
a) close to zero
b) 4% Pb
c) 17% Pb
d) 83% Pb
e) 96% Pb

52. The eutectic formed in this system will consist of

a) pearlite
b) dendrites
c) pro-eutectoid Cd
d) Cd and pure Pb
e) Cd and Pb-rich phase

53. An alloy containing 95% Pb is completely melted and then allowed to cool to
250QC. What is/are the phase/phases that it consists of at that temperature?
a) Cd and Pb-rich phase
b) just solid Pb-rich phase
c) pro-eutectic Pb-rich phase and liquid
d) just liquid
e) pro-eutectoid Cd and liquid

54. And, following on from the previous question, it will be found on examination with
a high temperature microscope to consist of
a) 12% solid Pb-rich phase and 88% liquid
b) allliquid
c) 50% liquid Cd and 50% solid Pb-rich phase
d) 100% solid Pb-rich phase
e) 88% solid Pb-rich phase and 12% liquid

55. Following on from the previous question, the solid phase at this point may also be
called
a) pro-eutectoid Pb-rich phase
b) pro-eutectic Pb-rich phase
c) pearlite
d) eutectoid Cd
e) none of the above

18
56. As this sample is cooled through the (L+Pb) two-phase region, the
a) eutectic starts to form
b) heat is absorbed from the environment
c) solid Cd forms
d) composition of the liquid phase becomes richer in Pb
e) composition of the liquid phase becomes richer in Cd

57. The sample is finally cooled to lOOQC. According to the Lever Rule, it will consist of
a) 5% Cd phase and 95% Pb-rich phase phase
b) 25% Cd phase and 75% pro-eutectic Pb-rich phase
c) alternating lamellae of Cd and Pb-rich phase
d) 83% Cd phase and 17% pro-eutectic Pb-rich phase
e) 96% Cd phase and 4% Pb-rich phase

58. If I apply the Lever Rule to the eutectic micro-constituent rather than to the Cd,
then the sample can be said to consist of about
a) 5% Cd phase and 95% Pb phase
b) 30% eutectic micro-constituent and 70% pro-eutectic Pb-rich phase
c) alternating lamellae of Cd and Pb
d) 83% Cd phase and 17% Pb phase
e) 96% Cd phase and 4% Pb phase

59. Which statement about this alloy is most likely to be true?

a) it would definitely not make a solder joint with acceptable mechanical
properties
b) it is comprised of toxic elements so it is not likely that it would be used much as a
solder
c) it is the basis of most commercially available soldering alloys
d) its melting point is too low for a good solder
e) it is likely to be of exceedingly high strength due to the formation of martensite

19
 Strengthening
60. The movement of dislocations in metals is responsible for their
a) very high strength
b) electrical conductivity
c) ductility
d) silver colour
e) none of the above

61. Alloying element atoms can

a) retard the movement of dislocations
b) generate stresses in the crystal lattice
c) increase the strength of the alloy
d) reduce the ductility of the alloy
e) all of the above

62. The Burger's vector of a pure edge dislocation

a) is zero
b) points at right angles to the line of the dislocation
c) is parallel to the line of a dislocation
d) is a spiral
e) can point in any direction

63. Dislocation movement occurs most easily on

a) surfaces of the metal
b) grain boundaries
c) interstitial elements
d) close-packed planes in the lattice
e) loosely-packed planes in the lattice

64. Magnesium is much less ductile than gold because

a) it has stronger interatomic bonding
b) it has fewer close-packed planes in its crystal lattice
c) it is less dense than gold
d) it is a non-metal
e) it is face-centred cubic

1
65. The Haii-Petch equation, O'yield = 0'0 + kyd-2, describes the effect of the grain size on
yield strength in terms of two constants cr0 and kv, and grain size, d. Decreasing the grain
size will
a) cause the yield strength to increase
b) cause the yield strength to decrease
c) have no effect

20
66. Following on from the above question, for a certain material and for units of MPa for the
stress and mm for the grain size, cr0 = 300 and kv=lOO N.mm-0 ·5 • What is the effect on Gv of
halving the grain size from 1.0 mm to 0.5 mm ?
a) strength is reduced from 300 to 363 MPa
b) strength is reduced from 400 to 363 MPa
c) strength is increased from 300 to 441 MPa
d) strength is increased from 400 to 441 MPa
e) there is no change

67. As the grain size gets bigger and bigger

a) kv and cr0 must change to compensate for it
b) the grain boundary area per unit volume increases
c) crv tends to infinity
d) crv tends to zero
e) Oy approaches <Jo.

68. The properties of an anisotropic material

a) are the same in all directions
b) vary with direction
c) are the same at all temperatures
d) do not depend on grain size or shape
e) none ofthe above

69. A rod of circular cross-section and diameter 10 mm is cold-rolled down to a diameter of 8

mm (area=n.r 2 ). The amount of cold work done on the rod is
a) 12%
b) 36%
c) 55%
d) 80%
e) 189%

70. Following on from the above question, we should expect that

a) the ductility ofthe rod will be increased
b) the dislocation density in the rod will be decreased
c) there will be less elastic stress in the rod
d) the strength and hardness of the rod will be decreased
e) the strength and hardness of the rod will be increased

71. The process in which we heat up a cold-worked piece of metal so that new grains nucleate
and grow in it is called
a) strain relief
b) recovery
c) recrystallization
d) quench and tempering
e) spheroidizing

21
Non-ferrous alloys

The phase diagram for Cu-Be below refers.

ll 00

1000

800
....
'U
::I
-;;... 700
6()()
E
.500
400
Copper+
300 a beryllJum
<:ompound
200

100

0
() 2 J ...
Cu Percent Be---+

72. Of the options provided, the most suitable composition for precipitation hardening is
a) 0% Be
b) 0.2% Be
c) 2% Be
d) 3% Be
e) 4% Be
73. A suitable temperature for the solution anneal part of the precipitation hardening heat
treatment (using the selection ofthe previous answer) is
a) 1100QC
b) 1000Q(
c) 900Q(
d) 800Q(
e) 700QC

74. A suitable treatment for the aging part of the heat treatment is
a) room temperature
b) 2SOQC
c) SSOQC
d) 850Q(
e) lOSOQC

22
75. When switching from steel to aluminium in a design, it is, in general, important to consider
a) the lower strength of AI
b) the lower Young's Modulus of AI
c) the relatively higher cost of AI
d) the effect of temperature on the tensile strength of AI
e) all of the above

76. 'Cartridge brass' is a common alloy, and is comprised of (by weight)

a) iron with 10% carbon
b) aluminium with 1.5% tin
c) copper with 30% zinc
d) cartridgium with gold
e) just sodium

77. By far the biggest end-market for titanium minerals (by tons) is
a) gears for motor cars
b) soft-drink beverage cans
c) sporting goods, such as golf clubs and bicycles
d) in aircraft airframes
e) as the oxide Ti0 2 in paint

78. Which one of the following metals is the most suitable candidate for the production of
nozzles for the engine of a rocket to launch satellites
a) Mg
b) Cu
c) AI
d) Ti
e) W

79. Which one of the following metals is the most suitable candidate for the production of die-
cast, light-weight cases for consumer electronics
a) Mg
b) Cu
c) AI
d) Ti
e) W

80. Which one of the following metals is the most suitable candidate for the production of
relatively high-strength, light-weight structural sheet to be used as side walls in caravans
and mobile homes
a) Mg
b) Cu
c) AI
d) Ti
e) W

23
81. Which one of the following metals is the most suitable candidate for the production of the
blades and rotor of the low temperature front end of a jet engine.
a) Mg
b) Cu
c) AI
d) Ti
e) W

24
 Steels

The following questions apply to the phase diagram for Fe and C {iron and carbon).

Liquid (L)

u
2....

723"C

Fc 3 C
(6. "Iwt 0/., C)

0 2 3 4 5 6
Fe Weight% C

82. Circle the statement that is WRONG. Ferrite and austenite

a) are allotropes of iron
b) are two of the phases of in the Fe-C phase diagram
c) can convert into one another as the temperature changes
d) have different crystal structures and densities
e) are the two strongest phases in steel

83. At 10002(, an Fe-C alloy containing 1% C consists of

a) ferrite
b) ferrite plus austenite
c) austenite
d) austenite plus cementite
e) ferrite plus pearlite

25
84. The alloy above is cooled to 7002C and allowed to transform. lt will then be found
to consist of
a) ferrite and intergranular austenite
b) pearlite and intergranular cementite
c) just ferrite
d) leduburite eutectic
e) austenite and cementite

85. By application of the Lever Rule, it can be found that at 9002( an Fe-C alloy
containing 2% C consists of about
a) 15% austenite, balance pearlite
b) 15% austenite, balance cementite
c) 85% austenite, balance pearlite
d) 85% austenite, balance cementite
e) 85% gamma phase, balance liquid

86. Fe-C alloys containing greater than about 1.5% Care usually known as
a) mild steel
b) hyper-eutectic steels
c) hypo-eutectoid steels
d) cast irons
e) ledeburite

87. Which of the statements below is the most correct? Cast iron is a popular
engineering material because ......... .
a) it has a much lower melting point than a steel
b) it is easily cast into intricate shapes
c) it is available in a variety of alloy types and microstructures
d) it is relatively cheap to manufacture and process
e) all of the above

26
The following five questions can be answered by reference to the two time-temperature
heat treatment diagrams given below. We may assume for the purpose of these exam
questions that these are isothermal time-temperature-transformation diagrams.

Steel 1
900

800

700

600 ··-··-1--····
I

v
:::l
500 l I
"§
1'5. 400
5
f-

300

200

100

0.5 2 3 4 5 10 10' 10.1 j()4

Time, secs

Steel 2
91H)

XOP

700

bOO

t
c..
I I
4\>0 w f·-·+
.l :\-1,
t-1
;no
j

!Ill/

]0 JIF !()-'

27
88. Which is the most correct statement, of the five given below:
a) Steel number 1 is more 'hardenable' than steel number 2
b) Steel number 1 is less 'hardenable' than steel number 2
c) Application of a normalizing heat treatment to Steel 1 will make martensite
d) Steel 2 is likely to contain a smaller amount of alloying elements and/or carbon
than Steel1
e) lt is not possible to form any pearlite in these steels by heat treatment

89. What is the temperature at which martensite starts to form from austenite when
these alloys are cooled?
a) about 8SOQC
b) about 727QC
c) about 340QC
d) about180QC
e) below room temperature

90. A sample of Steel1 is heated to 8SOQC, then suddenly cooled to 600QC by plunging
it into a bath of molten salt at that temperature. lt is then held at that temperature
for 10 seconds. At that point it is then quenched into iced water. After this
treatment the microstructure of the sample will be found to consist of
a) austenite only
b) austenite and ferrite
c) martensite and ferrite
d) ferrite and pearlite
e) martensite only

91. Exactly the same treatment as in the previous question is applied to Steel 2. Its
microstructure will then consist of
a) austenite only
b) austenite and ferrite
c) martensite and ferrite
d) ferrite and pearlite
e) martensite only

28
92. If I want my component to be completely made out of bainite then I should
a) choose Steel1 and transform isothermally at 600QC for at least 10 seconds
b) Choose Steel 2 and quench in to ice-cold water
c) Choose Steel 2, water quench, then reheat to 600QC for at least 10 seconds
d) choose Steel 1 and apply an isothermal heat treatment somewhere in the range
350 to 500QC for at least 2 minutes
e) Choose Steell, cool rapidly to 600QC, hold there for 100 seconds then quench
into water

93. Circle the INCORRECT statement made in regard to the steel used for high strength
cables such as those used in suspension bridges
a) This steel contains about 0.8% carbon by mass
b) The microstructure of the steel in the cables consists almost entirely of pearlite
c) This steel has a tensile strength in the range 1600 to 2000 MPa
d) This steel can be easily welded
e) This steel is hard and springy

94. Which is the INCORRECT statement made in regard to increasing the carbon
content of a steel. In general, increasing the carbon content
a) makes the steel more brittle
b) increases the tensile strength
c) decreases the fracture toughness
d) increases the ductility
e) decreases the elongation to fracture

95. Which is the INCORRECT statement made in regard to hypo-eutectoid steels.

a) these steels have no more than 0.8% carbon in them
b) in the 'normalized' condition these steels consist of ferrite and some pearlite
c) these steels are widely used in bridges and other structures
d) these steels cannot be heat treated
e) these steels can be welded (subject to certain precautions)

96. Which alloy in the following list would be the best option for a punch and die set
with which to 'strike' the pattern on coins
a) 0.01% C steel in normalized condition
b) 1.5% C steel, with alloying elements, in quenched but not tempered condition
c) 0.8% C steel cable, with alloying elements
d) 1.0% steel, with alloying elements in spheroidised condition
e) 1.0% C steel, with alloying elements, in quenched and tempered condition

29
97. The last two digits in a four digit USA AISl, SAE or similar specification for steel
indicate
a) the carbon content
b) the alloy family, e.g. chrome steel
c) are just an arbitrary number
d) how strong the steel is
e) the price of the steel

98. The last two digits in a four digit American AA or similar specification for aluminium
indicate
a) the carbon content
b) the alloy family, e.g. silicon hardened
c) are just an arbitrary number
d) how strong the aluminium is
e) the price of the aluminium

99. Steel alloy SAE 1010 is probably best suited for use in
a) nails, motor car panels, fencing wire
b) structural sections in bridges and buildings
c) suspension bridge cable
d) rocket bodies and airframes
e) steel files, chisels and drills

100. The greater the 'temper' of a cold worked alloy (steel or non-ferrous), the
a) the softer and weaker it is
b) the more expensive it is
c) the faster it has been quenched
d) the angrier it is
e) stronger and harder it is

101. If designing for a structure on the beach, the best stainless steel to use (of the list
provided, and in respect of maximum resistance to unsightly corrosion) would
probably be
a) Type 430 ferritic stainless steel (Fe-17% Cr)
b) Type 304 austenitic stainless steel (Fe-18%Cr-9%Ni)
c) Aluminium alloy 3400
d) Super-duplex stainless steel (Fe-24% Cr-10%Ni-5%Mo)
e) Martensitic stainless steel (Fe-12%Cr-0.2%C)

30
102. Choose the most correct statement in regard to use of Australian Standards in
your future job
a) There are situations when you will be legally obliged to follow an Australian
Standard and situations when you will not be
b) You will always have to adhere to an Australian Standard if you design something
in Australia
c) All information in all Australian Standards is open to negotiation between
supplier and purchaser
d) We should always use an overseas standard if possible rather than an Australian
one
e) You may not use or refer to Australian Standards if you are working in another
country

31
 Materials Selection
103. The first step in the materials selection process is

a) Define required material characteristics

b) Select test procedures
c) Conduct tests
d) Identify corrosion monitoring techniques

104. In selecting a ductile cast iron for a high strength/low ductility application you
find the following two tables in a standard reference. If specifications require a
tensile 550 MPa and a% elongation at 5%, which of these
alloys would be suitable?

a) 100-70-03
b) 80-55-06
c) 65-45-12
d) 120-90-02
e) Class B
For the following questions, reference to the bubble plots at the end of the paper
is suggested.

105. Which class of metallic alloy is the lightest?

a) Aluminium alloys
b) Steels
c) Magnesium alloys
d) Titanium alloys

106. Which are the stiffest?

a) Tungsten (W) alloys
b) Ni alloys
c) Steels
d) Titanium alloys

32
Consider the selection of a material for a simple cantilever beam. Consideration of the
application would suggest that strength, stiffness and cost would be three very
important properties for this application.
L

The design requirements are thus:

Constraints Length L specified

Stiffness: must not deflect too much under design load

Strength: must not fail under design loads

Objective: Minimise cost, C

Free variables: Cross section area of beam, A

Choice of material

107. The first materials index for this application, M 1, would be:
lj
a) Beam, minimum weight, stiffness
p
b) Tie, minimum weight, stiffness
p
lj
c) Column, minimum cost, buckling load
CmP

108. The second materials index for this application, M 2, would be:
. .
a) Bea m, mtmmum . ht, stt"ffness prescn"b ed, -E 1 / 2
wetg
p
lj
b) Beam, minimum cost, stiffness
CmP
lj
c) Column, minimum cost, buckling load
CmP

33
109. Which of the following materials would provide the best choices for M 1?

a) CFRP, reinforced concrete, SiC, timber

b) Concrete, stone, brick, woods

c) Concrete, stone, woods, cast iron, steels

d) CFRP, glass, steels, epoxies

110. Why would the ceramics be a poor choice?

a) They are too stiff

b) They are brittle and are weak in tension

c) They are brittle and weak in compression

d) They have too high a fracture toughness

111. Which material would give the best bending stiffness for weight?

a) Reinforced concrete

b) CFRP

c) Timber

d) Steels

112. How would the selections in Q 109 be minimised if cost was taken into

consideration

a) CFRP

b) Reinforced concrete

c) woods

d) steels

34
113. Stress analysis shows that a minimum of 400 MPa is needed, what materials

would meet this constraint?

a) CFRP

b) Steel

c) Wood

d) Reinforced concrete

35
 Diffusion and Joining
114. The diagram below explains the process of

®oee ooee ooee

ooee ooee 0 ,..,_...
..... or-oe oooe
ooee ooee ooee
increasing elapsed time

a) interstitial diffusion
b) substitutional diffusion
c) dislocation-assisted diffusion
d) melting
e) plasticity

115. The rate of diffusion can be expressed as a function of temperature as

D = D 0 e -Q;RT
where T is the temperature in Kelvin, R is the Universal Gas Constant, Q is the
activation energy for the diffusion process, 0 0 a constant, and D the rate of
diffusion. All else being equat if the temperature goes up, the rate of diffusion
a) goes down
b) is not effected
c) depends on R
d) goes up
e) none of the above

116. Following on from the question above, calculate the value of the diffusion
coefficient D (in m 2/s) at 650oC for the diffusion of Sn in Cu; assume that the values
of 0 0 and Q are 7.1 x 10-5 m 2/sand 112 kJ/mol, respectively.
a) 1.2x1016
b) 7x10- 5
c) 7.0x10- 13
d) 3.2 xl0- 11
e) 8x10- 17

36
 117. Following on from the previous question, use Fick's First Law of Diffusion,
c1-Cz
j = D - - , to calculate the flux of Sn atoms across a copper plate at 6SOQC.
xl-xz
C1=100 g Sn/m 3, C2=1 g Sn/m 3 , XrX2= 0.001 m.
a) can't be done because problem is mathematically undefined
b) 3 .2x10-6 g.m -2 .s -1
c) 1.2 x10 5 g.m-2 .s- 1
-2 -1
d ) 6.9 g.m .s
e) 6.9x10· 8 g.m- 2.s- 1

118. Which of the following statements made about carburizing and nitriding heat
treatments is INCORRECT?
a) both treatments rely upon diffusion
b) nitriding often makes use of ammonia gas
c) charcoal is a possible source of carbon for carburizing
d) nitrided surfaces are generally softer than carburized ones
e) surface heat treated surfaces are generally more resistant to fatigue cracking

Joining processes
119. The difference between 'welding' and 'brazing' is that
a} in welding the work piece is partially melted but not in brazing
b) there is no melting of any part of the work piece during welding
c) welding applies to steel, brazing to copper-base alloys
d) welding uses an electric arc, brazing uses a gas flame
e) there is no difference, they are two terms for the same thing

120. The foremost purpose of the flux in welding is to

a) make a nice shiny black coating on the weld
b) remove impurities that were in the alloy of the work piece
c) protect the surface of the molten metal from oxidation
d) attenuate the noise made by welding
e) increase the hardenability of the weld metal

121. What element is now strongly discouraged in solder alloys compositions used in
most industrialized nations?
a) Sn
b) Ag
c) Pb
d) In
e) Zn

37
122. A design called for a glued joint with a tensile strength of 100 MPa. All else being
equal, your best adhesive type (of the list below) would be based on a
a) polyurethane
b) acrylic/PVC
c) polystyrene
d) polyimide
e) epoxy

123. The type of weld shown here is a

a) butt weld
b) V joint weld
c) fillet weld
d) edge weld
e) U-joint weld

124. In the schematic picture of a butt weld below, the light grey region marked with
the X is known as the

a) weld pool
b) heat affected zone
c) flux region
d) substrate
e) weld joint

125. In case of accidental contact, the solvent for cyanoacrylate adhesive ('super
glue') is
a) acetone
b) water
c) ethanol
d) dish wash soap
e) baby oil

38
 Materials Processing

126. The chemical reaction to make iron metal inside a blast furnace is
a) 2Ab03 + 3C -+ 4AI + 3C02
b) 4Fe+ 302-+ 2Fe203
c) Si02+02+Fe-+ FeSi04
d) Fe30 4+ C-+ Fe + C02
e) Fe203+3CO-+ 2Fe+3C02

127. Steel is made from molten iron-carbon alloy by

a) removing the extra carbon with molten lime
b) burning out a controlled amount of carbon with a jet of oxygen or air
c) allowing the carbon to settle to the bottom of the furnace
d) beating the iron-carbon alloy with a hammer
e) adding extra alloying elements

128. The amount of electrical energy to make a kg of AI from its oxide is

a) about 1 MJ which would cost industry about $1
b) about 1 MJ which would cost industry about $10
c) about 55 MJ which would cost industry about $1
d) about 55 MJ which would cost industry about $10
e) trick question! no electrical energy is required to make AI

129. The amount of 'embodied energy' in steel compared to aluminium

a) 11 times greater
b) about the same
c) about half
d) 8 times less
e) 126 times less

130. In the process of 'investment casting'

a) a wax master is made, coated with ceramic and then melted out to make a
mould
b) liquid metal is cast into a mould made out of sand
c) an investor buys up a lot of castings
d) a steel part of hammered into shape by a blacksmith
e) a liquid metal such as aluminium is forced into a steel mould

39
131. The re-usable positive master shape used to make the cavity for the liquid metal
during the sand casting process is known as a
a) 'gear blank'
b) 'wooden piece'
c) 'permanent mould'
d) 'pattern'
e) die

132. A suitable material for making a permanent die for the repeated die casting of
molten aluminium or magnesium is
a) aluminium
b) steel
c) wood
d) high strength polymer
e) polystyrene foam

133. The diagram shown is a schematic illustration of the process of

a) rolling
b) forging
c) drawing
d) extrusion
e) continuous casting

134. Circle the process that does not 'belong' in the list below
a) forging
b) turning
c) milling
d) reaming
e) drilling

40
 l ") !

H periodic table I-fe

'" "'",, ., ., [gJ
I

1.01 I
hv.Jmorcn hclumu i

3 4 5 6 7 8 9 10
Li Be B c N 0 F
I

C
6.9'' 9.01 tl/011//{ f/1(/\\ Q 12 0 l !0.81 12 01 1101 16.00 !9.00 I
lilhium benli....
"""""' bonm
"""""' nuoJinc
n)lroll(tl (JX'-'SI.CJ) UCHn
'
ll 12 demem.P 13 14 15 16 17 18
s Cl Ar
i

Na Mg AI Si p
22.99 24.31 18 09 .'\(J 97 J5A5
olimn ma1111Ciium a1unumum 'utfiu- ddtwinc
..
tih!o!on l'!btlil'lhdlrtb af\K)n

19 20 21 22 ")")
24 25 26 27 28 29 30 31 33 34 35 .Ill

K Ca Se Ti
39.10 40.08 44.96 47.87
V
50.9·t
Cr Mn Fe Co Ni Cu Zn Ga Ge As Se Br Kr
54.94 55.85 5891 58.69 63.55 65.W 71.92 78.98 N.90
t<mmmc
ll<ll""'"'"" calcium scandium
39
t.ii1111ium \'an.lldiwn daumlum maJ1,g8llOIC iron oobah .mckcl
'""""'
47
Llh(;

48
t

49 50
IINCfUC

51
.'JI('(auum

52
Lr.·rtou

5-1-
37 38 40 41 42 43 44 45 46 :'3
Rb Sr y Zr Nb Mo Tc Ru Rh Pd Ag Cd In Sn Sb Te I Xe
85.47 87.62 88.91 91.22 92.91 95.94 (9891) 101.1 Hl2.'1 !06..1 107 1 ) I 12.1 1118 11 X. 7 121 X 7 <• 12h.9 1.11 .1
mbid1um :Mmntimn \1tmrn :nrcooitun nitlbiwn molvhdenum tt'l.imtUum rutbemum rhndmrn nnlladtum Mfvcr cadnuum mJmm tm fdlunum 1ndrne '""'1Will

55 56 57-71 72 73 74 75 76 77 78 79 80 RI l\2 8.1 l\4 85 l\(1

Cs Ba # Hf Ta
132.9 137.3 178j 180.9
w
183.8
Re Os Ir Pt Au
186.2 190.2 192.1 !'15.1 197.0
Hg 'T'l
}(Ill l1 20·1 l
Pb Bi
2Pl}.\f
Po At Rn
l2 !0.0) i211l I>) I {lj
caum barium limlumltk• hafnium tantalum rhenium )Jatlnum .mercun thallium lc-Sid tllsmulh ...,,k,.tuun a ....twte l;u.k•IJ

87 88 89-103 104 105 106 107 108 109

Fr Ra * Rf Db Sg Bh l-Is Mt
{:!23.0) :!26.0 261.1 161.! 263.! 26<11 t265 I l
francium rndium ll<'llnim rnthcrforduun tJubaiu.u1 bohrium h.&'i.:'>ium nlCltncnum

58 59 60 61 62 (l3 (l4 66 (,7 M< ()') 70 I

57
-rb 'I
(15

# lanthanides La Ce Pr Nd Prn Sm Eu (id I )2 !1

Dy llo Er Ttn Yb Lu
I !Id•) .1 ! ,0 .' .., <I
Ll8.9 140.1 1-W.'i 11·1.2 i IH•. 9 l 157.3 1 'X') Jl,\.') I
lanthaDUnl cmum tlL'!f.lJvmium I promcthmm sam:mum cun..ptum Jl-nJt•hmum l\.'l"hmm Jvspro.'imm h\\lnmun 1."'1hunn lhlll!UUl \ll..:ll•la'l"tl hHCIJUlll

89 90 91 92 .l 94 95 9(J 1J7 i.JX ()l) lOO 101 1112 w;

* actinides Ac Th Pa lJ Np Pu An1 Ctn Bk Cf Es Fin
232 () :5
Md No Lr
2.'\ 1 () (24-1) !21.') 1.:r:1
I

12711 (2·171 <>ll ! 1 ...;_X l I 2hl·; I

i><l oc,1inium lhl.:lfium .Pfll(lk.'tliHUin lU1Ulltillll ncph.munn rluMmunt .amcncunn cunum t'ocd.:.dmm c:;llf.,'oflllllln <ltl."!hkk\·1\om u,>tocl:tllll l;t•qi..'fll.. ldm I

41
 P.quations, Cliarts etc.

'#_alloj6

100

'ii 10
Q. Lmgit.Jdinal
Q. ......... speed Nontechnical
I.Q
...
.iZ
cQfllllllcs

""
J'l
1:11 1()'
c
""
1()2

100 1000 10,()')()

Dllnslty p

100
'ii'
lla!
10
3
...
:::1

I
0"11:
:::1

0.1

42
 MatEie and polyme<B: yiak:l atrergth, (J,
Ceramic.s, gle.I!I!B!l: m:xlulua d rup1llrn·. lvOR
Eie.BiorT81!l: lanoile taor atrnngth, 11 r
1000
O::tmpooites: tensie failre, a,

r-----ll_ Ccpper
100 · allC')'S

8: l
I
b f\ I
.c 10 · ·-·""···-l>C .. /
r.c Zlncalbya \
Q__ Lood ··
i Reinforced
concrete
· ·'

x
Fooms

0.1

1000 10.000
Donsity p

Bubble Plots from, Materials Selection in Mechanical Design, 41h Ed. M. Ashby, Elsevier, 2011

E
p
Elf2
p
2/3
1:_
p
El/2
Cmp
2!3
Boom, minimum cost, stnngth prescribed <y'
Cmp
Cofurm, minimum cost, budding loa:! proo<rt;OO Eli2
Cmp

Ep
1
J.CpP
Cpp
p,
p = d:tlsitt; E = modlll.lti; <y = e1eStiC limit; C,.. = costh<g J = tll(;mttll cofdc.dMty;
p,. = J'f'JSfst#J'Ity; Cp = sp;x:JIC llet:4

43
 E=kEfVf +Em Vm
1 V1 Vm
-=-+-
E Et Em

2D random, k = 0.375
3D random, k= 0.2

K = ()Y-J(rra)
Avogadro's Number = 6.022 x 10 23

Universal Gas Constant, R, = 8.313 Jmol- 1 K- 1

3FL
MOR = 2bhz
My
()=-
/
I \
c

* = arVr
a"d * (' ·•J
. .{ +um'(.1-Vr.
. . . 1--
21
')
' .

Tabulation of Error function Values

z erf(z) z erf(z) z erf(z)

0 0 0.55 0.5633 1.3 0.9340
0.025 0.0282 0.60 0.6039 1.4 0.9523
0.05 0.0564 0.65 0.6420 1.5 0.9661
0.10 0.1125 0.70 0.6778 1.6 0.9763
0.15 0.1680 0.75 0.7112 1.7 0.9838
0.20 0.2227 0.80 0.7421 1.8 0.9891
0.25 0.2763 0.85 0.7707 1.9 0.9928
0.30 0.3286 0.90 0.7970 2.0 0.9953
0.35 0.3794 0.95 0.8209 2.2 0.9981
0.40 0.4284 1.0 0.8427 2.4 0.9993
0.45 0.4755 1.1 0.8802 2.6 0.9998
0.50 0.5205 1.2 0.9103 2.8 0.9999

44