GTU Paper Analysis

Material Science & Metallurgy (2141903) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 1 – Introduction to Material science & Metallurgy

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Theory

1. State the importance of study of materials science and briefly. Explain

Engineering requirements of materials. 07

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2. Explain selection criteria for engineering materials. 07 07 07

3. Evaluate “After etching the micro specimen structure is visible”. Also

Write a short note on macro- examination. 07

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4. Define 1) Toughness 2) Hardness 3) Hardenability 4) Malleability 5)

Creep 6) Elasticity 7) Ductility. 03 05 07 04

5.

State utmost required engineering properties for following

applications: 1. Bolt 2. Gear 3. Helical Spring 4. Shaft 5. Cutting Tool 6.

Cylinder of I.C. Engine 7. Gas Turbine Blade.

07

6. Differentiate metal and non metal and enlist the engineering requirements of material.

04 04

7. Correlate the property of thermal conductivity and hardness with

internal structure of the material.

03

8.

State the four major materials groups for materials classification,

bring outthe basis of its classification and mention the important

characteristics of each group.

04

9. Differentiate: Ductility and Malleability. 03

GTU Paper Analysis

Material Science & Metallurgy (2141903) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

10.

Explain process to be followed for preparation of metallic specimen

to see the microstructure under optical microscope. Name only

commonly used etchant.

07

11. What is metallography ? What useful information can be obtained

from it ?

07

12. Draw neat sketch of metallurgical microscope. Explain its

construction. 07

13. Compare and contrast: micro and macro examination. 03 04

14. Discuss importance of knowledge on “Material Science & metallurgy” to mechanical engineers.

07

15. Define the following properties : (1) Toughness (2) Creep (3) Fatigue (4) Ductility

04

16. Explain Structure Property and Performance relationships with a suitable example

07

17. What are the various levels of structure? Explain in detail. 07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 2 – Crystal Geometry and Crystal Imperfactions

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1.

Explain with neat sketches the arrangement of atoms in B.C.C, F.C.C.

and H.C.P. lattice. Define unit cell. Show that a F.C.C. structure is

always more close packed than B.C.C. structure.

05

2. Draw any three most commonly observed space lattice structure in metallic elements.

03

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 3 – Plastic Deformation

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1. Differentiate between edge dislocation and screw dislocation 04 03

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 4 – Solidification of Metals and Alloys

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1. With neat sketches, explain Solidification of Metal. 07

2. Differentiate under-cooling and constitutional super-cooling in

context of solidification and its effect on final structure.

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3. Explain homogenous and heterogeneous nucleation with neat

sketches.

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4. Explain the three basic zones formed after solidification of alloys. 07

5. What are the various methods of controlling grain structure during

solidification? Explain in detail.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 5 – Phase and Phase Equilibrium

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Theory

1. What is solid solution? Explain types of solid solution. Also give Hume

Rothery’s Rules. 07

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2.

What is Gibb’s phase rule? Define system, phase and degree of

freedom. Show that the degree of freedom at eutectic point in a

binary phase diagram is zero.

07

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3.

The following data is for Pb-Sn alloy system : (Lead-Tin Solder)

· Melting point of lead (Pb) – 327⁰C

· Melting point of Tin (Sn) – 232⁰C

· Eutectic alloy is formed at 183⁰C with 62% Sn –38% Pb

· Maximum solid solubility of tin in lead at 183⁰C –19%

· Maximum solid solubility of lead in tin at 183⁰C –3%

· Maximum solubility of tin and lead at room temperature negligible.

(1)Draw the phase diagram with the help of above data and label all

the points, lines and regions on it.

(2) For 70%Pb – 30%Sn alloy composition, determine the amounts of

proeutectic and eutectic constituents at room temperature.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

4.

Say at point “Q” in (Liquid+Solid) region in a phase diagram, a line

passing through point “Q” and parallel to the base is drawn. The line

intersects the liquidus and solidus at points P and R respectively. Can

you determine %Solid at point Q if PR is 6 cm and QR is 2.4 cm in

length? If answer is YES, determine % Solid and if NO, justify your

answer.

04

5. What is the significance of Liquidus, Solidus and Solvus line in phase

diagram? 03

6. Draw cooling curve of (i) pure metal and (ii) An alloy of two metals which are completely soluble in liquid and solid phase.

03

7. What is phase diagram? Explain Lever rule. 07

8. What is cooling curve? How does the time temperature cooling curve

of an alloy of eutectic composition different from that of a pure metal?

05

9. Compare cooling curves for pure metal, isomorphous and non-isomorphous alloys. State the information revealed by these cooling curves.

07

10. Explain the thermal equilibrium diagram for a case wherein two metals are completely soluble in liquid and solid state forming an isomorphous alloy system.

03

11. What is solid solution? What are the types? Explain them with neat sketch. Under which condition interstitial solid solution is feasible?

07

12. What is substitutional and interstitial solid solution. Why solubility of solute is limited in interstitial solid solution? Justify.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 6 – Allotropy of Iron

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1. Define Allotropy. Explain allotropy of Iron. 03 05

2. Draw Iron Carbon Equilibrium diagram. 04 07

3.

With the aid of steel portion of an iron-iron carbide equilibrium

diagram, showing solid state transformations compare the

transformations during cooling under equilibrium conditions from

solidus to room temperature of typical hypereutectoid steel and

hypoeutectoid steels. Compare the resulting microstructure at room

temperature and related properties.

07

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4. State Critical Reactions of Iron Carbon Phase diagram. 06 07

5. Draw microstructure of (i) 0.4 % carbon steel and (ii) eutectoid steel

at room temperature.

05

6. Draw iron – iron carbide equilibrium diagram with all necessary details. Briefly explain cooling of 1.2 % carbon steel from liquid state to room temperature

04 07 07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 7 – Heat Treatment of steel

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1. Which are various Surface Hardening processes? Explain Induction

Hardening process with sketch. 07

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2. Which are the objectives of Heat Treatment? 03

3. Give difference between Annealing and Normalising. 04 07 06 07 07 04

4. Define Critical Cooling Rate of steel and show the same on a TTT

diagram with complete labelling. 07

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5. Write full names of following acronyms: BHN ; AISI ; ASTM ; TTT 04

6. Draw microstructure of eutectoid steel. 04

7. Differentiate between austempering and martempering. 05 07 03 04

8. Case carburizing heat treatment is not generally carried out for

medium carbonsteels. Why?

04

9. Explain flame-hardening process in brief. 04 03

10. State Case Hardening processes and explain any one in detail. 07 07

11. For hardening of steels, which quenchant would you prefer, water or

oil? Explain reasons.

07

12. Compare and contrast flame hardening and induction hardening on the basis of uniformity of case depth, parametric controls, process

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

features, process limitations and applications.

12. Compare and contrast carburizing and nitriding process with reference to parametric controls, process features, process limitations and applications.

07

13.

What is the purpose of heat treatment ? Differentiate Annealing and Normalizing on the basis of : (I) Rate of cooling (II) Microstructure after cooling (III) Grain size distribution (IV) Internal Stresses (V) Mechanical properties (VI) Application

07

14. What is strain hardening ? Explain how the effect of strain hardening can be eliminated by recrystallization?

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 8 – Alloy steels

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1. Briefly explain why ferritic and austenitic stainless steels are not

heat treatable. ii Distinguish between hardness and harden ability

07

2. State composition, specific properties and applications of high carbon

steel.

07

3. Explain the method of Sulphur Printing for steels and state the inferences that could be drawn out by the technique

03

4. On the basis of microstructure and chemical composition explain the properties obtained in high speed steel and stainless steel.

07

5. It is require finding out hardenabilty of an alloy steel. Explain procedure to be followed to find out and the equipments required for the same.

07

6. What is plain carbon steel? Also explain all type of plain carbon steel with the composition and specific application.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 9 – Cast Iron

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1. List properties of wrought Iron. 04 07 05

2. Give composition, properties and uses of malleable cast iron. 07 07 07

3. Differentiate between gray cast iron & spheroidal cast iron in terms of

microstructure, properties, composition & applications. 07

07

4. What is “Wrought Iron”? Enlist the properties and uses of it. 07 04

5. Specify, with reasons alloy suitable for the manufacture of : Bolts and

Nuts ; Lathe Bed ; Milling Cutte

06

6. Differentiate between white cast iron and grey cast iron. 07 04

7. Enlist properties of a good bearing material. 05

8. Classify types of cast iron. Discuss any on. Draw its microstructure

also.

05

9. State composition, specific properties and applications of White Cast

Iron.

07

10. Draw the microstructure of wrought iron and enlist the properties and uses of wrought iron.

03

11. Compare malleable cast iron and spheroidal graphite iron on the basis of microstructure, properties and applications.

07 07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

12. On the basis of colour and sparking pattern in the spark test, differentiate gray cast iron from malleable iron.

03

13. Classify different types of cast iron. Why silicon is added to cast iron? Explain the effects of any four alloying elements on the properties of cast iron.

07

14. Draw microstructure of [i] Nodular cast iron [ii] eutectoid steel at room temperature along with magnification, etchant used and description of microstructure.

07

15. Explain the property requirement from a bearing material. Explain journal bearing material in detail.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 10 – Non-Ferrous alloys

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Theory

1. Give composition, properties and uses of Y alloy. 07

2. What are the purposes of alloying? Give effects of Nickel as an

alloying element. 07

07

3. Give composition and uses of Monel metal and Nichrome. 07

4. Define “Alloy”. Also state composition, properties & uses of any two

copper alloys 07

5. State the difference between impurities and alloying elements. State

importance of alloying.

04

6. State function of following alloying elements in steel : Sulphur ; Nickel ; Chromium ; Boron

04

7. State composition and specific applications of : Muntz metal ; German

silver ; Naval brass

06

8. What are the properties of bearing alloys What are the properties of

aluminium alloys

07

9. Give composition and use of White metal and Monel metal. 07 04

10. Explain modified aluminum silicon alloys. 05

11. Define the term “Non Ferrous”. State composition, specific properties 07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

and applications of 1. Muntz Metal 2. Duralumin

12.

How will you classify brasses based on the composition of zinc

Explain the properties & application of the main type of brasses.from

it ?

05

13. State the Qualities Required in Bearing Metals. State composition,

specific properties and applications of Babbit

07

14. Enlist the properties of pure copper and mention the composition, properties and application of phosphorus bronze.

07

15. Enlist the properties of pure Aluminum and mention the composition, specific properties and application of any one aluminum alloys

07

16. Mention in brief the role of Nickel, Chromium, Molybdenum and Vanadium as alloying element in steel.

07

17. On the basis of microstructure and chemical composition explain the properties obtained in bearing alloys and aluminum silicon alloys.

07

18. Enlist copper and its alloys. Explain any two of them along with its properties and use

07

19. Write following alloys giving their important constituents & Application : (I) Monel (II) Invar (III) Nichrome

03

20. Classify Brasses based on the composition of zinc ? Explain properties & Application of the main type of Brasses.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 11 – Powder Metallurgy

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1. Which are advantages and limitations of powder metallurgy? 07 07 06 07 07 07 07 04

2. Explain any two methods for production of metal powders. 07 05

3.

What is powder metallurgy? Describe various steps involved in

powder metallurgy with each step controlling properties of final

sintered component

07

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4. Enlist the products made from powder metallurgy. Explain all four

steps of power metallurgy.

07

5.

Explain the process steps involved in making of a powder metallurgical product. As regards to powder metallurgy, explain the role of process parameters, positive features and limitations of this method.

07 07 07

6. How can we produce porous self lubricating bearings through powder metallurgy? Explain the process steps and process limitations for manufacturing the same.

07

7. How can we produce cemented carbide tools through powder metallurgy? Explain the process steps and process limitations for manufacturing the same.

07

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

Chapter 12 – Non-Destructive Testing

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1. What is non destructive test? List various non destructive tests.

Explain X ray Radiography. 07

2. Explain Ultrasonic testing with advantages and limitations. 07 07 07 07 07 07

3.

State the advantages or importance of nondestructive testing over

destructive testing of materials. Differentiate between X-ray

radiography & γ-ray radiography of materials

07

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4. Explain the NDT method widely used for inspection of castings 06

5. Suggest and explain a simple and economical NDT method to

determine minute surface defects in large size component.

04

6. Write the procedure for Jominy end quench practical and discuss its conclusion.

07 07 07

7. Which non-destructive test is used for finding defects on welded

joints? Explain it.

07 07

8. Compare and Contrast: Destructive test with Non Destructive test. 04

9.

Suggest with suitable reasoning the non destructive tests required to determine slag inclusions and porosity in the fusion weld joint. The fusion weld butt weld joint is made in 5 mm thick plain carbon steel sheet (carbon 0.15% by wt) by the arc welding process.

03

GTU Paper Analysis

Material Science & Metallurgy (2131904) Department of Mechanical Engineering Darshan Institute of Engineering & Technology

10. It is required to find out surface defects for the cast product. Which NDT process you will use? Explain basic principle and limitations of the test you have selected

07

11. Explain the steps of Dye Penetrant Testing with neat sketch 07