JEPPIAAR ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

ME 6403 ENGINEERING MATERIALS AND

METALLURGY

II YEAR/ IV SEMESTER

QUESTION BANK
 Vision of Institution
To build Jeppiaar Engineering College as an institution of academic excellence in
technological and management education to become a world class university.
Mission of Institution
 To excel in teaching and learning, research and innovation by promoting the
principles of scientific analysis and creative thinking.
 To participate in the production, development and dissemination of knowledge and
interact with national and international communities.
 To equip students with values, ethics and life skills needed to enrich their lives and
enable them to meaningfully contribute to the progress of society.
 To prepare students for higher studies and lifelong learning, enrich them with the
practical and entrepreneurial skills necessary to excel as future professionals and
contribute to Nation’s economy.
Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and
PO1 an engineering specialization to the solution of complex engineering problems.
Problem analysis: Identify, formulate, review research literature, and analyze complex engineering
PO2 problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and
engineering sciences.
Design/development of solutions: Design solutions for complex engineering problems and design
PO3 system components or processes that meet the specified needs with appropriate consideration for the
public health and safety, and the cultural, societal, and environmental considerations
Conduct investigations of complex problems: Use research-based knowledge and research methods
PO4 including design of experiments, analysis and interpretation of data, and synthesis of the information to
provide valid conclusions.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
PO5 engineering and IT tools including prediction and modeling to complex engineering activities with an
understanding of the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal,
PO6 health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional
engineering practice.
Environment and sustainability: Understand the impact of the professional engineering solutions in
PO7 societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the
PO8 engineering practice.
Individual and team work: Function effectively as an individual, and as a member or leader in diverse
PO9 teams, and in multidisciplinary settings.
Communication: Communicate effectively on complex engineering activities with the engineering
PO10 community and with society at large, such as, being able to comprehend and write effective reports and
design documentation, make effective presentations, and give and receive clear instructions.
Project management and finance: Demonstrate knowledge and understanding of the engineering and
PO11 management principles and apply these to one’s own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments.
Life-long learning: Recognize the need for, and have the preparation and ability to engage in
PO12 independent and life-long learning in the broadest context of technological change.
 JEPPIAAR ENGINEERING COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING

VisionoftheDepartment

To create excellent professionals in the field of Mechanical Engineering and to uplift the
quality of technical education on par with the International Standards.

Department Mission

1. To reinforce the fundamentals of Science and Mathematics to Mechanical

Engineering and critically and relatively investigate complex mechanical systems and
processes.
2. To engage in the production, expansion and practice of advanced engineering
applications through knowledge sharing activities by interacting with global
communities and industries.
3. Toequip students with engineering ethics, professional roles, corporate social
responsibility and life skills and apply them for the betterment of society.
4. To promote higher studies and lifelong learning and entrepreneurial skills and develop
excellent professionals for empowering nation’s economy.
PEO’s

5. To enrich the technical knowledge of design, manufacturing and management of

mechanical systems and develop creative and analytical thinking in research.
6. To relate, strengthen and develop the theoretical knowledge of the Mechanical
Engineering by exhibiting various concepts applied through diverse industrial
exposures and experts’ guidance.
7. Facilitate the students to communicate effectively on complex social, professional and
engineering activities with strict adherence to ethical principles.
8. Create awareness for independent and life long learning and develop the ability to
keep abreast of modern trends and adopt them for personal technological growth of
the nation.
PSO’s

1. To understand the basic concept of various mechanical engineering field such as

design, manufacturing, thermal and industrial engineering.
2. To apply the knowledge in advanced mechanical system and processes by using
design and analysis techniques.
3. To develop student’s professional skills to meet the industry requirements and
entrepreneurial skills for improving nation’s economy stronger.
 ME 6403 ENGINEERING MATERIALS AND
METALLURGY

COURSE OUTCOMES

Relate the atomic arrangements of different metal combination and variation of carbon content
C213.1
in iron

C213.2 Outline the knowledge of various heat treatment process with different cooling curves

C213.3 Classify the physicsl characteristics of ferrous and non ferrous metals and its alloys

C213.4 Distinguish the knowledge of various polymers,ceramics and composites.

C213.5 Elaborate mechanical properties and different deformation mechanisms.

ME6403 ENGINEERING MATERIALS AND METALLURGY L T P C 3 0 0 3

OBJECTIVES:

 To impart knowledge on the structure, properties, treatment, testing and applications

of metals and non-metallic materials so as to identify and select suitable materials for
various engineering applications.

UNIT I ALLOYS AND PHASE DIAGRAMS 9

Constitution of alloys – Solid solutions, substitutional and interstitial – phase diagrams,
Isomorphous, eutectic, eutectoid, peritectic, and peritectoid reactions, Iron – carbon
equilibrium diagram. Classification of steel and cast Iron microstructure, properties and
application.

UNIT II HEAT TREATMENT 10

Definition – Full annealing, stress relief, recrystallisation and spheroidising – normalising,
hardening and Tempering of steel. Isothermal transformation diagrams – cooling curves
superimposed on I.T. diagram CCR – Hardenability, Jominy end quench test - austempering,
martempering – case hardening, carburizing, Nitriding, cyaniding, carbonitriding – Flame and
Induction hardening – Vacuum and Plasma hardening. .

UNIT III FERROUS AND NON-FERROUS METALS 9

Effect of alloying additions on steel- α and β stabilisers– stainless and tool steels – HSLA,
Maraging steels – Cast Iron - Grey, white, malleable, spheroidal – alloy cast irons, Copper
and copper alloys – Brass, Bronze and Cupronickel – Aluminium and Al-Cu – precipitation
strengthening treatment – Bearing alloys, Mg-alloys, Ni-based super alloys and Titanium
alloys.
UNIT IV NON-METALLIC MATERIALS 9
Polymers – types of polymer, commodity and engineering polymers – Properties and
applications of various thermosetting and thermoplastic polymers (PP, PS, PVC, PMMA,
PET,PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE, Polymers – Urea and Phenol
formaldehydes)- Engineering Ceramics – Properties and applications of Al2O3, SiC, Si3N4,
PSZ and SIALON –Composites-Classifications- Metal
Matrix and FRP - Applications of Composites.
UNIT V MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS 8
Mechanisms of plastic deformation, slip and twinning – Types of fracture – Testing of
materials under tension, compression and shear loads – Hardness tests (Brinell, Vickers and
Rockwell), hardness tests, Impact test lzod and charpy, fatigue and creep failure mechanisms.

TOTAL : 45 PERIODS

OUTCOMES:

Upon completion of this course, the students can able to apply the different materials, their
processing, heat treatments in suitable application in mechanical engineering fields.

TEXT BOOKS:
1. Avner,, S.H., “Introduction to Physical Metallurgy”, McGraw Hill Book Company,1994.
2. Williams D Callister, “Material Science and Engineering” Wiley India Pvt Ltd, Revised
Indian Edition 2007

REFERENCES:
1. Raghavan.V, “Materials Science and Engineering”, Prentice Hall of India Pvt. Ltd., 1999.
2. Kenneth G.Budinski and Michael K. Budinski, “Engineering Materials”, Prentice Hall of
India Private Limited, 4th Indian Reprint 2002.
3. Upadhyay. G.S. and Anish Upadhyay, “Materials Science and Engineering”, Viva Books
Pvt. Ltd., New Delhi, 2006.
4. U.C.Jindal : Material Science and Metallurgy, "Engineering Materials and Mettalurgy",
First Edition, Dorling Kindersley, 2012
 JEPPIAAR ENGINEERING COLLEGE

Jeppiaar Nagar, Rajiv Gandhi Salai – 600 119

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

IV SEMESTER
ME 6403 ENGINEERING MATERIALS AND METALLURGY
Regulation – 2013
 JEPPIAAR ENGINEERING COLLEGE
Jeppiaar Nagar, Rajiv Gandhi Salai – 600 119

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

SUBJECT : ME 6403 ENGINEERING MATERIALS AND METALLURGY

YEAR /SEM: II /IV

UNIT I ALLOYS AND PHASE DIAGRAMS

Constitution of alloys – Solid solutions, substitutional and interstitial – phase diagrams,
Isomorphous,eutectic, eutectoid, peritectic, and peritectoid reactions, Iron – carbon equilibrium
diagram.Classification of steel and cast Iron microstructure, properties and application.
PART-A
CO Mapping: C212.1
Q.No Questions BT Competence PO
Level
1 What is an alloy? BTL-1 Remembering P01
2 How many components are found in an alloy? BTL-2 Understanding P02
3 What is meant by base metal? BTL-2 Understanding P02
4 What are alloying elements? BTL-1 Remembering P01
5 Distinguish between substitutional and BTL-1 Remembering P01
interstitial solid solution.
6 How Hume Ruther’s rules for formation of BTL-1 Remembering P04
substitutional solid solutions.
7 What are intermediate phases? BTL-1 Remembering P01,P02
8 What are intermetallic compounds? BTL-1 Remembering P01,P02
9 What are electron compounds? BTL-1 Remembering P01,P02
10 Define phase’. What different kinds of phases
are possible? BTL-1 Remembering P01,P02

11 What is an equilibrium phase diagram? BTL-1 Remembering P06

12 What are the advantages of the equilibrium BTL-1 Remembering P01
diagrams?
13 Explain Gibb’s phase rule? BTL-1 Remembering P11
14 What are cooling curves? BTL-2 Understanding P02
15 What is liquids line? A Solidus line? A solves
line? BTL-1 Remembering P01

16 What pieces of information can be obtained for BTL-1 Remembering P10

each point in a phase diagram?
17 What is tie-line? BTL-1 Remembering P09
18 What is the lever-law calculation and what
information can it provide? Opposite arm of BTL-1 Remembering P11
lever
19 What is mean by invariant reaction? BTL-1 Remembering P07
20 What do you understand by allotropy of iron’? BTL-5 Evaluating P01,P02,P03
21 Define: ferrite and austenite. BTL-1 Remembering P01,P02
22 Define: Cementite and Pearlite? BTL-2 Understanding P02
23 Define: martensite, and bainite? BTL-1 Remembering P12
24 Define: martensite, and bainite? BTL-1 Remembering P01,P02
25 Define: martensite, and bainite? BTL-3 Applying P08
26 Define Solid Solution BTL-1 Remembering P01,P02
27 Define eutectic reaction BTL-3 Applying P01
28 What are three primary groups of plain carbon BTL-1 Remembering P13
steels?
29 Define solid solution? BTL-1 Remembering P01
30 What are the limitations of equilibrium diagram? BTL-1 Remembering P01
PART-B&C
1 Explain the various invariant reactions involved
in the system with the help of the Fe-C BTL-1 Remembering P01
equilibrium diagram.
2 Metal ‘A’ has melting point of 1000° C. Metal
‘B’ has melting point of 500° C. Draw one phase
diagram (between the elements ‘A’ and ‘B’ ) for
each of the following conditions The two BTL-2 Understanding P01,P02
elements exhibit unlimited solid solubility.
ii. The alloy system shows formation of two
terminal solid solutions and a Eutectic point at
60% A at 700 ° C.
3 Explain the microstructure, properties and
applications of any two types of BTL-2 Understanding P10
Steel and Cast iron.
4 Explain with a phase diagram of eutectoid and
paratactic reaction. BTL-1 Remembering P10

5 Explain with neat sketch the eutectic systems. BTL-2 Understanding P10
Give examples for these systems.
6 Explain the two types of solid solution with the BTL-1 Remembering P01,P02
help of neat sketch
 UNIT II HEAT TREATMENT
Definition – Full annealing, stress relief, recrystallisation and spheroidising – normalising, hardening and
Tempering of steel. Isothermal transformation diagrams – cooling curves superimposed on I.T. diagram CCR
– Hardenability, Jominy end quench test - austempering, martempering – case hardening, carburizing,
Nitriding, cyaniding, carbonitriding – Flame and Induction hardening – Vacuum and Plasma hardening.
PART-A
CO Mapping: C212.2
Q.No Questions BT Competence PO
Level
1 Define the term heat treatment BTL-1 Remembering P01,P02
2 What are the purposes of the processing heat
treatments? BTL-1 Remembering P01,P02

3 List the various stages of a heat treatment

process. BTL-1 Remembering P05

4
List some of the important heat treatment BTL-1 Remembering P01,P02
operations widely used.

5 What is meant by annealing? BTL-1 Remembering P01

6 What are the purposes of annealing? BTL-1 Remembering P03
7 List the different types of annealing. BTL-1 Remembering P01,P02
8 What is meant by normalizing? BTL-1 Remembering P01,P02
9 What is quenching? List some of the
quenching medium generally used in BTL-1 Remembering P01,P02
industries.

10 What are the factors should be considered while BTL-1 Remembering P04
selecting a quenching?
11 What are the three stages for quenching BTL-1 Remembering P01
12 What does the term hardening refer? What are BTL-1 Remembering P09
the factors affecting the hardness?
13 Distinguish the work hardening with the age
hardening process. BTL-4 Analyzing P01,P02

14 Justify the tempering process usually follows BTL-5 Evaluating P10

hardening process.
15 What is the effect of: (a) tempering temperature,
and (b) tempering time, on the hardness of BTL-1 Remembering P06
steels?

16 What do you mean by temper embrittlement? BTL-2 Understanding P05

17
What is TTT diagram? BTL-1 Remembering P01

18 What is the significance of TTT diagram in the

heat treatment of steel? BTL-1 Remembering P13

19 Why are TTT diagrams usually not applicable to BTL-1 Remembering P01,P02
industrial engineering practices?
20 What is CCT diagram? BTL-1 Remembering P09
21 Define the term critical cooling rate. What are BTL-1 Remembering P11
the factors affecting it?
22 What is significance of the critical cooling rate? BTL-1 Remembering P01
23 What is meant by hardenability? What are the BTL-1 Remembering P01,P02
factors affecting it?
24 What is the difference between hardness and BTL-1 Remembering P01
hardenability?
25 What is martempering and austempering? BTL-1 Remembering P12
26 Define hardenability. BTL-1 Remembering P01,P02
27 Define spheroidizing? BTL-1 Remembering P01
28 What is the purpose of the deep freezing in the BTL-1 Remembering P10
heat treatment of steel?
29 Differentiate annealing and normalizing? BTL-1 Remembering P01,P02

30 Differentiate carburizing and nitriding? BTL-1 Remembering P01,P02

PART-B&C
1 Distinguish between annealing and normalizing. BTL-4 Analyzing P01,P02,P03
2 Explain with neat setup figure the working BTL-5 Evaluating P01,P02,P03
principle of an induction hardening
3 Explain Jominy test (or) End quench
hardenability test with the help of the neat BTL-5 Evaluating
sketches
4 What is annealing? Discuss in detail on different
types of annealing and compare with BTL-1 Remembering P07
normalizing.
5 Develop a short note on: (i)Hardenability , (ii) BTL-3 Applying P10
Nitriding, (iii) Flame hardening ,(iv) Cyaniding.
6 Distinguish between hardness and hardenability.
With suitable sketches, explain the hardness test BTL-4 Analyzing P01,P02
for hardenability.
7 Explain TTT diagram with neat sketch and BTL-5 Evaluating P05
indicte all the phases with microsturcture.
 UNIT III FERROUS AND NON-FERROUS METALS
Effect of alloying additions on steel- α and β stabilisers– stainless and tool steels – HSLA, Maraging
steels – Cast Iron - Grey, white, malleable, spheroidal – alloy cast irons, Copper and copper alloys –
Brass, Bronze and Cupronickel – Aluminium and Al-Cu – precipitation strengthening treatment –
Bearing alloys, Mg-alloys, Ni-based super alloys and Titanium alloys.
PART-A
CO Mapping: C212.3
Q.No Questions BT Level Competence PO
1 What are the properties of steel? BTL-1 Remembering P01
2
What are metals? Classify engineering materials BTL-1 Remembering P01,P02
3 What are ferrous metals? Classify ferrous BTL-1 Remembering P01,P02
materials.
4 How to you enhance mechanical strength of Al? BTL-1 Remembering P01
5 How can you specify steel? What is the difference BTL-1 Remembering P01
between 4140 steel and 4340 steel?
6 What are three primary groups of plain carbon BTL-1 Remembering P03
steels?
7 What are alloy steels? How are alloy steels
classified? BTL-1 Remembering P01,P02

8 List four important alloying elements added in BTL-3 Analyzing P01,P02

alloy steels.
9 Why is alloying done? BTL-1 Remembering P01,P02
10 What are the primary effects of chromium, and BTL-1 Remembering P01
copper as alloying elements in steel?
11 What are the effects of lead and sulphur on the BTL-1 Remembering P01
machinability of steels?
12 Which alloy elements are basically a) carbide
formers, and b) graphite promoters? BTL-1 Remembering P01,P02

13 What makes stainless steel stainless? BTL-1 Remembering P01

14 Why do stainless steels lose their corrosion
resistance when the chromium in solution drops BTL-1 Remembering P01,P02
below 12%?

15 What determines whether a stainless steel is

austenitic ferritic, or martenistic? BTL-1 Remembering P06

16 What are the required properties of a tool steel? BTL-1 Remembering P01,P02
17 How can you classify tool steels? BTL-1 Remembering P01,P02
18 What is meant by 18-4-1 high speed steel? BTL-1 Remembering P08
19 What are HSLA steels? Where are they used? BTL-1 Remembering P01,P02
20 What are maraging steels? Give its composition. BTL-1 Remembering P01,P02
21 What are the heat resisting steels and free- BTL-1 Remembering P09
machining steels?
 22 What are the features that make cast iron an
important material? BTL-1 Remembering P01,P02

23 What are the effects of carbon on the properties of BTL-1 Remembering P01
cast iron?
24 What is the influence of cooling rate on the BTL-1 Remembering P10
properties of a cast iron?
25 How can you classify cast irons? BTL-1 Remembering P12
26 Define Toughness BTL-1 Remembering P01,P02
27 What is twinning in metals? BTL-1 Remembering P12,P13
28 What is creep? BTL-1 Remembering P01,P02
29 What is the effect of chromium alloying element BTL-1 Remembering P01,P02
on the properties of steel?
30 What is bearing alloys? BTL-1 Remembering P11
PART-B&C
1 Explain precipitation hardening with a neat sketch, BTL-1 Remembering P01,P02
2 Choose the composition, properties and uses of BTL-1 Remembering P01,P02
bearing alloys.
3 Develop short notes about the following materials
in terms of composition ,properties and
applications.(i) Maraging steels BTL-3 Applying P01,P02
(ii) Alpha-beta brasses (iii) Austenitic stainless
steels (iv) Ferrite stainless steels
4 What are the influences of alloying Al, Cr, Ni, Mo, BTL-1 Remembering P01,P02
Si, Mn, V and Cu in steel? Explain in brief.
5 What are the properties of aluminium? And what
is the effect of different types of alloying elements BTL-1 Remembering P01,P02,P03
such as copper, iron, managanese, magnesium
used with aluminium and its application? Explain.
6 Develop short notes on:
i)Maraging steels, (ii) Stainless steels, (iii) High BTL-5 Applying P01,P02,P03
speed steels iv) Tool steels iv)HSLA

7 Name non-ferrous materials for the following

articles
a. Bush
b. Furnaces heating element
c. Type writer parts
d. Coins
e. Girders for airship BTL-1 Remembering P01,P02
f. Big end bearing
g. Filament of electric lamps
h. Turbine blades
(ii)Write short notes on
Bearing metals, Brasses.

8 Explaining age hardening of Al-Cu with the heplp BTL-5 Evaluating P01,P02,P03
of phase diagram
 UNIT IV NON-METALLIC MATERIALS
Polymers – types of polymer, commodity and engineering polymers – Properties and
applications of various thermosetting and thermoplastic polymers (PP, PS, PVC, PMMA,
PET,PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE, Polymers – Urea and Phenol
formaldehydes)- Engineering Ceramics – Properties and applications of Al2O3, SiC, Si3N4, PSZ
and SIALON –Composites-Classifications- Metal Matrix and FRP - Applications of Composites.
PART-A
CO Mapping: C212.4
Q.No Questions BT Competence PO
Level
1 What are polymers? BTL-1 Remembering P01
2 List any four attractive characteristics of
polymers. BTL-1 Remembering P01

3 Classify polymers. BTL-1 Remembering P02

4 Define the following terms: i) Monomer, ii)
Homo polymer, and iii) Copolymer. BTL-1 Remembering P01

5 What is meant by isomerism? BTL-1 Remembering P01,P02

6 What is meant by the term „unsaturated BTL-1 Remembering P01
molecule’? State its significance in plastics
7 What is polymerisation? BTL-1 Remembering P01,P03
8 Define the term „degree of polymerisation’? BTL-1 Remembering P01
9 What is the difference between
addition polymerisation and BTL-1 Remembering P01,P02
condensation polymerisation?

10 Why are additives added to polymers? BTL-1 Remembering P01

11 What are the characteristics of plastics which
account for their wide use as engineering BTL-2 Understanding P01,P02
materials?

12 Why are the fillers and plasticizers added to

polymers? BTL-1 Remembering P01

13 Distinguish commodity plastics with engineering BTL-4 Analyzing P01

plastics.
14 Name any four commodity plastics and BTL-1 Remembering P01
engineering plastics.
15 Name any four thermoplastics and thermosetting BTL-1 Remembering P01,P02
plastics. Thermoplastics:
16 What advantages do thermoplastic polymers
have over thermosetting polymers, and vice BTL-1 Remembering P06
versa?
17 What are the sources of raw materials for
plastics? BTL-1 Remembering P12

18 What do the following acronyms PE, PP, PS, BTL-1 Remembering P01
PVC, PTFE, and PMMA
19 List the properties and typical applications of BTL-1 Remembering P01
PVC.
20 What are acrylic materials? Name two of them. BTL-2 Understanding P01,P02
21 Write short notes on nylons BTL-4 Analyzing P01,P02
22 What are bakelites? Also state their applications. BTL-1 Remembering P10
23 List the characteristics of urea-formaldehyde. BTL-1 Remembering P13
24 What are engineering ceramics? BTL-1 Remembering P01
25 List some of the distinct characteristics of
engineering ceramics. BTL-1 Remembering P08

26 Discuss fiber reinforced composites? BTL-6 Creating P01

27 What do you understand by the plastic BTL-1 Remembering P01
deformation?
28 What does impact test signify BTL-1 Remembering P01
29 Define degree of polymerization? BTL-1 Remembering P09
30 Distinguish brass from bronze? BTL-4 Analyzing P01
PART-B&C
1 Develop notes on:
i)PVC (ii) PF (iii) Glass (iv) PMMA BTL-6 Creating P01,P02,P03
v)Formaldehyde

2 What is polymerization? Describe addition BTL-1 Remembering P01,P02,P03

polymerization and condensation polymerization
3 How plastic materials are classified? Explain each BTL-1 Remembering P01,P02,P03
classification
4 What are the properties and application of PVC, BTL-1 Remembering P03,P04
PET, PP and PC? Explain
5 Develop a short note on
i)PTFE ii)Phenol formaldehyde
PO1,PO2,
(iii)Engineering Ceramics BTL-3 Applying
PO3,PO4
(iv)Fiber Reinforced Plastic.

6 What do you understand by polymerization? With

the help of suitable examples, compare and contrast BTL-1 Remembering P01,P02,P03
the process of addition polymerization and
condensation polymerization.
7 i) Develop short note about the different types of
matrix materials and reinforcement materials used to BTL-6 Creating P01,P02,P03
make polymer matrix composites.(8)

(ii) Discuss the properties and application of Al3O BTL-6 Creating P10,P11,P12
and SiC.
 Unit – V MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS
Mechanisms of plastic deformation, slip and twinning – Types of fracture – Testing of materials
under tension, compression and shear loads – Hardness tests (Brinell, Vickers and Rockwell),
hardness tests, Impact test lzod and charpy, fatigue and creep failure mechanisms.
PART-A
CO Mapping: C212.5
Q.No Questions BT Competence PO
Level
1 What is meant by mechanical properties of BTL-1 Remembering P01
materials?
2 Distinguish between elasticity and plasticity. BTL-4 Analyzing P01
3 Distinguish between ductility and malleability. BTL-4 Analyzing P01,P02
4 Define the terms brittleness and hardness. BTL-1 Remembering P01,P02
5 What do you mean by toughness and stiffness? BTL-1 Remembering P01
6 List any four technological properties of metals. BTL-1 Remembering P01,P02
7 What are the factors affecting mechanical
properties? BTL-1 Remembering P01,P02

8 What is the effect of the grain size on the BTL-1 Remembering P04
mechanical properties of the materials?
9 What is the effect of heat treatment on the BTL-1 Remembering P01
mechanical properties of the materials?
10 Define the terms slip and twinning. BTL-1 Remembering P01
11 Explain the Schmid’s law. BTL-2 Understanding P07,P08
12 What are the causes of twins? BTL-1 Remembering P01
13 What is meant by fracture? BTL-1 Remembering P03
14 List the different types of fracture in a material. BTL-1 Remembering P01
15 What is brittle fracture? BTL-1 Remembering P01
16 What is ductile fracture? BTL-1 Remembering P01,P02
17 How can you prevent the ductile fracture? BTL-1 Remembering P13
18 What is meant by fatigue fracture? BTL-1 Remembering P01
19 What is S-N diagram? What is the significance BTL-1 Remembering P01,P02
of it?
20 What are the factors affecting fatigue strength? BTL-1 Remembering P01
21 How can you prevent fatigue fracture? BTL-1 Remembering P12
22 What is meant by creep fracture? BTL-1 Remembering P01
23 What are the factors affecting creep? BTL-1 Remembering P01
24 How can you prevent the creep fractures? BTL-1 Remembering P09
25 Distinguish between destructive and non- BTL-4 Analyzing P11
destructive tests.
26 List some important destructive tests carried out BTL-1 Remembering P01
on a material.
27 What is creep? BTL-2 Understanding P01,P02
28 What is the difference between HRB and HRC? BTL-1 Remembering P01
29 Define plastic deformations BTL-1 Remembering P01
30 What is endurance limit? BTL-1 Remembering P01
PART-B&C
1 Explain the different types of mechanical
properties and mechanism of plastic deformation BTL-2 Understanding P01,P02
by slip and twinning.
2 Choose the S-N curve for mild steel and
aluminum and explain its features .Explain the BTL-3 Applying P01,P02,P03
procedure used to obtain S-N diagram
3 Explain briefly about Charpy impact test. BTL-2 Understanding P01,P02
4 Explain in brief the testing of materials to
measure tension and compression with a graph BTL-2 Understanding P01,P02,P03
and an example.
5 What is hardness test and impact test? Explain BTL-1 Remembering P11,P12
with a sketch and an example.
6 Ilustrate and describe the fatigue test. BTL-2 Understanding P08,P09
7 Distinguish between ‘ductile’ and ‘brittle’
fracture. Name two ductile and brittle materials BTL-4 Analyzing P01,P02
and also derive Schmid’s law of critical resolved
shear stress.
8 Construct a typical creep curve and brief on the BTL-3 Applying P01,P02,P03
mechanism
 UNIT – I ALLOYS AND PHASE DIAGRAMS

Constitution of alloys – Solid solutions, substitutional and interstitial – phase diagrams,

Isomorphous,eutectic, eutectoid, peritectic, and peritectoid reactions, Iron – carbon
equilibrium diagram.Classification of steel and cast Iron microstructure, properties and
application.

1. What is an alloy? MAY 2012

A metal alloy, or simple an alloy, is a mixture of two or more metals or a metal (Metals)
and a non-metal (non-metals).
2. Classify the components are found in an alloy? May 2012
Two or more components are found in an alloy.

3. What is meant by base metal?

In an alloy, the element which is present in the largest proportion is called the base metal.

4. What are alloying elements?

In an alloy, all elements other than the base metal are called the alloying elements.

5. Distinguish between substitutional and interstitial solid solution.

substitutional solid solution:

In a substitutional solid solution, the solute atoms (impurities) substitute for parent
solvent atoms in a crystal lattice.
interstitial solid solution:

In interstitial solid solution, the solute atoms fit in to the space between the solvent
or parent atoms.
6. How Hume Ruther’s rules for formation of substitutional solid solutions. June 2014
1. Size factor: The atoms must be of similar size, with less than a 15% difference in
2. Atomic radius (in order to minimize the lattice strain).
3. Crystal structure: The materials must have the same crystal structure.
4. 4. Valence: The atoms must have the same valence.

Electro negativity: The atoms must have approximately the same electro Negativity.
7. What are intermediate phases?
If an alloying element is added in excess of the limit of solid solubility, a second Phase
appears along with the primary solution. If the second phase differs in both crystal
Structure and properties from primary solid solution, then it is known as an intermediate
Phase.

8. What are intermetallic compounds?

The compound formed by two or more metals in apparently stoichiometric proportion

is called intermetallic compounds.
9. What are electron compounds?

If two metals consist of atoms more or less similar size but different valency, then the
Compounds formed are called electron compounds.
10. Define phase’. What different kinds of phases are possible?

A phase is defined as any physically distinct, homogeneous and mechanically Separable

portion of a substance. Three different kinds of phases are solid, liquid and vapour.
11. What is an equilibrium phase diagram?

A phase diagram can be defined as a plot of the composition of phases as a function

of temperature in any alloy system under equilibrium condition.
12. What are the advantages of the equilibrium diagrams?
1. To show what phases are present at different compositions and temperature
Under equilibrium conditions.

2. To indicate the equilibrium solid solubility of one element in other element.

3. To indicate the temperature range over which solidification of a material occurs.
4. To indicate the temperature at which different phases start to melt.
13. Explain Gibb’s phase rule? June 2014
Gibb,s phase rule is given by

F=C-P+2

Where,
F=degrees of freedom of system or number of variables (such as temperature,

Pressure or composition) that may be changed independently without altering

the Equilibrium;

C=number of components (usually elements or compounds) forming the system;

P=no of phases present in the system

14. What are cooling curves?

Cooling curves are obtained by plotting the measured temperatures at equal intervals
during the cooling period of a melt to a solid.
15. What is liquids line? A Solidus line? A solves line?
In a phase diagram, liquidus line is the line or boundary that separates liquid and
liquid+solid phase regions. Solidus line is a line or boundary that separate solid and solid
liquid phase region.Solvus line separate single-phase solid regions from two-phase solid
region.
16. What pieces of information can be obtained for each point in a phase diagram?

Using a phase diagram, one can obtain at least the following three information.

1. The phases that are present,

2. The composition of each phase, and
3. The amount of each phase present.
17. What is tie-line?

A tie line is simply an isothermal line drawn through point of consideration, extending
across the two-phase region and terminating at the phase boundary lines on either side.
18. What is the lever-law calculation and what information can it provide?
Opposite arm of lever

Phase fraction= ----------------------------

Total length of tie line

Opposite arm of lever

And phase percentage = --------------------------- × 100

Total length of tie line

Using the lever law calculations, one can compute the phase fraction and the
phase percentage.

19. What is mean by invariant reaction? NOV 2015

The eutectic reaction is also called an invariant reaction since it occurs under equilibrium
conditions at a specific temperature and alloy composition that cannot be varied.
20. What do you understand by allotropy of iron’?

Allotropy refers to the possibility of existence of two or more different crystal Structures
for a substance depending upon temperature.
21. Define: ferrite and austenite. MAY 2013

Ferrite
Ferrite is a primary solid solution based on iron having BCC structure. Maximum
solubility of carbon in iron is 0.025% carbon at 723°C, while its solubility at room
Temperature is only about 0.008%.
Austenite
Austenite is a primary solid solution based on iron having FCC structure. The maximum
solubility of carbon in FCC iron is about 2% at 1140°C.
22. Define: Cementite and Pearlite?
Cementite
Cementite is the name given to the carbide of iron (Fe3C). It is the hard, brittle,
intermetallic compound of iron with 6.69% of carbon.

Pearlite
Pearlite is the eutectoid mixture of ferrite (87.5%) and cementite (12.5%). It is formed
when austenite decomposes during cooling. It contains 0.8% of carbon.
23. Define: martensite and bainite?
Martensite
It is the super saturated solid solution of carbon in iron. It is formed when steel is
very rapidly cooled from the austenitic state.

Bainite
It is a decomposition product of austenite, consisting of an aggregate of ferrite and
carbide. Bainite has hardness in between the hardness of pearlite and martensite.
24. Define Solid Solution Dec 2011
A solid solution may be defined as a solid that consist of two or more elements atomically
dispersed in a single- phase structure.

25. Define eutectic reaction Dec 2013

A reaction wherein, upon cooling, one liquid phase transforms isothermally and
Reversibly into two new solid phases that are intimately mixed is called eutectic
Reaction.

26. What are three primary groups of plain carbon steels? May 2013
1. Low-carbon steels: Those contain less than 0.25% carbon.
2. Medium-carbon steels: Those containing between 0.25 and 0.60% carbon.
3. High-carbon steels: Those containing more than 0.60% carbon.
27. Define solid solution? Nov /Dec 2011
Solution: Homogenous mixture in which the atoms or molecules of one substance are
dispersed at random in to another substance.

Solid Solution: Solid that consists of two or more elements automatically dispersed in a
single phase structure.

Solute: Solute is the minor part of the solution or the material which dissolved.

Solvent: Solvent constitutes the major portion of the solution.

28. What are the limitations of equilibrium diagram?

A phase diagram (or equilibrium diagram) is a diagram with T and composition as axes,
showing the equilibrium constitution. (or) It is graphical representation of what phase
present in a materials system at various temperature, pressure and compositions.

Phase is the part of an alloy with the same physical and chemical properties and the same
 composition. Phase must be distinguished from component, which is a distinct chemical
substance from which the phase is formed.

For solids: Chemically and structurally distinct

For liquids: Miscibility

For gases: Always 1 phase

E-g: water is one phase, but water mixed with ice is two phases.

The Al-Si, Cd-Zn and Al-Cu alloys are all made up of two phases.

PART – B

1. Explain the various invariant reactions involved in the system with the help of the Fe-C
equilibrium diagram. (MAY 2015, 2016 & 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 230 – 234

2. Metal ‘A’ has melting point of 1000° C. Metal ‘B’ has melting point of 500° C. Draw one
phase diagram (between the elements ‘A’ and ‘B’ ) for each of the following conditions.
(MAY/JUNE 2014)
i. The two elements exhibit unlimited solid solubility.
ii. The alloy system shows formation of two terminal solid solutions and a Eutectic
point at 60% A at 700 ° C.
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 170 – 172

3. Explain the microstructure, properties and applications of any two types of Steel and Cast
iron. (NOV 2015 , JUNE & NOV2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 394 – 406

4. Explain with a phase diagram of eutectoid and paratactic reaction. (NOV/DEC 2013)
(APRIL 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 313 – 314

5. Explain with neat sketch the eutectic systems. Give examples for these systems.
MAY/JUNE 2013
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 298 – 311

6. Explain the two types of solid solution with the help of neat sketch. (MAY/JUNE 2013
& NOV/DEC 2015)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 150 – 154
 UNIT – II HEAT TREATMENT

Definition – Full annealing, stress relief, recrystallisation and spheroidising – normalising,

hardening and Tempering of steel. Isothermal transformation diagrams – cooling curves
superimposed on I.T. diagram CCR – Hardenability, Jominy end quench test - austempering,
martempering – case hardening, carburizing, Nitriding, cyaniding, carbonitriding – Flame and
Induction hardening – Vacuum and Plasma hardening.

1. Define the term heat treatment

Heat treatment may be defined as an operation or combination of operations involving

Heating and cooling of a metal/alloy in solid state to obtain desirable properties.

2. What are the purposes of the processing heat treatments?

a. To relieve internal stresses.
b. To improve machinability.
c. To refine grain size.
d. To soften the metal.
e. To improve hardness of the metal surface.
3. List the various stages of a heat treatment process.
Stage 1: Heating a metal/alloy beyond the critical temperature.

Stage 2: Holding at that temperature for a sufficient period of time to allow necessary
changes to occur.

Stage 3: Cooling the metal/alloy (i.e., quenching) at a rate necessary to obtain the desired
properties. That is, cooling at a rate necessary to obtain the desired Changes in the nature
form, size and distribution of micro-constituents.

4. List some of the important heat treatment operations widely used.

1. Annealing2. Normalizing. 3. Hardening. 4. Tempering. 5. Austempering. 6.
Martempering and 7. Case hardening.

5. What is meant by annealing?

Annealing is defined as a softening process consisting of heating the steal to a

Temperature at or near the critical point, holding there for a proper time and then
allowing it to cool slowly in the furnace itself.
6 .What are the purposes of annealing? MAY 2013
i. To relieve or remove stresses.
ii. To induce softness.
iii. To refine grain structure.
iv. To alter ductility, toughness, electrical, magnetic or other properties.
v. To remove gases.
vi. To produce a definite microstructure.
 7. List the different types of annealing.
i. Full annealing.
ii.Process annealing.
iii.
Stress relief annealing.
iv.Recrystallization annealing, and
v. Spheroidise annealing.
8. What is meant by normalizing?
Normalizing is similar to full annealing, but cooling is established in still air rather
than in the furnace.

9. What is quenching? List some of the quenching medium generally used in

industries.
Quenching refers accelerated cooling. Some of the quenching medium that is
usedgenerally in industries are: 5-10% caustic soda, 5-20% brine (NaCl), cold water,

Warm water, mineral oil (obtained during the refining of crude petroleum), animal
oil, and vegetable oil (such as linseed, cottonseed, and rapeseed).

10.What are the factors should be considered while selecting a quenching?

i. Desired rate of heat removal.
ii. Required temperature interval.
iii. Boiling point.
iv. Viscosity.
v. Flash point (if combustible).
vi. Stability under repeated use.
vii. Possible reactions with the material being quenched.
viii. Cost.
11. What are the three stages for quenching? MAY2014
i. Stage 1: Vapour-jacket stage.
ii. Stage 2: Vapour-transport cooling stage.
iii. Stage 3: Liquid Cooling stage.
12. What does the term hardening refer? What are the factors affecting the hardness? MAY
2012
Hardening refers to the heat treatment of steel which increases its hardnes. The hardness
obtained from the hardening process depends upon the Following factors: 1. Carbon
content, 2. quenching medium, 3. Specimen size, and 4. other factors.
13. Distinguish the work hardening with the age hardening process. June 2014

Work hardening also known as strain hardening, is the process of hardening a metal,
while working on it (under cold-working conditions).

Age hardening also known precipitation hardening, is the process of hardening a metal
when allowed to remain or age after heat treatment.
14. The tempering process usually follows hardening process. Justify.

The martensite which is formed during hardening process is too brittle and lacks good
ductility and toughness. Hence, it cannot be used for more applications. Also the internal
residual stresses that are introduced during hardening have a weakening effect. The
ductility and toughness of martensite can be enhanced and these internal stresses are
relieved by a heat treatment process known as tempering.
15. What is the effect of: (a) tempering temperature, and (b) tempering time, on the hardness
of steels?
a. The hardness gradually decreases as the temperature is increased.
b. The hardness decreases with the increase in tempering.
16. What do you mean by temper embrittlement?

The tempering of some steels/steel alloys may result in a reduction of toughness (i.e.,
increase in brittleness). This phenomenon is referred as temper embritlement.
17. What is TTT diagram?

The TTT diagram is a plot of temperature versus the logarithm of time for a steel alloy of
definite composition. It is a tool used by heat treaters to predict quenching reactions in
steels.
18. W
hat is the significance of TTT diagram in the heat treatment of steel? MAY 2014
The TTT diagram is most useful in giving an overall picture of the transformation
behavior of austenite. This enables the metallurgist to interpret the response of steel to
any specified heat treatment.

Using a TTT diagram, one can plan practical heat treatment operations to get desirable
micro constituents, to control limited hardening or softening, and the time of soaking.

19. Why are TTT diagrams usually not applicable to industrial engineering practices?

The data for the construction of TTT diagrams are obtained from the isothermal
transformation of austenite at differing temperatures. But most industrial heat treatments
involve continuous cooling from the austenitic temperature to room temperature. Thus a
TTT diagram may not five a fully accurate representation of the temperatures and times
of the transformations occurring.

20. What is CCT diagram?

The CCT diagram is a plot of temperature versus the logarithm of time for a steel alloy of
definite composition. It is used to indicate when transformations occur as the initially
austenitised material is continuously cooled at a specified rate. In addition, it is also used
to predict the final microstructure and mechanical characteristics.
21. Define the term critical cooling rate. What are the factors affecting it?

The slowest rate of cooling of austenite that will result in 100% martensite transformation is
known as the critical cooling rate. Factors affecting the critical rate are: 1. Chemical
composition of steel, 2.Hardening temperature, and 3. Metallurgical nature (i.e, Purity) of
steel.
22. What is significance of the critical cooling rate?
The critical cooling rate is most important in hardening. In order to obtain a 100% martensitic
structure on hardening, the cooling must be must be much higher than the critical cooling rate.

23. What is meant by hardenability? What are the factors affecting it? NOV 2015

The term hardenability refers to the ease with which hardness may be attained. In other words,
hardenability is a measure of ease of forming martensite.The factors affecting the
hardenability are: 1. Composition of the steel, 2.Austenitic grain size, 3. Structure of the steel
before quenching, and 4.Quenching medium and the method of quenching.
24. What is the difference between hardness and hardenability?
The term hardness is the property of a material by virtue of which it is able to resist abrasion,
indentation and scratching. It is mechanical property related to strength and is a strong
function of the carbon content of a metal.
On the other hand, hardenability is the susceptibility of a material to get hardened. It is
affected by the alloying elements in the material and grain size.
25. What is martempering and austempering? MAY 2012

Martempering, also known as marquenching, is an interrupted cooling procedure used for

steels to minimize stresses, distortion and cracking of steels that may develop during rapid
quenching. The Austempering is an isothermal heat treatment process, usually used to reduce
quenching distortion and to make tough and strong steels.

26. Define hardenability. JUNE 2012

It is the property of material by virtue of which it is able to resist abrasion, indentation and
scratching.

27. Define spheroidizing?

The steel is cooled by quenching (in a water bath or oil bath) to the room temperature. The
cooling rate should be higher than the critical cooling rate (deep freezing) in order to get the
completely martensitic structure.

28. What is the purpose of the deep freezing in the heat treatment of steel?
Medium and high carbon steels having a microstructure containing even coarse pearlite is too
hard to conveniently machine or plastically deform. These steels are spheroidising annealed.ie
heat treated to develop the spheroidite structure. The spheroidised steels have a maximum
softness and ductility and also they are easily machined or deformed.
29. Differentiate annealing and normalizing?
Annealing: Normalizing:
 It refers to heat treatment in which a  It is similar to full annealing but cooling
material is exposed to an elevated is established in still rather than in the
temperature for an extended time furnace.
period and then slowly cooled.
 It is costly treatment  It is more economical
 It is more time consuming  It is less time consuming
 It provides a fine grain structure  It provides coarse grain structure

30. Differentiate carburizing and nitriding?

carburizing Nitriding
 It is process in which carbon  It is a process of introducing nitrogen
atoms are introduced on to the atoms to obtain hard surface of steel
surface of low carbon steels to components.
produce a hard case of surface,
while the interior or core remains
soft.
PART – B

1. a. Distinguish between annealing and normalizing. (6) (MAY/JUNE 2013, 2014)

Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 248 - 254

b. Explain with neat setup figure the working principle of an induction hardening (10).
(MAY/JUNE 2013,2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 333 – 335

2. Explain Jominy test (or) End quench hardenability test with the help of the neat sketches.
(MAY/JUNE 2013,2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 298 – 301

3. What is annealing? Discuss in detail on different types of annealing and compare with
normalizing. ( MAY/JUNE 2012, APRIL 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 248 – 254

4. Write a short note on:(i)Hardenability, (ii) Nitriding, (iii) Flame hardening, (iv) Cyaniding.
NOV/DEC 2013
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 316 – 328

5. Distinguish between hardness and hardenability. With suitable sketches, explain the hardness
test for hardenability. MAY/JUNE 2014 (APRIL 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 333 – 337

6. Explain TTT diagram with neat sketch and indicted all the phases with microstructure. (JUNE
2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 264 - 266
 UNIT – III FERROUS AND NON-FERROUS METALS

Effect of alloying additions on steel- α and β stabilisers– stainless and tool steels – HSLA,
Maraging steels – Cast Iron - Grey, white, malleable, spheroidal – alloy cast irons, Copper and
copper alloys – Brass, Bronze and Cupronickel – Aluminium and Al-Cu – precipitation
strengthening treatment – Bearing alloys, Mg-alloys, Ni-based super alloys and Titanium alloys.

1. What are the properties of steel? Nov 2013

1. Conductivity
2. Malleability
3. Ductility
2. What are metals? Classify engineering materials.

Metals are elemental substances. Metals are composed of elements which readily give up
electrons to provide a metallic bond and electrical conductivity.

Types of metals:

i. Ferrous metals, and

ii. Non-ferrous metals.
3. What are ferrous metals? Classify ferrous materials.
The metals, which contain iron as their main constituent, are called ferrous Metals.

Types of ferrous metals:

i. Steels, and
ii. Cast irons.
4. How to you enhance mechanical strength of Al? Nov 2010
By alloying aluminium with one or more allying element such as Cu, Mg, Mn, Si and Ni.

5. How can you specify steel? What is the difference between 4140 steel and 4340 steel?
The AISI/SAE designation for the steels is a four digit number: First two Digits indicate the
alloy content, and Last two digits indicate the carbon concentration. 4140 steels is alloy of Cr-
Mo with 0.40% C, whereas 4340 steel is an alloy of Mo-Cr-Ni with 0.40%C.
6. What are three primary groups of plain carbon steels? June 2013
1. Low-carbon steels: Those contain less than 0.25% carbon.
2. Medium-carbon steels: Those containing between 0.25 and 0.60% carbon.
3. High-carbon steels: Those containing more than 0.60% carbon.
7. What are alloy steels? How are alloy steels classified?

Alloy steels mean may steels other than carbon steels. Alloy steels can be divided into two
main groups as:
i. Low alloy steels: These contain up to 3 to 4% of alloying elements.
ii. High alloy steels: These contain more than 5% of alloying elements.
8. List four important alloying elements added in alloy steels.
The most commonly used alloying elements are chromium, nickel, molybdenum, Vanadium,
tungsten, cobalt, boron, copper and others.
9. Why is alloying done?

The alloying steel is generally done:

To increase its strength.

To improve hardness. To improve toughness.

To improve resistance to abrasion and water. To improve machinability.

To improve ductility.

10. What are the primary effects of chromium, and copper as alloying elements in steel? Dec
2011
Effects of alloying chromium: Increases corrosion and oxidation resistance, increases
hardenability, increases high-temperature strength, and resists abrasion and wear (with high
carbon).
Effects of alloying copper: Increases strength, and increases corrosion resistance.

11. What are the effects of lead and sulphur on the machinability of steels?
Lead improves the machinability whereas sulphur reduces it.

12. Which alloy elements are basically a) carbide formers, and b) graphite promoters?
i. Carbide formers: Cr, W, Ti, Mo, Nb, V, and Mn.
ii. Graphite promoter: Si, Co, Al, and Ni.
13. What makes stainless steel stainless?

The chromium oxide (extremely dense-thin) protective layer acts as a barrier to retard further
oxidation, rust or corrosion. As this steel cannot be stained easily, it is called stainless steel.
14. Why do stainless steels lose their corrosion resistance when the chromium in solution drops
below 12%?
When the weight% of chromium drops below 12% the corrosion rate increases sharply. As
the corrosion rate increases, the resultant chromium-oxide protective layer unable to retard
oxidation, rust or corrosion effectively.

15. What determines whether a stainless steel is austenitic ferritic, or martensitic?

The predominant phase constituent of the microstructure present in a stainless steel

determines whether a stainless steel is austenitic, ferritic, or martensitic.
What are the required properties of a tool steel?

Tool steels should have the following requirements: 1. Good toughness, 2. Good wear
resistance, 3. Very good machinability, 4. Slight change of form during hardening, 5. Little
risk of cracking during hardening.5. Resistance to softening on heating.
17. How can you classify tool steels?

1. Cold work tool steels, 2. Shock resisting tool steels, 3. Hot work tool steels,

4. High speed tool steels, 5. Plastic mold tool steels and 6. Special purpose tool steels.

18. What is meant by 18-4-1 high speed steel?

A widely used high-speed tool steel is 18-4-1 high speed steel. This steel contains 18%
tungsten, 4% chromium, and 1% vanadium. It is considered to be one of the best of all
purpose steels.

19. What are HSLA steels? Where are they used? MAY 2015

HSLA steels are nothing but high-strength low-alloy steels. HSLA steels, also known as
micro alloyed steels, are low-carbon steels containing small amounts of alloying elements.
These HSLA steels are widely used as structural or constructional alloy steels.
20. What are maraging steels? Give its composition.

Maraging steels are low-carbon, highly alloyed steels. These are very high strength materials
that can be hardened to obtain tensile strengths of up to 1900 Mpa.
Composition: Maraging steels contain 18% nickel, 7% cobalt, and small amounts of other
elements such as titanium. The carbon content is low, generally less than .05%.
21. What are the heat resisting steels and free-machining steels?

Steels which can resist the creep and oxidation at high temperatures and retain sufficient
strength are called heat resisting steels. Free-machining steels, also known as free cutting
steels, machine readily and form small chips so as to reduce the rubbing against the cutting
tool and associated friction and wear.
22. What are the features that make cast iron an important material?
1. It is a cheap metallurgical substance,

2. Good castability,

3. Good mechanical rigidity and good strength under compression.

4. Good machinability can achieved when a suitable composition is selected.

23. What are the effects of carbon on the properties of cast iron?

If a cast iron contains more of the brittle cementite, then its mechanical
properties will be poor.
24. What is the influence of cooling rate on the properties of a cast iron?

High rate of cooling results in a weak and brittle cast iron. Slow cooling rate
results in tough and strong cast iron.
25. How can you classify cast irons?

Grey (General-Purpose) White (Hard and wear resistant) Malleable (Heat-treated for
ductility) SpheroidalGraphite (Some ductility) Alloy cast irons (Special-purpose)
26. Define Toughness Dec 2011
Toughness is the property of a material by virtue of which it can absorb maximum energy before
fracture takes place.
27. What is twinning in metals? April 2010
Atoms in a part of crystal subjected to stress rearrange themselves so that one part of the
crystal became a mirror image of the other part.

28. What is creep? Dec 2011

The creep is defined as the property of a material by virtue of which it deforms continuously
under a steady load.

29. What is the effect of chromium alloying element on the properties of steel?
i. Increase corrosion and oxidation resistance.
ii. Increase hardenability.
iii. Increases high temperature strength.
iv. Resists abrasion and wear.
30. What is bearing alloys? May 2012
Bearing alloys are the materials used for making bearing. The widely used bearing materials
are white metals copper base alloys aluminum base alloy.

PART – B

1. a. With a neat sketch, explain precipitation hardening. (8) (MAY/JUNE 2014,2016)

b. State the composition, properties and uses of bearing alloys. (8)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 374 – 376

2. Write short notes about the following materials in terms of composition, properties and
applications.
(i) Maraging steels

(ii) Alpha-beta brasses (iii) Austenitic stainless steels (iv) Ferrite stainless steels
(MAY/JUNE 2014)

Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 527

3. What are the influences of alloying Al, Cr, Ni, Mo, Si, Mn, V AND Cu in steel? Explain in
brief. (NOV/DEC 2013 APRIL 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 377-383, 469-471, 629

4. What are the properties of aluminium? And what is the effect of different types of alloying
elements such as copper, iron, managanese, magnesium used with aluminium and its
application? Explain. NOV/DEC 2013
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 353 - 353
5.Write short notes on: (MAY 2013, 2016)
(i)Maraging steels, (ii) Stainless steels (iii) High speed steels. iv) Tool steels and iv) HSLA

Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 409 – 411

6. i. Name non-ferrous materials for the following articles (8). MAY/JUNE 2013
i. Bush
j. Furnaces heating element
k. Type writer parts
l. Coins
m. Girders for airship
n. Big end bearing
o. Filament of electric lamps
p. Turbine blades

ii. Write short notes on (8):

Bearing metals, Brasses.

Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 380, 387 - 392

a. Explaining age hardening of Al-Cu with the heplp of phase diagram (MAY 2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 390 – 391
 UNIT – IV NON-METALLIC MATERIALS

Polymers – types of polymer, commodity and engineering polymers – Properties and

applications of various thermosetting and thermoplastic polymers (PP, PS, PVC, PMMA,
PET,PC, PA, ABS, PI, PAI, PPO, PPS, PEEK, PTFE, Polymers – Urea and Phenol
formaldehydes)- Engineering Ceramics – Properties and applications of Al2O3, SiC, Si3N4,
PSZ and SIALON –Composites-Classifications- Metal Matrix and FRP - Applications of
Composites.

1. What are polymers?

Polymers are composed of a large number of repeating units of small molecules

called manometers. Polymers may be defined as giant organic, chain-like
molecules having molecular weight from 10000 to more than 1,000,000 g.mol.
2. List any four attractive characteristics of polymers.
q. Low density.
ii. Good thermal and electrical insulation properties.
iii. High resistance to chemical attack.
iv. Ease of fabrication.
v. Relatively low cost.
3. Classify polymers.
1. Elastomers,
2. Adhesives,
3. Coatings,
4. Fibres.
4. Define the following terms: i) Monomer, ii) Homopolymer, and iii) Copolymer.

Monomer is a small molecule consisting of a single mer i.e., a single unit/blocking block.

Homopolymer is a polymer made out of identical monomer. Copolymer is a polymer

which is obtained by adding different types of monomers.
5. What is meant by isomerism?

Isomerism is a phenomenon wherein different atomic configurations are possible for the
same configuration.
6. What is meant by the term „unsaturated molecule?
State its significance in plastics. A compound in which the valence bonds of the carbon
atoms are not satisfied is said to be unsaturated. Such unsaturated molecules are
important in the polymerization i.e.,joining together of small molecules into large one
having the same constituents.

7. What is polymerisation? NOV 2011

Polymerisation is the process of forming a polymer.
8. Define the term degree of polymerisation’? MAY 2012
Degree of polymerisation is the number of repetitive units (or mers) present in One
molecule of a polymer.

Mathematically,

Molecular weight of a polymer

Degree of polymerisation = ---------------------------------------------------

Molecular weight of a single monomer

9. What is the difference between addition polymerisation and condensation

polymerisation?
Addition polymerization, also known as chain reaction polymerisation, is a process by
which two or more chemically similar monomers are polymerized to form long chain
molecules. Condensation polymerization, also known as step-growth polymerisation, is
the formation of polymers by stepwise intermolecular chemical reactions that normally
involve at least two different monomers

10. Why are additives added to polymers?

The various polymer additives include:1. Filler materials, 2. Plasticizers, 3.

Stabilizers, 4. Colorants, 5. Flame retardants,6. Reinforcements, and 7. Lubricants.
11. What are the characteristics of plastics which account for their wide use as engineering
materials?
Plastics are extensively used in engineering applications due to their important properties
such as low price, colour range, toughness, water resistance, low electrical and thermal
conductivity, ease of fabrication, etc.
12. Why are the fillers and plasticizers added to polymers?
1. Fillers

To improve tensile and compressive strengths.

To improve dimensional and thermal stability, and other properties. To reduce the
cost of the final product.

2. Plasticisers

To improve the flexibility, ductility, and toughness. To reduce the hardness and
stiffness.

To increase and control the flow of the polymer duringmolding.

13. Differentiate commodity plastics with engineering plastics.

The plastics which are not generally used for engineering applications are known as
commodity plastics. H plastics which are used in engineering applications are known as
engineering plastics.

14. Name any four commodity plastics and engineering plastics.

Commodity plastics: i) Polyethylene (PE), ii) Polypropylene (PP), iii) Polystyrene (PS),
iv) Polyvinyl chloride (PVC).

Enginering Plastics: i) Ethenic, ii) Polyamides, iii) Cellulosics, iv) Acetals.

15. Name any four thermoplastics and thermosetting plastics.

Thermoplastics: Polythenes, Polypropylene, Polystyrenes, PVC. Thermosetting plastics:
Polyesters, phenolics, epoxides, melamine formaldehyde.

16. What advantages do thermoplastic polymers have over thermosetting polymers, and
vice versa?
Since thermoplastics have low melting temperature and can be repeatedly moulded and
remoulded to the desired shape, they have a good resale/scrap value. The thermosetting
plastics are generally stronger, harder, more brittle, more resistant to heat and solvents
than thermoplastics.

17. What are the sources of raw materials for plastics?

1. Animal and vegetable by-products,
2. Coal by-products,
3. Petroleum by-products.
18. What do the following acronyms PE, PP, PS, PVC, PTFE, and PMMA.MAY 2012
PE: Polyethylene; PP: Polypropylene; PS: Polystyrene; PVC; Polyvinyl chloride;

PTFE: Polytetrafluro ethylene; PMMA: Polymethyl methacrylate

19. List the properties and typical applications of PVC.

Properties: Good low-cost, general purpose materials; ordinary rigid, but can be made
flexible with plasticizers; susceptible to heat distortion.

Typical applications: Pipes, valves, fittings, floor tiles, wire insulations, toys,
phonograph records, safety glass interlayers.
20. What are acrylic materials? Name two of them.

Acrylic materials are thermoplastic polymers based on the polymerization of esters of

acrylic acid and/or methacrylic acid.The most commonly used acrylic polymers are:
i. PMMA (Polymethyl methacrylate),
ii. PAN (Polyacrylonitrile)
21. Write short notes on nylons. JUNE 2013

Polyamides (PA), also known as nylons, are the products of condensation reactions
between an amine and an organic acid.There is number of common polyamides. They are
usually designated as nylon 6, nylon 6/6, nylon 6/10, nylon 6/12, nylon 11, and nylon 12.
These suffixes refer to the number of carbon atoms in each of the reacting substances
involved in the condensation polymerization process.

22. What are bakelites? Also state their applications.

Phenolics, also known as Bakelites, are the oldest family of thermosetting plastics. The
most important phenolic materials is the polyformaldehydes.Typical applications include
electrical plugs, sockets, switches, telephones,door knobs and handles, adhesives,
coatings, and laminates.
23. List the characteristics of urea-formaldehyde.
1 They are similar to the phenolics.
2 They are hard and rigid thermosets.
3 They have good electrical insulation properties.
4 They are light in colour.
5 They exhibit good resistance to most chemicals.
23. What are engineering ceramics?

Engineering ceramics are also known as technical/industrial ceramics, are those

ceramics that are specially used for engineering applications or in industries.
25. List some of the distinct characteristics of engineering ceramics.
1. High resistance to abrasion and wear.
2. High strength at high temperature.
3. Good chemical stability.
4. Good electrical insulation characteristics.
26. Discuss fiber reinforced composites?
Fibre reinforced composites are those in which the dispersed phase is in the form of a
fibre. In these composites high strength fibres are encased within a tough matrix.

27. What do you understand by the plastic deformation?

Plastic deformation is the deformation of a body which remains even after removing the
external load from the body.

28. What does impact test signify?

The impact test is performed to study the behavior of materials under dynamic load i.e.,
suddenly applied load.

29. Define degree of polymerization?

Degree of polymerization is the number of repetitive units present in one molecule of a
polymer.
30. Differentiate brass from bronze?

Brass: Bronze :
 It contain zinc as the alloying element  It contain copper as the alloying
element
 Brass has high resistance to corrosion and  Bronze possesses superior mechanical
is easily machinable it also act as good properties and corrosion resistance
bearing material
PART - B

1. Write notes on: MAY/JUNE 2013,NOV 2016

a. PVC (ii) PF (iii) Glass (iv) PMMA v)Formaldehyde
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 538 - 540

2. What is polymerization ? Describe addition polymerization and condensation

polymerization.(10) MAY/JUNE 2013,2016
a. (ii) How plastic materials are classified? Explain each classification.( 6)
MAY/JUNE 2013
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 400

3. What are the properties and application of PVC, PET, PP and PC? Explain.(16) Nov/Dec
2013
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 538-540

4. Write a short note on ( Nov/Dec 2013,2016)

a. PTFE
b. Phenol formaldehyde
c. Engineering Ceramics
d. Fiber Reinforced Plastic.
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 541-542

5. What do you understand by polymerization? With the help of suitable examples, compare
and contrast the process of addition polymerization and condensation polymerization.
(MAY/JUNE 2014)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 545-546

6. Write short note about the different types of matrix materials and reinforcement materials
used to make polymer matrix composites. (8)
a. (ii)Discuss the properties and application of Al3O and SiC. (8)
(MAY/JUNE2014,NOV 2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 555-556
 UNIT – V MECHANICAL PROPERTIES AND DEFORMATION MECHANISMS

Mechanisms of plastic deformation, slip and twinning – Types of fracture – Testing of

materials under tension, compression and shear loads – Hardness tests (Brinell, Vickers and
Rockwell), hardness tests, Impact test lzod and charpy, fatigue and creep failure mechanisms.

1. What is meant by mechanical properties of materials?

Mechanical properties are those characteristics of material that describe its behavior
under the action of external forces.
2. Distinguish between elasticity and plasticity.

Elasticity is the property of a material by virtue of which it is able to retain its original
shape and size after the removal of the load.

Plasticity is the property of a material by virtue of which a permanent deformation

(without fracture) takes place, whenever it is subjected to the action of external forces.
3. Differentiate between ductility and malleability.

Ductility is the property of a material by virtue of which it can be drawn into wires
before rupture takes place.

Malleability is the property of a material by virtue of which it can withstand

deformation under compression without rupture.
4. Define the terms brittleness and hardness.

Brittleness is the property of a material by virtue of which it can withstand

deformation under compression without rupture.

Hardness is the property of a material by virtue of which it able to resist abrasion,

indentation (or penetration), machining, and scratching.
5. What do you mean by toughness and stiffness?

Toughness is the property of a material by virtue of which it can absorb maximum

energy before fracture takes place.

Stiffness is the property of a material by virtue of which it resists deformation.

6. List any four technological properties of metals.

i. Machinability
ii. Castability,
iii. Weldability,
iv. Formability or workability.
7. What are the factors affecting mechanical properties?
i. Grain size,
ii. Heat treatment,
iii. Atmospheric exposure, and
iv. Low and high temperatures.
8. What is the effect of the grain size on the mechanical properties of the materials?

The materials having smaller grains (i.e., fine grained structure) have high yield strength,
high tensile strength, and more hardness. Also fine grain results in better resistance to
cracking and better surface finish.
9. What is the effect of heat treatment on the mechanical properties of the materials?
The heat treatment improves mechanical properties like tensile strength, toughness,
hardness, ductility, shock resistance and resistance to corrosion. It also improves
workability, forgeability and machinability of metals.
10. Define the terms slip and twinning.

Slip may be defined as the sliding of blocks of the crystal over one another along
definite a mirror image of the other part.

Twinning is the process in which the atoms in a part of a crystal subjected to stress,
rearrange themselves so that one part of the crystal becomes a mirror image of the other
part.

11. State the Schmid’s law.

The stress required at a given temperature to initiate slip in a pure and perfect single
crystal, for a material is constant. This is known as Schmid’s law.
12. What are the causes of twins?

1. Mechanical twins: Twins that are produced by mechanical deformation are called
mechanical twins.
2. Annealing twins: Twins that are produced by annealing are called annealing twins.
13. What is meant by fracture?

Fracture is the mechanical failure of the material which will produce the separation or
fragmentation of a solid into two or more parts under the action of stresses.
14. List the different types of fracture in a material.
1. Brittle fracture,
2. Ductile fracture,
3. Fatigue fracture,
4. Creep fracture.
15. What is brittle fracture?

A brittle fracture may be defined as a fracture which takes place by a slow

propagation of crack with appreciable plastic deformation.
16. What is ductile fracture?

Ductile fracture may be defined as the fracture which takes place by a slow
propagation of crack with appreciable plastic deformation.
17. How can you prevent the ductile fracture?

In order to prevent the ductile fracture, the material should have the following
characteristics:

The material should have fine grains. It should have higher hardness value.

It should have higher Young,s modulus and cohesive energy.

It should not have any defects/dislocations.

18. What is meant by fatigue fracture?

A fatigue fracture is defined as the fracture which takes place under repeatedly applied
fatigue stresses.
19. What is S-N diagram? What is the significance of it?

The S-N diagram is a graph obtained by plotting the number of cycles of stress reversals
(N) required to cause fracture against the applied stress level (S). Using S-N diagram, the
fatigue life of a material can be determined.
20. What are the factors affecting fatigue strength?

1. Fatigue strength is influenced by many factors such as chemical

composition, grain size, and amount of cold working.
2. Fatigue strength is high at low temperatures and gradually decreases with
Rise in temperature.

3. Environmental effects such as corrosion of the product by moisture

Decreases.

4. The design of the product also influences the fatigue strength.

21. How can you prevent fatigue fracture?
The following methods can be adopted to prevent the fatigue failure.

1. Use of good design to avoid stress concentration by eliminating sharp recesses and
severe stress raisers.

2. Control of the surface finish by avoiding damage to surface machining, punching,

stamping, shearing, etc.

3. Reduction of corrosion environmental effects by surface heat treatments like

polishings, coatings, carburizing, nitriding, etc.
22. What is meant by creep fracture?

The creep is defined as the property of a material by virtue of which it deforms

continuously under a steady load.
23. What are the factors affecting creep?
1 Grain,
2 Thermal stability of the micro-structure,
3 Chemical reactions,
4 Prior strain.
24. How can you prevent the creep fractures?
The following methods can be adopted to prevent the creep failure.

1. Use of coarse grained materials will avoid creep fracture.

2. Strain hardening can be done to avoid creep fracture.
3. The material should be free from any residual stresses and dislocations.
4. Precipitation-hardened alloys can be used to avoid creep fracture.

25. Differentiate between destructive and non-destructive tests.

In destructive type of testing, the component or specimen to be tested is destroyed and

cannot be reused.In non-destructive type of testing, the component or specimen to be
tested is not destroyed and can be reused after the test.
26. List some important destructive tests carried out on a material.
1. Tensile test, 2. Impact test, 3. Bend test, 4. Fatigue test, 5. Torsion test and 6. Creep
test.
27. What is creep? May 2013
It is the property of a material by virtue of which deforms continuously under steady load.

28. What is the difference between HRB and HRC?

Brinell hardness test (HRB) Rockwell hardness test (HRC)

 An indenter is pressed in to the testing  In this the dial gives a direct
surface of the material by slowly reading of hardness no need for
applied known load and the extent of measuring indention diameter or
the resulting impression is measured diagonal length using the
mathematical or optically. a large microscope.
impression for a given load and
indenter indicates a soft material and a
small impression indicates a hard
material.
29. Define plastic deformations May 2013
It is the deformations of body which remains even after removing the external load from
the body

30. What is endurance limit? May 2006

It is defined as the maximum stress which a specimen can endure without failure when
this stress is repeated for a specified number of cycles.
 PART – B

1. Explain the different types of mechanical properties and mechanism of plastic

deformation by slip and twinning. (MAY 2014,2016, 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 118, 203 and 211

2. a. Draw the S-N curve for mild steel and aluminum and explain its features .Explain the
procedure used to obtain S-N diagram. MAY/JUNE 2014
b. Explain briefly about Charpy impact test. MAY/JUNE 2014
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 45 – 46

3. Explain in brief the testing of materials to measure tension and compression with a graph
and an example. NOV/DEC 2013
Refer: “Material Science and Engineering”, by Williams D Callister Page No: 154 – 155

4. What is hardness test and impact test? Explain with a sketch and an example.
(NOV/DEC 2013) & (APRIL 2017)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 42

5. Sketch and describe the fatigue test. MAY/JUNE 2013

Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 44

6. a. Distinguish between ‘ductile’ and ‘brittle’ fracture. Name two ductile and brittle
materials and also derive Schmid’s law of critical resolved shear stress.(8) ( MAY/JUNE
2012)
b. Draw a typical creep curve and brief on the mechanism (8). (NOV/DEC 2015, 2016)
Refer: “Introduction physical metallurgy” by Avner. S. H Page No: 118 - 119