TOPIC 1 - MATERIAL STRUCTURE AND BINARY ALLOY SYSTEM

1. Understand material structure and Element Periodical Table (EPT)

Material structure can be classified by the general magnitude of various features being
considered. The three most common major classification of structural listed generally
in increasing size are atomic structure.
The element periodical table in the tabular arrangement of the elements according to
their atomic numbers so that elements with similar properties are in the same column.

2. Define the terminology of
a. Atom
b. Element
c. Mixture
d. Coumpond

a. Atom are basic structural unit of matter which are composed of electron, proton, and
neutron.
b. Element is a molecule consist of two or more atoms of the same element that are
chemically bound together.
c. Mixture is a substance made by combining two or more different materials without a
chemical reaction occurring.
d. Compounds are made when atoms of different element are chemically combined
together.


3. Define atomic number and atomic mass of EPT

Atomic number : the number of proton(+ve particle) that are in its nucleus.
Atomic mass : total number of protons and neutrons in the nucleus of an atom.



4. Determine the total number of atomic orbits

Number of orbit (n) Number of electron
First orbit (n=1) 2
Second orbit (n=2) 8
Third orbit (n=3) 18
Fourth orbit (n=4) 32
Table 1.1 maximum number of electrons for each principal atomic shell.

5. Explain the elements sequence in EPT


The elements are arranged in order of their atomic number. The atomic number is the number
of protons each atom has in its nucleus. By arranging the elements in this way, those with
similar properties (characteristics) are grouped together. As with any grid, the periodic table
has rows running left to right, and columns running up and down. The rows are
called periods and the columns are called groups.


6.Explain these crystallized structure
a. Simple cubic
b. Body-centered cubic (BCC)
c. Face-centered cubic (FCC)
d. Hexagonal close-packed (HCP)

a. Simple cubic is a cube with an atom at each corner of the unit cell and contains only
one atom per unit cell.
b. Body-centered cubic has a cubic unit cell with atoms located at all eight corners and a
single atom at the cube centre.
c. Face-centered cubic is atom that are located at each of the corners and on the centres
of all the faces of cubic unit cell.
d. Hexagonal close-packed is the top and bottom faces of the unit cell consist of six
atom that form regular hexagons and surround a single atom in the centre.


7. Explain terms use in recrystallization process
a.Crystal
b. Space lattice
c. Grain
d. Grain boundary

a. Consist of large number of unit cells stacked together.
b. The arrangement of atoms in a crystal can be describe with respect to a 3D net of
straight lines.
c. A small region of a metal, having a given and continuous crystal lattice orientation.
d. The interface between two grains, or crystallites.


8. Explain these types of bonds
a. Covalent bond
b. Ionic bond
c. C

a. Is formed between two or more similar or dissimilar atoms by mutually sharing at
least one electron among themselves to achieve stability.
b. Is a type of chemical bond that involves a metal and a non-metal ion
through electrostatic attraction and formed by the attraction between two oppositely
charged ions.
c. Occurs as a result of electromagnetism and describes the electrostatic attractive force
that occurs between conduction electrons and positively charged metal ions.


9. Describe the

The solidification of metals and alloys is an important industrial process since most
metals are melted and the casted into a semi-finished or finished shape.











10. Explain solidification phase of
a. Nucleus
b. Dendrite
c. Grain



a. Solidification at one point forming a nucleus.
b. Dendrite grow in a tree like structure. It spread out and meet other dendrites to form
the grain boundary.
c. Solidification ends with the formation of grain (crystal)


11. Differentiate between metals and alloys

Metal has same elements, extreme properties and cannot fulfil the need for
engineering work.
Alloy is metallic materials consisting of two or more elements combined in such a
way that they cannot be readily separated by physical means.


12. Define term and formation of solid solution

Term in solid solution :
Solute : is the element that is added to the solvent.
Solvent : a liquid substance capable of dissolving other substances.

Formation solid solution occur when solute is added to the solvent, the crystal
structure of solvent remains unchanged and the mixture remains in a single
homogeneous phase.


13. Distinguish between substitution and interstitial solid solution

Substitution solid solution:
If the atoms of the solvent metal and solute element are of similar sizes, where part of
the solvent atoms are substituted by atoms of the alloying element.

Interstitial solid solution:
If the atoms of the alloying elements are considerably smaller than the atoms of the
matrix metal, where the matrix solute are located in the space between large solvent
atoms.

14. Explain the process of solidification for pure metal and alloy according to the cooling
curve

When the temperature drops below the freezing point of the material, solidification
stars.
Solidification involves a change of phase of the material and differs depending on
whether the material is a pure element or an alloy.
A pure metal solidifies at a constant temperature, which is its melting point.
For alloys, the solidification occurs over a temperature range depending upon the
composition.





15. Explain the phase balance diagram, which comprises of a few cooling curve for solid
solution

Balance phase diagram represent the relationship between temperature and the
compositions and the quantities of phase present at equilibrium.
It can be as a map that determines the phase depending on composition and
temperature.







TOPIC 2 FERROUS METAL



1. State the content of iron core

Types Characteristic
Magnetile Containing 72% iron,
Has magnetic properties
Black in colour
Iron carbonate Containing less than 30% iron
Others are carbon and phosphorus
Grey in colour
Hematile Containing 40%-65% iron
Dark brown reddish in colour
Harder than pure iron
More brittle
Limotile Containing 20%-55% iron and 40% water
Yellow brownish in colour
Also known as lemon rock


2. Explain the process of iron production by using Blast Furnace

The charge consists of iron core, coke and limestone are carried to the top of the blast
furnace and dumped into it.
Limestone is added to the blast furnace to remove the impurities in the iron core.
Limestone reacts with the silica to form molten slag in the blast furnace.
Slag flows to the bottom of the furnace where it floats on the liquid iron and hot air is
blasted into the furnace causing coke to burn rapidly and raise the temperature to 2000
celsius.
Carbon +oxygen = carbon dioxide + heat

The carbon dioxide then react with hot carbon to form carbon monoxide which reduce
iron in the core to iron metal.
Iron falls to the bottom of the furnace and is tapped off periodically is easily removed.


3. Explain the process of steel production by using these methods:
a. Basic Oxygen Furnace (BOP)
b.Electric Arc Furnace

4 . Describe the plain carbon steel\

5. Sketch completely the different phases in equilibrium phase diagram up to 1.7% carbon.

6. differentiate between iron, steel and cast iron in the iron-carbon equilibrium phase diagram






































REFERENCE

https://www.nde-
ed.org/EducationResources/CommunityCollege/Materials/Structure/introduction.htm
http://www.factmonster.com/dk/science/encyclopedia/periodic-table.html
https://www.princeton.edu/~achaney/tmve/wiki100k/docs/Ionic_bond.html