The Islamic University of Gaza

Industrial Engineering Department

Engineering Materials, EIND 3301
Final Exam

.Instructor: Dr. Mohammad Abuhaiba, P.E

Exam date: 20/01/2011 Fall 2010

Final Exam Exam Duration: 2

hours
Pages 2 &3: Closed book Pages 4 to 12: Open
Book

Name: _______________________________ ID: ________________________

Questi Grade Maximum Grade

on
1 10
2 5
3 5
4 9
5 9
6 6
7 16
8 2.5
9 2.5
10 12
11 6
12 4
13 10
14 3
Total 100

Page 1 of 15
Question #1: (10 points) Fill in the blanks
1. The two fundamental types of dislocations are ____Edge_ and _Screw_.
2. Plastic deformation corresponds to the deformation of large number of
_Dislocation_.
3. For a particular crystal structure, the slip plane is the plane that has
the _greatest planner density_.
4. The smallest repetitive volume which contains the complete lattice
pattern of a crystal is called _Unit Cell_.
5. The 4 Point Defects are:
__ Vacancy
__ Self-interstitial atom
__Substitional impurity atom
__ Intersitial impurity atom

6. For the iron-iron carbide phase diagram:

a. For pure iron, at room temperature the stable form of solid solution
called ferrite (or iron) has _BCC_ crystal structure with
maximum soluibilty of _0.022 at a temperature of _727 o C_.
b. Ferrite experiences a polymorphic transformation to austenite (or
iron) at 912o C which has _FCC_ crystal structure with maximum
solubility _2.14%_ at temperature _1147 o C_.
c. Austenite persists to 1394o C at which it reverts back to a BCC
phase known as ferrite which finally melts at _1538o C.
d. Composition axis extends only to 6.7 wt% C at which _Cementite_
is formed along the right vertical axis.
e. One _Eutectoid_ point at 0.76 wt % C and 727o C; at which solid
phase transforms into iron and cementite.
f. Ferrite is soft and __Ductile_ and cementite is __Hard__ and brittle.

Page 2 of 15
Question #2: (5 points) True or False
1. The ratio of the shear stress to the shear strain in the elastic range is
known as the modulus of elasticity. (False)
2. Alloying metals with impurity atoms (substitutional or interstitial) into
solid solution is another technique to strengthen and harden metals
(True)
3. For a particular crystal structure, the slip direction is that direction in
the slip plane having the lowest linear density. (False)
4. A fine-grained material (one that has small grains) is softer than one
that is coarse grained. (False)
5. High-purity metals are almost always softer and weaker than alloys
composed of the same base metal. (True)

Question #3: (5 points) Select the most correct answer

1. If either stress or temperature is increased, which of the following
combinations of effects will result?
a. The steady-state creep rate decreases, the instantaneous strain at
the time of stress application decreases, and the rupture lifetime
decreases.
b. The steady-state creep rate decreases, the instantaneous strain at
the time of stress application decreases, and the rupture lifetime
increases.
c. The steady-state creep rate increases, the instantaneous strain at
the time of stress application decreases, and the rupture lifetime
decreases.
d. The steady-state creep rate increases, the instantaneous strain at
the time of stress application increases, and the rupture lifetime
decreases.
2. Once a system is at a state of equilibrium, a shift from equilibrium
may result by alteration of which of the following?
a. Pressure
b. Composition.
c. Temperature.
d. All of the above.
3. A eutectoid reaction involves which of the following phases?
a. One liquid and one solid
b. One liquid and two solid
c. Two liquids and one solid
d. Three solid
4. A phase diagram, shows the relationships among:
a. The temperature, the composition, and pressure in a particular
alloy system under equilibrium conditions.
b. the temperature, the composition, and maximum tensile stress of a
particular alloy system under equilibrium conditions
c. The temperature, the composition, and the phases present in a
particular alloy system under equilibrium conditions.
5. Metals such as lead and tin do not strain harden at room temperature
because their re-crystallization temperatures lie

Page 3 of 15
 a. Below room temperature
b. Above room temperature
c. None of the above.

Question #4: (9 points)

Below is shown the lead-tin phase diagram. Find out the phase(s) present,
their composition(s), and their amount(s) for:
a. An alloy of composition 30 wt% Sn-70 wt% Pb at 200C.
b. An alloy of composition 80 wt% Sn -20 wt% Pb at 250C

Solution:
30 wt% Sn-70 wt% Pb at 80 wt% Sn -20 wt% Pb at

200C 250C
Phase +L L
Compositi wt% Sn + L (56.8 wt%
L (80 wt% Sn)
on Sn)
= (56.8-30)/(56.8-17.7) =

Amount 68.5% 100% L

L = 31.5%

Page 4 of 15
Question #5: (9 points)
For a bronze alloy, the stress at which plastic deformation begins is 267MPa
and the modulus of elasticity is 115GPa.

a. What is the maximum load (in N) that may be applied to a specimen

having a cross-sectional area of 300mm 2 without plastic deformation?
b. If the original specimen length is 137mm, what is the maximum
length (in mm) to which it may be stretched without causing plastic
deformation?

Solution:
(a)The maximum stress that may be applied without plastic deformation
taking place is the yield strength, y;

The load at yielding (or maximum load), Fy, is

= 80,100 N
(b)Combining Hooke's law (at the stress corresponding to the yield
strength)

, = 137.3 mm

Page 5 of 15
Question #6: (6 points)
The yield strength for an alloy that has an average grain diameter of 1.6 x
10-2 mm is 320MPa. At a grain diameter 3.9 x 10 -3 mm, the yield strength
increases to 480MPa. At what grain diameter (in mm) will the yield strength
be 441MPa?

Solution:
It is necessary to set up two simultaneous equations of the Hall-Petch form,

Now, incorporating values of y and d, these equations become

And, from these equations it is possible to solve for values of 0 and ky; thus
0 = 164 MPa, ky = 19.7 MPa-mm1/2
Finally, the grain diameter required to give a yield strength of 441 MPa may
be determined by rearrangement of the first equation--that is

= 0.00506 mm

Page 6 of 15
 Question #7: (16 points)
Refer to the Iron-Iron carbide phase diagram shown below. Find:

a. Show all liquidus and solidus lines on the diagram. (3)

b. The eutectic temperature and composition. (1)
c. The eutectoid temperature and composition. (1)
d. the main phases present for an alloy of 1% C at 1600 oC, 1400 oC,
1200 oC, 740 oC, and 600oC. (5)
e. The chemical composition of each phase present for an alloy of 1%
C at 1600 oC and 1400 oC. (1.5)
f. Amount of each phase present for an alloy of 1% C at 1200 oC and
600oC.(1.5)
g. Amount of pearlite for an alloy of 1% C at 1200 oC and 600oC. (1)
h. Locate the hypo-eutectoid and hyper-eutectoid steels in terms of
carbon content on the diagram. (1)
i. What is the maximum solubility limit of C in ferrite, and at which
temperature it occurs? (1)

Liquidus

Solidus

Solidus

0.01 0.7 1.7

Solution:
a. See the labels on the figure
b. The eutectic temperature and composition: 1147C, 4.30 wt%C (1.0
point)
c. The eutectoid temperature and composition: 727C, 0.76 wt% C(1.0
point)
d. the main phases present for an alloy of 1% C at: (5.0 point)
1600 oC: liquid
1400 oC: + L
1200 oC:
740 oC: + Fe3C
600oC: + Fe3C
e. The chemical composition of each phase present for an alloy of 1% C
at: (1.5 point)
Page 7 of 15
 1600 oC: 1.0 wt% C
1400 oC: (0.72 wt%C+ L (1.74 wt%C)
f. Amount of each phase present for an alloy of 1% C at: (1.5 point)
1200 oC: 100%
600oC: W =100*(6.7-1)/(6.7-0.014) = 85%, WFe3C = 15%
g. Amount of pearlite for an alloy of 1% C at: 1.0 point)
1200 oC: 0%
600oC: Wpearlite = 100*(6.7-1)/(6.7-0.76) = 96%
h. hypo-eutectoid steels: %wt C < 0.76wt% (1.0 point)
hyper-eutectoid steels:2.14wt%< %wt C > 0.76wt%
i. Maximum solubility limit of C in ferrite = 0.022wt%C at which 727C
(1.0 point)

Page 8 of 15
Question #8: (2.5 points)
What are the Miller indices for the plane shown below?

'Z

X
Solution:
'

Shift xyz coordinate system to the right as shown.

Intercepts: (1, -1, 2/3), reciprocals: (1, -1, 3/2), Clear fractions: (2, -2,
3)

Plan:

Question #9: (2.5 points)

Determine the Miller indices of the direction shown in the figure.

Solution:

Tail: (2/3,2/3,0), head: (1/2,0,1/2), Head Tail = (-1/6, -2/3, 1/2),

Clear Fractions: (-1, -4, 3)

Direction:

Page 9 of 15
Question #10: (12 points)

Determine the carburizing time (in s) necessary to achieve a carbon

concentration of 0.44 wt% at a position 1.9 mm into an iron-carbon alloy
that initially contains 0.031 wt% C. The surface concentration is to be
maintained at 1.2 wt% C, and the treatment is to be conducted at 1020C.
Assume that D0 = 5.1 x 10-5 m2/s and Qd =154 kJ/mol.

Solution:

The time required to achieve the stipulated carburization time may be

determined by solving Fick's second law:

For the given boundary conditions, the solution is as follows:

Incorporation of composition values provided in the problem statement

leads to

The value of z for which the error function is 0.6500 may be determined by
using data in the table provided in the problem statement and by linear
interpolation as follows:

which leads to z = 0.6612. Thus

Or

Now, solving for the diffusion coefficient at this temperature, using data
provided in the problem statement

Incorporation of this value into the above equation, the time is equal to

Page 10 of 15
= 67,900 s

Page 11 of 15
Question #11: (6 points)
A fatigue test was conducted in which the mean stress was 46.2MPa and the
stress amplitude was 219MPa.

a. Calculate the maximum stress level (in MPa).

b. Calculate the minimum stress level (in MPa).
c. Calculate the stress ratio.
d. Calculate the magnitude of the stress range (in MPa).
Solution:

Solving these two expressions simultaneously for max and min (and
incorporating values of m and a given in the problem statement) yields

(c) The stress ratio, R, is defined as

(d) The stress range r is equal to

Page 12 of 15
Question #12: (4 points)
Estimate the rupture lifetime (in h) for some cylindrical component originally
10.5mm in diameter and 496mm long that is fabricated from a low carbon-
nickel alloy; assume that it is to be exposed to a tensile load of 6300N at
538C. The logarithm stress versus logarithm rupture lifetime plot for this
alloy is given below.

Solution:
For a cylindrical specimen that is loaded in tension, load and stress are
related by the equation

And, incorporating values of F and d0 provided in the problem statement,

the stress is equal to

From the 538C line in the plot provided in the problem statement, the
rupture lifetime corresponding to 72.8MPa is about 10 4 h.

Page 13 of 15
Question #13: (10 points)
For some metal alloy it is known that the kinetics of re-crystallization obey
the Avrami equation, and that the value of k in the exponential is 2.73 x 10-
6
, for time in seconds. If, at some temperature, the rate of re-crystallization
is 0.0014 s-1, what total time (in s) is required for the re-crystallization
reaction to go to 90% completion?
Solution:

Since the rate of transformation r is defined as:

using the specified rate value it is possible to solve for t0.5 ( the time
required for the transformation to go to 50% completion), as

Using the Avrami equation--i.e.,

at the point of 50% transformation completion, this equation takes the form

And, solving for n leads to

which, upon entering the value t0.5 computed above as well as the value of k
provided in the problem statement yields the following value for n:

Finally, using this n value, the time t required for the second degree of re-
crystallization may be determined using another rearranged form of the
original Avrami equation as

Page 14 of 15
Question #14: (3 points)

Using the continuous cooling transformation diagram shown below for an

iron-carbon alloy of eutectoid composition, name the micro-structural
products of specimens having this eutectoid composition that are first
completely transformed to austenite, then cooled to room temperature at
the following rates:

a. 175C/s
b. 90C/s
c. 15C/s
Solution:
a. At a rate of 175C/s, only martensite forms since this rate is greater
than the critical rate of 140C.
b. At a rate of 90C/s, both martensite and pearlite form since this rate is
less than the critical rate (140C) yet greater the maximum rate for
formation of a totally pearlitic structure (35C).
c. At a rate of 15CC/s, only pearlite forms since this rate is less than the
maximum rate for the formation of a totally pearlitic structure (35C).

Page 15 of 15