EXERCISE QUESTIONS IN MECHANICAL METALLURGY Module 1 to Module 5

1. Distinguish between elastic, plastic and Viscoelastic deformations. 1.5 M 2. Draw Idealized flow curves for a) Rigid ideal plastic materials b) Ideal Plastic material with elastic region c) Strain hardening (piecewise linear) material. 1.5 M 3. Distinguish between elastic limit and proportionality limit. Explain the significance of offset yield strength. 1.5 M 4. a. Derive the expression for CRSS. What is Schmid factor. 2 M b. Determine the tensile stress that is applied along the[110] axis of a silver crystal to cause slip on (111) the [011] system. The CRSS is 6 M Pa. 2 M c. CRSS should decrease as the provided that the total number of imperfections is not zero. 1 M 5. What is twinning. Explain with help of schematic. 2 M What are the differences between slip and twinning? 1.5 M What is Twin Cry? What are the ways in which twins can be produced? 1.5 M What are the differences between twinning and diffusionless shear transformation of martensite. 1.5 M 6. Explain deformation bands and kink bands. 2 M Explain the reason for Bauschinger effect? 2 M What is a sessile dislocation? 1 M 7. Draw the generalized shear stress Vs. shear strain curve for fcc single crystal. Explain in detail various stages. 4 M What are different sources for dislocation generation? 1 M 8. Explain the role of grain boundaries in the plastic deformation of polycrystalline materials. 4 M What is hall-petch equation? Describe the terms used in the equation. 1 M 9. Differentiate low angle grain boundaries and high angle grain boundaries. 2.5 M Explain the yield point behavior. 2.5 M 10. Explain the terms Strain ageing and Portevin- Lechatelier effect. 3 M What is Blue Brittleness? 1 M How can you differentiate quench ageing from strain ageing? 1 M

Strengthening Mechanisms (Module 6 and 7)

11. i. How the grain boundary angle effect the strength of the materials? 1 M ii. Usually hardness near the grain boundary is higher than the center of the grain. Justify. 1 M iii. Distinguish between statistically stored dislocations and geometrically necessary dislocation. 1 M iv. What is Equicohesive temperature? 1 M v. Which strengthening mechanism do we use to increase strength without loss of ductility? 1 M 12. State Hall Petch equation. 1 M

Briefly explain different dislocation- solute atom interactions. 3 M State which interactions are long range and which interactions are short range. 1 M 13. What is age hardening? 1 M Explain the age hardening of Al alloys. Draw the variation of yield stress with ageing time. 4 M

Module 8 12 (Tension Test)

14. Define Resilience and toughness. Give suitable expressions to calculate them. 2 M Give the expressions for true stress and true strain in terms of engg stress and strain. 2 M Explain the significance of true stress and true strain curve. 1 M 15. Prove that rate of strain hardening equals the stress at necking. 2.5 M What is the effect of temperature on flow properties? 2.5 M

Hardness, Tension, Compression, Impact and Torsion

16. What are the general types of hardness measurement test. What is Mohs hardness test. 2 M What is Brinell Hardness Number. Give suitable expression(s) for BHN. 1 M What is the condition required to produce the same BHN number for even non-standard loads. 1 M What are the major advantages and disadvantages of Brinell Hardness Testing? 1 M 17. How do you define Mayers Hardness Test. Give suitable expression? 1.5 M What is Mayers Law. 1 M Briefly comment on the relationship between flow curve and hardness. 1.5 M Why the included angle in Vickers hardness test is 136. 1 M 18. Derive the expression to calculate the maximum shear stress arising due to Torsion Moment on a cylindrical solid bar. 3 M Differentiate Torsion Test from Tension Test. 2 M 19. What are the factors that contribute for brittle failure of materials. 1 M Explain with schematic, Izod and Charpy impact tests. 4 M 20. Give the diagrammatic representation of effect of temperature on notch toughness. Expalin various criteria of Transition Temperature. 5 M

Fatigue
21. What are different types of fatigue stress cycles? 1.5 M Give expressions for r, m, a, Stress ratio and stress amplitude. 1.5 M What are basic factors necessary to cause fatigue failure. 2 M 22. What is a fatigue curve (S-N curve)? Explain briefly. 2 M Draw the typical S-N curves for ferrous and non- ferrous metals. 1.5 M What is Basquin equation? 1.5 M

23. Show the effect of mean stress and stress ratio on the S-N curve. 3 M What is the significance of Goodmann diagram. 2 M 24. Explain the response of metals to cyclic stress strain cycles with respect to cyclic softening and cyclic hardening. 3 M Explain the procedure for drawing the cyclic stress strain curve. 2 M 25. What is Coffin Manson relation. Explain its significance. 3 M 26. Explain different stages which lead to fatigue failure . 5 M 27. Derive the equation for fatigue life in terms of fracture crack size. 5 M 28. What are different fatigue design criteria. Briefly explain. 5 M

Creep
29. Draw a typical creep curve showing different steps of creep. Show the difference between constant load and constant stress test. 5 M 30. Differentiate between stress rupture and creep test. 2 M 31. Explain different mechanisms of creep deformation. 5 M 32. Draw a diagram to show the influence of stress and temp on deformation mechanism of creep. OR Draw simplified deformation mechanism maps. 2 M 33. What are different modes of high temperature fracture? Give schematic. Explain the favorable conditions for each mode. 3.5 M What are different types of cracks for intergranular creep facture? Differentiate them. 1.5 34. What is Larsen-Miller Parameter? Explain its significance. 2 M

Fracture
35. Derive the expression to find the theoretical cohesive strength of materials. 4 M Determine the cohesive strength of a silica fiber, if E= 95 G Pa, s= 1 J m-2, a0= 0.16 nm. 1M 36. Give the expression for fracture stress in terms of crack length. 1 M Calculate the fracture stress for a brittle material with the following properties. E= 100 G Pa, s= 1 J m-2 and crack length is 2.5 m. 1 M 37. State Griffith theory of brittle fracture. 2 M 38. Derive the expression for strain energy release rate? 39. What is R- Curve? Draw R curve for ductile and brittle materials.