UNIVERSITY OF ZIMBABWE

METALLURGICAL ENGINEERING DEPARTMENT BSc (Hons) Engineering Part I FINAL EXAMINATION ENGINEERING MATERIALS (CE101) TIME: 3 HOURS INSTRUCTIONS: SECTION A Answer Section A in a separate booklet from Section B. 1(a) An impact tester shown in Fig 1 below has a striker of weight 1.2kg in position A. On striking the specimen the pointer on an attached protractor scale originally at O indicates 105o from position O. Calculate the impact energy. [6 Marks] Answer THREE questions from Section A. DATE: JUNE 2004

Fig. 1 (b) A 100mm wide plate of thickness 5mm has a transverse hole of 35mm in diameter drilled in the plate. The plate is subjected to a tensile force of 170N. Using the stress concentration factor data below, calculate the maximum value of the tensile stress in the section. Hole in m Stress concentration factor 0,1 2,72 0,2 2,51 0,3 2,37 0,4 2,25 0,5 2,17
[6 Marks]

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(c)

Alloys that are fast cooled from the recrystalisation temperature are quench hardened and become brittle. Explain the: (i) (ii) (iii) Quench hardening phenomena in brans. Tempering of high carbon steels. Decarburization of steel.
[3 Marks] [3 Marks] [2 Marks]

2(a)

With the aid of neat sketches describe the bonding in: (i) (ii) (iii) copper and explain why copper is a good conductor of electricity. [4 Marks] magnesium oxide and explain why magnesium oxide is an insulator. [4 Marks] PVC and explain why PVC is an insulator. [4 Marks]

(b) (c) 3(a)

Give the electronic configuration of Cu and Mg atoms given atomic numbers for Cu and Mg to be 29 and 12 respectively. [4 Marks] Calculate the interplanar spacing for an aluminium of atomic radius of 0,1431nm for the (110) set of planes. [4 Marks] The radius of a bcc iron is 0,124nm. Calculate: (i) (ii) The density of the iron. [3 Marks] The diameter of the largest carbon atom that can form an interstitial solid solution.
[3 Marks]

(b)

Justify that the coordination numbers for (i) (ii) (iii) BCC unit cells is 8 FCC unit cells is 12 HCP unit cells is 12
[2 Marks] [2 Marks] [2 Marks] [ Marks] [2 Marks]

(c) (d) 4(a)

Calculate the atomic packing factor for BCC, FCC and HCP. Why is tungsten refractory?

hand tool of 0,7%C steel is being decarburized at 1200K under conditions that maintain a constant carbon concentration of 0,1% at the surface. After time t the concentration at a depth of 1.0mm from the surface was 0,4%. (i) How much longer would be required for the carbon to attain 0,4% concentration at a depth of 2,5mm? Given the diffusion coefficient for carbon in austenite is 2 x 10-5mm2/s. [4 Marks] Using a clear sketch explain the mechanism of diffusion in decarburizing the hand tool. [4 Marks]

(ii)

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(b)

Explain the following mechanisms of diffusion giving examples: (i) (ii) 2 ring diffusion 4 ring diffusion
[3 Marks] [3 Marks]

(c) 5(a)

Using clear diagrams explain how substitutional diffusion occurs in alloying carbon steel to produce HSS by introducing Tungsten, Chromium and Titanium. [6 Marks] To avoid coarsening of grains the case hardening process is done at 850oC instead of 900oC. (i) Calculate the diffusion coefficient D, of carbon in austenite for the two temperatures using the formula D = Do exp (-Q/RT). Given Do Q R (ii) = = = 0,21cm2/s 140KJ/mole 8,314Jm-1K-1

[4 Marks]

What time is required to case harden at 850oC if it is required to get the same result as is obtained when case hardening at 900oC for 10 hours. [4 Marks]

(b)

Explain giving examples any two of the following factors that affect corrosion of metals: (i) (ii) (iii) Temperature Heat Treatment Stress
[4 Marks] [4 Marks] [4 Marks] [4 Marks]

(c)

Draw the electrochemical corrosion circuit and label.

END OF SECTION A

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SECTION B INSTRUCTIONS: Answer TWO questions from this section.

REQUIREMENTS: The provided answer sheet for Question 6 should be attached to the answer booklet. 6(a) With the help of sketches explain the following: Effective size diameter Coefficient of curvature Cc Uniformity coefficient Well graded soil Uniformly graded Gap graded soil (b)

[6 Marks]

The following readings were taken from a sieve analysis. Draw the grain distribution curve on the graph provided. Use the same form for your calculations. Determine the effective size diameter (D10), the uniformity coefficient, and the coefficient of curvature. (Do your work on the answer sheet provided) [14 Marks]

1. CE 101 2004
1.1 Grain size distribution Size Retained Mm G 20 0 6.5 5.6 4.75 6.1 2.36 13.7 1.18 15.6 0.6 17.9 0.3 21.1 0.15 9.8 0.075 5.2 retainer 3.5

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Answer sheet for Question 6

1. CE 101 2004
1.1 Grain size distribution Size retained Mm G 20 0 6.5 5.6 4.75 6.1 2.36 13.7 1.18 15.6 0.6 17.9 0.3 21.1 0.15 9.8 0.075 5.2 retainer 3.5

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7(a)

Name the two main types of timber and state which is the major type used in construction. What factors must be considered before the timber is used for the desired construction?
[5 Marks]

(b)

Give reasons why timber must not be: (i) (ii) seasoned to a point below the fibre saturation. stored in a damp and humid environment.

[5 Marks]

(c)

Discuss briefly: (i) (ii) the factors which affect the strength of timber. the factors normally considered during the stress-grading of timber.

[5 Marks]

(d) 8. (a) (b) (c) (d) (e) (f) (g)

Name and discuss briefly any five sources and forms of timber deterioration. [5 Marks] Answer any five questions Name four basic ingredients of Portland Cement.
[4 Marks]

What is soundness of cement and what are the causes of unsoundness of cement?
[4 Marks]

How does the shape of the aggregate particles affect the properties of fresh concrete? What are the dangers of using sea water as mixing water? What is mass concrete and explain why it is a composite material? What are the factors affecting workability of concrete? Explain the influence of cement to water ratio on strength of concrete.
[4 Marks] [4 Marks] [4 Marks] [4 Marks] [4 Marks]

END OF EXAMINATION PAPER

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