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ME2109: Engineering Science 2

Materials and Manufacture
Part 2 Examination

xxxxxxxxxxx 2012

xxxx - xxxx

Answer THREE questions only

Number of answer books to be provided: One with graph paper

Calculators permitted: Casio FX-83/85 MS/ES/GT+ ONLY
Dictionaries permitted: None
Additional materials: None
Can question paper be removed from the examination room: NO

External Examiner:
Internal Examiners:

Dr R J Goodey

Page 1 of 4

Question 1
Consider the plate of unit thickness shown in Figure Q1.
a)

Assuming the material is elastic and by considering the geometry shown, determine an
expression for the elastic energy released upon formation of the crack, length a.
[10 marks]

b) If the material is brittle then the energy absorbed upon formation of the crack is given by
S = 2a. Use this and the equation determined in Part (a) to sketch a curve showing the
relationship between crack length and energy in the system. Show on this curve how you
would determine the critical crack length.
[10 marks]
c)

If material is ductile rather than brittle, discuss the effect this has on formation of a crack.
[5 marks]

pa

Fig. Q1

Question 2
There are many choices available for the processing of plastics. The final cost of each plastic
component will be a function of a number of factors. Discuss the influence of these factors on
cost per component. You may wish to consider production method, capital costs, production
volume, material costs and labour costs although this list is not exhaustive.
[25 marks]

Page 2 of 4

Question 3
Table Q3 shows the influence on the Vickers hardness number of cold working a sample of
copper alloy.
a)

Explain the cold working process and how it affects the structure of the copper alloy.
What is the practical significance of this process?
[10 marks]

b) By consideration of the results shown in Table Q3, what effect would you expect cold
working to have on the tensile strength and ductility of the copper alloy? On the same
axes, sketch four curves to represent the tensile stress-strain response of each of the
copper alloy samples.
[8 marks]
c)

Brittle behaviour is generally undesirable in metal alloys. Explain how annealing can
reduce the effects of cold working.
[7 marks]

Percentage cold work

0
20
40
60

Vickers hardness number

80
135
150
160
Table Q3

Question 4
a) Explain what is meant by creep in materials. What factors affect the creep rate of a given
material?
[4 marks]
b) Sketch and label a typical creep curve for metal. Indicate the region in which power law
creep applies.
[4 marks]
c) State 3 components where creep behaviour must be considered during design. For each
application explain the effects of creep over the lifetime of the component.
[9 marks]
d) Describe a test that could be performed in the laboratory in order to determine the creep
properties of a material.
[8 marks]

Page 3 of 4

Question 5
a)

Discuss what occurs when a plain carbon steel of the eutectoid composition (0.76wt% C)
cools in equilibrium from 800C to a temperature below 727C.
[5 marks]

Figure Q5 shows the isothermal transformation diagram for the same steel alloy discussed in
Part a).
b) Estimate the cooling rate required (starting at 727C) to give a 100% Martensitic steel at
room temperature.
[5 marks]
c)

Explain why, in practice, it is not possible to achieve alloys that are 100% Martensite.
[5 marks]

d) From Figure Q5, what microstructure will arise if a steel alloy at 727C is cooled rapidly
to 600C, held there for 100s and then quenched to room temperature?
[5 marks]
e)

Explain why, in general, Figure Q5 is impractical for determining cooling regimes to

produce specific alloys. What may be a more practical way to treat the cooling of metal
alloys?
[5 marks]

Fig. Q5

Page 4 of 4