Mock Exam, CP303 Section A 2013/14

Q1. 25 marks
(a) 10 marks
(i) A pipeline constructed of cast iron #100 (i.d. 102.3 mm, o.d. 114.3 mm) failed after 3
years operation. On examination it was found that the wall thickness had been reduced by
corrosion to about half the original value. If the pipe was handling an acid at temperatures
above 150oC, using the corrosion chart (provided at the end of the tutorials), provide a list of
possible liquids the pipeline was handling as well as their concentrations.
(ii) In the pipeline described in question above a decision has to be made on what material to
use to replace the pipe. Three suggestions have been made:
1. Replace with the same schedule carbon steel pipe and accept renewal at 3-year
intervals.
2. Replace with a thicker cast iron #200 pipe (o.d. 114.3 mm, i.d. 97.2 mm).
3. Use stainless steel pipe, which will not corrode.
The estimated cost of the pipes, per unit length is: #100 cast iron 3, #200 cast iron 5
($8.3), stainless steel 15 ($24.8). Installation and fittings for all the materials adds 10 per
unit length. The downtime required to replace the pipe does not result in a loss of production.
If the expected future life of the plant is 7 years, recommend which pipe to use.
(b) 5 marks
What are zeolites? List applications of zeolites and discuss one application with suitable
examples.
(c) 5 marks
The density and associated percent crystallinity for two polytetrafluoroethylene materials are
as follows:
(g/cm3)
crystallinity (%)
2.144
51.3
2.215
74.2
(i) Compute the densities of totally crystalline and totally amorphous polytetrafluoroethylene.
(ii) Determine the percent crystallinity of a specimen having a density of 2.26 g/cm3.
Q2. 50 marks
(a) 25 marks
(i) Derive linear density expressions for BCC [110] and [111] directions in terms of the
atomic radius R.
(ii) Compute and compare linear density values for these same two planes for tungsten.
(b) 25 marks
Gallium arsenide (GaAs) and gallium phosphide (GaP) both have the zinc blende crystal
structure and are soluble in one another at all concentrations. Determine the concentration in
weight percent of GaP that must be added to GaAs to yield a unit cell edge length of 0.5570
nm. The densities of GaAs and GaP are 5.316 and 4.130 g/cm3, respectively.
Q3. 25 marks
(a) 15 marks
Following is tabulated data that were gathered from a series of Charpy impact tests on a
tempered 4140 steel alloy.
T (C)
100

Impact Energy (J)

89.3

75
50
25
0
25
50
65
75
85
100
125
150
175

88.6
87.6
85.4
82.9
78.9
73.1
66.0
59.3
47.9
34.3
29.3
27.1
25.0

(i) Plot the data as impact energy versus temperature.

(ii) Determine a ductile-to-brittle transition temperature as that temperature corresponding to
the average of the maximum and minimum impact energies.
(iii) Determine a ductile-to-brittle transition temperature as that temperature at which the
impact energy is 70 J.
(b) 10 marks
Atomic radius, crystal structure, electronegativity, and the most common valence are
tabulated in the following table for several elements; for those that are nonmetals, only
atomic radii are indicated.
1.
Element Atomic Radius (nm) Crystal Structure Electronegativity Valence
Cu

0.1278

FCC

1.9

+2

0.071

0.046

0.060

Ag

0.1445

FCC

1.9

+1

Al

0.1431

FCC

1.5

+3

Co

0.1253

HCP

1.8

+2

Cr

0.1249

BCC

1.6

+3

Fe

0.1241

BCC

1.8

+2

Ni

0.1246

FCC

1.8

+2

Pd

0.1376

FCC

2.2

+2

Pt

0.1387

FCC

2.2

+2

Zn

0.1332

HCP

1.6

+2

Which of these elements would you expect to form the following with copper:
(a) A substitutional solid solution having complete solubility
(b) A substitutional solid solution of incomplete solubility
(c) An interstitial solid solution

Data Sheet and Equations

SOME USEFUL PHYSICAL CONSTANTS
1. kB = 8.63x10-5 eV/K
2. l for the 1025 steel is 12.0 10-6 (C)-1
34
3. Plancks constant = 6.6310 J - s

4. Avogadros number = 6.022x1023 molecules/mol

SOME USEFUL EQUATIONS

M n = ( DP)m

n=

q( n p )

Q N
Q
N v = N exp v = A exp v
A
kT
kT

Aavg

100
C1 C 2

A1 A2

A similar equation as the one above can be constructed for avg.

VC =

n Aave
ave N A

LD =

number of atoms centered on the direction vector

length of the direction vector

C (%crystallinity) =

Cost rating

m=

c ( s a )
s ( c a )

Mn
DP

Ec (u) = EmVm + EpVp

Ec (l ) = Em Ep ( EpVm EmVp )

USEFUL PROPERTIES OF MATERIALS

Material
Carbon steel
Copper alloys
Aluminium
PVC
PP

Element

Material

kg/m3

Cost
/tonne
300
800
900
360
360

7.85
8.9
2.7
1.3
0.9

Atomic
Radius (nm)

Iron

0.124

Tungsten

0.137

Modulus of
Elasticity (GPa)

Yield Strength
(MPa)

Poisson's
Ratio

Aluminum alloy

70

200

0.33

Brass alloy

101

300

0.34

Steel alloy

207

400

0.30

Titanium alloy

107

650

0.34