Question Bank 1
Question Bank 1
Question Bank 1
It
I
QUESTION BANK
. '
METALLURGICAL ENGINEERING
! t
Sr. No. Contents
VOLUME-I'
Page No.
1. GATE-1990 I
SOLUTIONS I ANSWERS 8
2. GATE-1991 25
SOLUTIONS I ANSWERS 34
3. GATE-1992 48
SOLUTIONS I ANSWERS \ 59
4. GATE-1993 72
SOLUTIONS I ANSWERS 92
5. GATE-1994 • 118
SOLUTIONS I ANSWERS 132
6. GATE-1995 152
SOLUTIONS I ANSWERS 167
******************
GA/QBIMT-1 Elite Academy 1
GATE-1990
MT : METALLURGICAL ENGINEERING
Instructions to Candidates
PART-A
ID
(I)
- (11) Creep stress exponent in Coble creep is equal to-----------------
N
....
.... (12) Domains of corrosion behaviour of metals in aqueous solutions is 1epesented
....
.J
1'1-
0
by ----------------- diagram.
N
0
(13). The chemical formula for forsterite is -----------------
0
1'1-
N
(14) The diffusion co-efficient D = ----------------- exp (-QIRT)
m
...
.0'1 (15) Minimum temperature at which a fuel vaporizes to produce a flame is kDowa •
I :::...
; ... ·----------------- point.
I' "'o
. !Ill (16) The driving force for the process of precipitate coarsening is ----------- energy.
I
L
'(L (17) A solder wets a metal surface if it forms an ---------------- compound.
.
:> (18) The crystar structure of martensite in plain carbon steels is ----------------
0
c
L
IJ (19) Fe30 4 exhibits----------------- spinel structure at room temperature.
I
1-
(20) YBa 2 Cu 3o 7 ceramic exhibits----------------- at liquid nitrogen temperatures.
II. Write in the third and fourth pages of the answer book the question number
and correctness of the statement as TRUE or FALSE (Do not write T of F),
with one line reason or justification against each. Answers without proper
justification carry no marks. Marks (20 x 2 = 40)
2. Von Mises criterion is based on the total eriergy stored in the material.
3. Effective diffusivity of a gaseous component in a porous solid is equal to its free
diffusivity in the gas phase.
4. Welded •: stainless st~l joinB' are likely to fall as a result of inte;granUlar attack
PART-B
Answer the questions in PART-Bin serial o.rder. Marks (6 x 2 = 12)
IV. Answer the following briefly and to the point. Marks (10 x 4 = 40)
1. What is the rate of nucleation at the equilibrium transformation temperature?
2. How many degrees of freedom are there in a single phase filed of a binary alloy
(use condensedphase rule)? Specify the variables.'
3. Outline briefly the reasons for the high strength of freshly quenched martensite in steel.
4. What are the factors responsible for the occurrence of 'hot tear' defects in castings?
5. Why should flashless forgings be preferred to castings in case of the production of
small nearnet-shape components?
6. What are the factors which contribute to brittle cleavage fracture?
7. Show that Ef := E~ where E's are the 111ole fraction interaction p~ameters and i
and j are solutes in a solvent metal M.
8. State the optimum conditions required for desulphurization of molten steel.
9. Enumerate the factors that influence the reaction kinetics in Van Arkel iodide process.
.
10. Thennodynamically pure silicon caruiot reduce MgO when the reactants and the
products are in their standard state. How has this been overcome in Pidgeon's
pr9cess? Explain.
2- Give the temperature profile of gas and solid in an iron blast furnace along its
height. Label different zones indicating the chemical reactions taking place
therein.
·3. Give the flow sheet of a process used for the production of iron powder based on
hydrogen reduction of mill scale.
4. Draw a typical diagram for fatigue crack growth rate versus stress-intensity
-
factor.:....range for steel, indicating the different regions and the influence of
structure.
Given the melting point of A and B components to be. 1000° C and 700° C
respectively,.draw the phase diagram. .Label all the phase fields.
VI. Solve the following proble~s indicating the equation(s) used and. defining
symools involved in each. Marks (6 x 8 = 48)
where xPb = mole fraction oflead. Write the corresponding equation for 'Ysn and
......
Q't
3. A large she.et of a high strength material contains a central crack of length 25 mm.
.
0
The fracture strength of this sheet is 400 MPa. Find the fracture strength if the
Ill
•
L
Q.
crack length is 100 mm .
Ill
::>
0
4. Sphere shaped particles of the beta phase nucleate homogeneously in the
c
L
supersatUrated alpha matrix. Given: AGa-fl·=-100 J/mole, Yap= 100mJ/m 2
~•u '
and molar volume = 9x10-6 m 3 /mole, calculate the activation energy and the
size of the critical nucleus.
********************
-
8 · Elite Academy· GAIQB/Ml'-4
SOLUTIONS I ANSWERS
..
-
PART-A· ....
2. False
Von Mises yield criterion is based on the strain energy of distortion of the
· material. Yielding will ~cur when the strain energy of distortion per unit volume
exceeds the strain energy of distortion per unit volume for a specimen strained to .
the yield stre~s in uniaxial tension or compression.
4. True
Heating to about 500- 800°C can cause the chromium near the grain boundaries
'
to be removed from solid solution to form chromium carbide precipitates. The
thin layers alongside the grain h?undaries, being depleted the chromium are then
no longer protected by the passivating film and become anodic relative to the rest
of the -surface.
5. True
Iron oxide, silica and alumina can form low melting constituents bringing down
the refractoriness
6. False
· Equilibrium cons~nt depends on the free energy change that takes place in the
reaction which may increase or decrease. It is only the kinetics that improves
with temperature.
8. False
Fonnation of G-P zones is only the first. step in the precipitation. Formation
9. False
1
Higher- tendency to dezincification is in beta brasses which have higher zi~
constant.
11. False
• - _:.;_~4~:•
.· .. ltltJ-·~.........-
j..;,
As can be seen from the above reactions, the reducibility of hematite and
magnetite are different.
Hematite
12. False
Phosphorous can cause deoxidation only . upto a limited extent. Also, with
additions of P the electrical conductivity reduces due to residual P.
13. False
Lever rule can be applied where phases form. At exact eutectic temperatures the
phases do no form. So we always take the tie line at eutectic temperature but
consider the phases formed just below the eutectic. Also lever rule can be applied
at any temperature to find out the proportion of phases.
In the ball mill the balls should be lifted upto the top and then they should drop on
the charge for size reduction. If the speed is too low the balls will not be lifted.,
At very high speeds of rotation the. balls may carried centrifugally and may not
cause impact. Hence the power input cannot be considered as a linear function of
speed.
17. True
18. True
High strength low alloy steels contain low C ahd low quantities of alloying
elements (Sl, V, Nb, etc). The carbide forming elements form the fine carbides
which refine the grain size.
19.. True
Wustite (FexO) is the lowest form of iron oxide. Other oxides progressively '
!
reduce to this stage and final reduction takes place through wustite.
20. False
PART-B
III.
· 1. Uphill Diffusion: Normally in a diff\lsion process, thel'e is a movement of atoms
. down the concentration gradient. (i.e. they move from a region of higher
concentration to a region of lower concentration). In uphill diffusion, the atoms
move against the concentration gradient. (i.e. they move from lower
concentration to higher concentration) e.g. precipitation hardened alloys.
Kc = Y cr.J;
5. Degree of liberation
. .
of a .mineral: In an ore fine particles of mineral are usually
.
embedded in gangue. These mineral particles can be 'liberated' from the gangue
only if there is considerable size reduction of ore. ·Finer the size more will be the
'liberation' of mineral particles. The ratio of 'liberated' mineral to total mineral
in the ore can be expressed as degree of liberation of the mineral.
3. (1) The carbon atoms which are highly soluble but have little strengthening_
effect in austentite(fcc) are forced into the bee lattice by the martensitic ·
GA/QB/MF-1 Elite Academy 15
by a reducing slag to remove the sulphur. However, this technique can be used
efficiently only in the electric arc steel making. In the other processes the oxygen
potential of the metal is lowered after first oxidising C, Si, Mn, P, by stopping the
iron ore and mill scale additions or stopping or reducing the oxygen blowing. In
this respect the electric arc process offers the highest removal of s while the
I
i oxygen blown processes after only limited s removal.
.I
9. Van Arkel process is a process for refining of metals such as zirconium and
titanium. The halides of the multivalent metals are usually much more reducible
than the oxides, and several of these halides, being more covalent than ionic are
highly volatile.
GAIQB/MT-1 Elite Academy
In the process for refining of Ti, the impure titanium is held against the inside face of a
silica vessel by a molybdenum cage. The vessel, which contains a small amount of
iodine, is evacuated and heated to 170- 200° C. The iodine vapour attacks the titanium
and forms Til 4 which is volatile at this temperature. Down the centre of the vessel is a
Til 4 vapour are decomposed by heat when they touch the filament. Crystals of pure Ti
metal grow on the filament by deposition from this vapour and the iodine vapour returns
to the vessel and continues the process.
10. Although magnesium has a very high affinity for oxygen, the oxide is rather
easier to reduce at high temperatures than those of most other reactive metals
because of the effect of magnesium vaporization on the free energy line.
v.
1. The curves are shown in flg\lre soln. V-1. It can be seen that
(i) Low C steels show a sharp
ductile-brittle transition
,_
(ii) The transition is more gradual
as the C content increases
I
1;
o•HC
Cl
(iii) Increase in the C content
increases the temperature at
which the transition occurs.
-t
(iv) The impact strength decreases -too
with increase in the C content.
I MW scale r
'
(Gr~- 1)0 mesh I
Recirculate ~
4. Under cyclic stresses the crack propagation can occur at a stress intensity factor
(K = cr &
.
) much lower .than the fracture toughness
.
factor K,I . As a
da =C (11K)n
dN
where 2a = the crack length
N the number of cycles
daldN the fatigue crack growth rate
11K the stress intensity factor= Kmax - Kmin
C and N are constants depending on the material and the conditions. If log daldN
is plotted verus log ~K we get a curve of sigmoid shape showing three
characteristics regions as in figure soln. V-3. Region I con-esponds to the
nucleation period, crack growth decreases rapidly approaching the lower limiting
value of stress intensity factor Kth, which is the threshold value below which
region of the curve to the value of l\K = 1, log C = log da/dN. it should b~
emphasized that the Paris equation is applicable only for a certain range of values
in region II.
As the mean stress intensity increases, l~Kmax ~pproaches the fracture toughness
K IC and ductile tearing takes place leading to failure. In region III near the
fracture toughness the crack grov.th rate becomes so rapidly that only a limiteJ
number of cycles can be accumulated before failure occurs. On the other hand a
small error in the threshold data and in region I may result in a large overestimate
of fatigue life.
I II til
I
I •
I
I
I
-II~ I
-•e
If:
I
I
l
M
I
I
Iu I
• I
VI.
2. Bragg's Law: nA. =2d sin 8 (1)
22 Elite Academy GA/QB/MT-1
Substitute in ( 1) to get
dhkl = dwo k= o
d = 2 dhki = d 110 1= o
d = 3 dhkl = dlll
"~ e,.:Er
where y = surface energy
(400)2 = 2 yE
1t X12.5
yE = (400)2 x 1t x 12.5
2
GA/QB/MT-1 Elite Academy 23
Fore= 50mm
a = 2 X ( 400)- X
., 1t X 12.5 Jl/2
( 21t X 50
2 y o.l3
y* =
~G o.-13
~G
-13 = 100 J I 9 x 10 - m 3
6
a
J
ac
= -D --
ax
where J is the flux or diffusion current density
D is the diffusion coefticient
c is the volume concentration of atoms
x is the distance along the direction in which ditiusion occurs.
]-I Elite Academy GA/QB/A~JT-1
(12 kg I m 3 - 0)
J = - 9 x 10-10 m 2 s- 1 x ·-
2mmx 10-3 m
12 X 910-lO k I 2
X
= ·g m s
2x 10-3
=-54 x 10-7 kg 1m 2 s
The -ve sign indicates that the flux flow against the direction of concentration
gradient.
6. Hint: From the composition of the fuel find out the amount of oxygen required
i.n terms of kg/moles. The components of the fuel that burn are
C to C0 2 and
l.volume of air required (at NTP) for combustion. The air supplied is 15% extra.
Therefore calculate the.volume of air supplied. .
As caloritic value of fuel is given calculate the heat generated by 200 kg fuel.
The air that is supplied is converted to fuel gas. Volume of fuel gases can be
found out. Heat going out through fuel gases can be fvund out.
When combustion air is preheated to 350°, the heat supplied by the air can be
calculated. The quantity of fuel required will be less in this proportion.
********************
GA!QB;MT--1 Elite Academy
GATE- 1991
MT : METALLURGICAL ENGINEERING
Instructions to Candidates
1. Select the correct auswer(s) for each of the following questions. There m:1y
be more than one correct answer. Full marks will be given only when all ~he
correct answers have been identified. There is no patiiai markin1!,. Use only
capital alphabets A, B, C and D for your answer. (15 X 2::: 30l
(C) (D)
(AI8GJ
' I T,P,n 2
(iii) The activity of pure hydrogen gas at 1000° C and 5 atmospheric pressure:
(A) is always less than 1
(B) is al~ays greater than 1
(C) can be 5
(D) depends on the choice of the standard state.
(viii) Earing is a defect found in steels after the following metal working operation(s):
(A) Deep drawing (B) Rolling
(C) Extrusion (D) Wire drawing
(x) lbe technique(s) which can be used for the direct observation of dislocations is fare]:
(A) Scanning electron microscopy (B) Transrnis..<:>ion electron microscopy
(C) Field-ion microscopy (D) Electron probe micro analysis
2. Fill in the blanks with appropriate answers. Write only the missing word as
your answer. (l~xJO=lO)
(ii) The enthalpy change of the system for a cyclic process is ----------------
(iii) In Parke's process---------------- is added to remove silver from lead.
(v) A soft magnetic material should have high permeability and-~=------------- area of
hysterisis loop.
3. Write down whether the following statements are TRUE or FALSE (Do not
write T or F), followed by reasons or justiraeations in one or two sentences.
No marks will be given for answers without proper reasons or justifications.
(15 X 2 = 30)
(viii) Steel produced by B.O.F. process is ideally suited for manufacturing flat products.
(x) The serious effect of fibering upon mechanical properties of rolled products is its
tendency to product poor ductility transverse to the direction of fibers.
(xi) Dimples are observed on the fractured surface of brittle metals and alloys.
(xii) It is easy to cast an alloy having long freezing range.
(xiii) Presence of delta ferrite is beneficial in the fusion zone of welded austenitic
stainless steel.
(xiv) In wire drawing the applied stress on the wire is below its flow stress.
(xv) Cathodic protection is always the safest approach to corrosion control.
----------- ---------
(iii) Explain the characteristics of tin-based Babbit metal that make it suitable
as a.bearing material.
(v) Why the slope of the metal - metal oxide lines are positive whereas it is
zero for the C - CO 2 and negative for the C - CO lines in the Ellingham
diagram?
GA/QBlMT--1 Elire Academy
(vi) Explain the particle si1ape sequence with distance from the nozzle in the gas
atomization of liquid metals.
(vii) Describe the salient features of the conventional methods used for welding steel
rails.
(ix) Draw a flow sheet for the production of uranium metal from its ore.
(x) High tern perature or low partial pressure of carbon monoxide is essential for the
stainless steel making. Give reasons.
(xi) Explain the role of frother, collector and activator in the floatation of rninerals.
(xii) Name the bonds that form during sintering of self-fluxed sinter. Why its
reducibility is more than that of unfluxed sinter.
(xiii) Draw a typical creep curve showing the various stages of creep Wldcr (a) constant
load condition, and (b) constant stress condition, in the same figure. For
engineering design }~~1rposes, which stage of creep is critical?
(xiv) Calculate the amount of neck free stretching in a material having strain hardening
coefficient of0.5.
(xv) Explain the mechanism of crack initiation and growth when a metal is subjected
to cyclic stress.
solid and liquid lead is 31 J/mole Kin the temperature range of 550 ··· 600 K. The
atomic weight of lead is 207.
(ii) The wall of a gas fired furnace is constructed with fire brick of 0.2m thick and
steel plate of 3 mm thick. The inside and outside temperatures of the furnace wall
are 1340 K and 310 K respectively. The total area of the fui"nace wall is I 0 m 2 .
Calculate the rate of gas firing required at the steady state to compensate the heat
loss through the walL Th~ calorific value of gas is 10 MJ/m 3 and the thermal
conductivities of fire brick and steel are 1 and 44 W /mK respectivdy. Assume
that the thermal resistance of steel is insignificant and one dimemional
approximation is valid.
(iii) Two metals, A and B, arc used to form an alloy X containint 60 vvt % A and 40 wt
% B. Metal A melts at 1200 K and B at 700 K. When alloyed together these
metals form no compounds or solid solutions, but fonn an eutectic at 70 \\1. % A
and 30 ·wt% B. Assume that the liquid lines are straight. The eutectic solidifies at
500 K. If the alloy X is cooled at a very slow rate from the molten stat<.:. calculate:
(a) the temperature at which the alloy will start solidifying, and
(b) the percentage of eutectic in the alloy at room tcmpcrarure (300 K).
(Graphical Solution is NOT permitted)
(iv) Calculate the approximate load necessary to reduce the thickness of 1.000 mm
wide annealed aluminium sheet from 3 mm to 2.5 mm by cold roliing with no
spread. The material tallows the following uniaxial flow curve relationship:
The radius of the roll is 200 mm. Assume 20% margin for the friction.
GA/QB/MT-1 Elite Academy 33
(v) (a) A thick plate of an alloy contains a through thickness centrally located
crack of length 60 mm. The \\·idth of the plate is 300 mm. If the plate
fails at an applied axial stress of 100 MNm -z, calculate the plane strain
fracture toughness ofthe alloy.
(b) The sr.ear modulus of a precipitation hardenable alloy is 26 GPa and the
magnitude of Burgers vector is 0.25 nm. lf the yield stress of the alloy in
the overaged condition is 270 MPa, calculate the -interparticle spacing in
the alloy.
********************
34 Elite Academy GA/QB/MT-1
SOLUTIONS I ANSWERS
Because for solids and liquids the effect of pressure can be neglected.
(ii) True
(iii) False
(iv) True
GAIQB!MT-1 Elite Academy
By using basic refractory lining, basic slags can be produced for refining and
adjusting the composition of steel.
(v) False
(vi) False
(vii) False
7
(viii) (a) 2a=60mm cra PP =100 MN I m- =100 MPa
K 1c =a crft1-;
a.- a parameter depending on the geometry of the specimen
Let us take a =l
Ku: =lxlOO:<i 6 ~nx30x10··-J =30699801 Paf;.; =30.7 MPa~
36 Elite Academy GAIQB/MT-1
(ix) True
(xi) True
In the brittle fracture of brittle metals and alloys tensile failure occurs by the
necking down or ductile bridges between holes existing along the path of failure.
(xii) False
Alloys with long freezing range possess poor fluidity, and they are more difficult
to feed.
(xv) True
The sacrificial anodes are affected and the metal to be protected (which is made
cathodic) remains fully protected.
(ii) Stoke's law: The rate at which a spherical particle will settle in a viscous fluid is
given by
2gr p 2
v = -----·-···
g,t)
GA/QB/MT-1 Elite Academy
l1 = viscosity of fluid
(iv) Burgers vector: A characteristics vector quantity which expresses the local
lattice translation associated with the movement of dislocation. It is a unit slip
vector and designated as b.
5. Distinguish between
(b) Well defined path stream (b) There are compounds of velocity
lined transverse to the principal direction
of flow. These compounds
constantly change in magnitude.
long time
6.
(i) For the welded pairs, so commonly used in investigation of metallic diffusion, it
seems obvious to choose an x axis rigidly fixed in the pair, although volume
change could introduce some uncertainty. In this case of the welded pair it '.vas
found convenient to choose the origin, or point from which the distance x i<;
measured, in such a manner that the two areas of tig. Soln. 6-(i) arc equal. This
choice of origin \Vas suggested on empirical grounds by Matano and is kr..mvn a~
0
Distance, x
..-,~~· Soln. 6-{i): Matam; inteJ:filce
(ii) During quenching of the steel for martcns_ite formation, if the quench is
interrupted at some temperature in the martensitic range, and the metd held th,~n:
for :;~. period, the tral!sformation is then ddayed on subsequent cooling until a
certain degree of undercooling is achieved, when it resumes again with a burst of
new martensite plat;:s.
(iii) (1) The tin-based babbit has a soft matrix which yields to the pressure on it
and· aligns itself to the shaft.
(2) The softness also prevents high stresses developing at asperities between
the bearing and shaft, and so allows the shaft to run in dirty oil without
being scored by particles of grit which get into the bearing interface.
(3) Antimony and copper present in tin babbits fonn intermctallic phases
which are bard and impart certain stiffening to enable it to support the
bearing pressme and preYcnt it of becoming squeezed out at ends.
Elite Academy GA/QB/Afi--1
(iv) The Fe- Fe 3 C eutectic occurs at lower temperature than Fe-Gr eutectic. Since
the solubility lines also continue in the same direction, the solubility of C in
austenite in Fe- Fe 3 C system is more.
(v) The slope ofthe lines in the Ellingham diagram indicate the entropy change of the
reactions involved.
e.g.
For this reaction, as for all others involving metal oxide formation the
standard entropy change, ~so, is negative, since during the reaction one
mole of oxygen gas is used up (i.e. gaseous volume changes 1 ~ 0
volume).
i.e. positive. It can thus be seen that in plots of the standard free energy
change of formation for metal oxide against temperature the invariable
- ~so value for the reaction gives rise to a positive slope for the resulting
graph.
,.. · ... .- .
GAIQB/MT-1 Elite Academy -+1
sand mixture is rammed on the pattern. In order to harden the sand CO 2 gas is
Following reaction occurs giving silica gel which binds the sand grains and
hardens the mould.
Na 2 Si0 3 xH 2 0 + C0 2 ~ Na 2 C0 3 + Si0 2 xH 2 0
silica gel
42 Elite Academy
Ore
Mining Crushing
Grinding
Water
Pulp .....---~so4 ,Mn~
Waste441-----ll Fiition I
Leach liquor
Uranium ingot
Fig. Soln. 6-(ix): Production of Uranium.
(xi) Frother: It is used to ensure the formation of a stable froth with sufficient
buoyancy to carry the load of floatable mineral out of the pulp. It should not itself
be a strong collector, especially or minerals intended to 'sink, and the froth should
not be so persistent to resist destruction by spray after separation of the pulp. Pine
oil and cresylic acid are the conventional frothers.
Collector: Surface properties of ore and gangue minerals vary within too
narrow a range to be useful for separations directly. Such ~ifferences as do
exist must be amplified by bringing about selective adsorption or
chemisorption of certain organic compounds called 'collectors' on to the
mineral it is desired to float. Therefore three types of collectors ---oils, organic
acid and their salts, and organic bases. The organic acids and bases are all
compounds whose molecules are composed of large non-polar groups and a
polar group" These compounds are in aqueous solution. The polar group can
attach itself to an ion of opposite sign on the mineral surface. If the minerai
surface is sufficiently covered in this way it assumes the surface properties of
the corresponding hydrocarbon particularly in so far as it displays a high
contact angle with water.
(xiii) The relevant curves are shown in Fig. Soln. 6-(xiii). For engineering design
purposes, steady state creep or secondary stage is critical.
44 Elite Academy GA/QB/MT-1
13 >Tz >Tl
Rupture a3 >a2 >al
T<O<Tm
Time
Time. t
A typical creep curve ofstrain versus time The influence ofstress cr and
at constant stress and elevated temperature. temperature Ton creep behavior.
The minimum creep rate AE I At is the slope
ofthe linear segment in the secondary region.
Fig. Soln. 6-(xiii)
(xv) Fatigue-failure begins by the formation, fairly early in the life of the specimen, of
a small crack, almost always at a point on the external surface. This crack then
slowly grows into the material, roughly perpendicularly to the main tensile axis,
as a sharp narrow fissure until the remaining unbroken cross-section is so small
that it can no longer support the applied load and undergoes a simple tensile
failure. Experiments have proved that the fatigue crack front advances a small
distance during each stress cycle and each stage of advance is marked on the
fracture surface by a small undulation or ripple line. These lines form a series of
roughly circular and concentric arcs, which mark successive positions of the crack
front and focus back to the origin of fracture. Under ideal conditions they are too
fine and evenly spaced to the seen, except by special metallographic methods, but
under practical conditions fluctuations in the amplitude of the stress cycle
generally produce a few ripples much larger and prominent than the rest.
GA/QB/MT-1 Elite Academy -+5
7.
(i) (a) Hint: Enthalpy of transition = Latent heat of solidification (Lm) + heat
change while cooling from 600K to 550K = 24 kJ + (600- 550) Cp
31 31
Cp = - J /kg ok = - x 1000 kJ /kgoK
207 207
A
LlS = f° Cp dT + Latent heat of solidification(Lm)
60
-----------'-~
550
T Tm solidification
207 550
Since calorific value of the gas is 10 MJ I m 3 , we can find out tt'le volume of the gas
Q in watts
Volume of gas= i Watt = 1 J I sec
cal. value of gas l 0 MJ I m 3
'
''
8
. . 700 - 500
The slope of hqmds 2 = = -200
100-30 70
(v) (a) Hint: For plain strain fracture toughness detennination the operating
r--
formula is K IC = 0' d .../ 1ta , where 0' d is the operating design stress.
r..1N m - 2 in the present case). a is half the crack length (30 rnm in th~s
Calculate 1.
********************
48 Elite Academy GA/QB/MT-1
GATE-1992
MT: METALLURGICAL ENGINEERING
1. Write down whether the following statements are TRUE or FALSE (Do not
write T or F), followed by reasons or justifications in one or two sentences.
No ma~ks will be given for ans\\:ers without proper reas?ns or justifications.
(15 X 2 = 30)
(i) If G is a property that is a function of state for a homogenous closed system, then
00
dG = ( 8G)
8T p
dT + ( J
8P JT
dP in the absence of gravitational, magnetic and
(ii) . Entropy of a metallic glass at 0 K is zero, provided the glass is cooled very slowly
from room temperature to 0 K.
(iii) Isoactivity lines for a ternary ideal liquid solution are parallel to the sides of the
Gibbs' triangle.
GA/QB/MT-1 Elite Academy
(vi) Phosphorous removal during steel making is better under acidic conditions than
basic conditions.
(vii) Considering the condensed phase rule, there is one degree of freedom in a four-
phase region of a ternary system.
(viii) There is a change in composition of the matrix phase during precipitate coarsening.
(ix) Grain boundaries always move towards their center of curvature during grain growth.
(x) During hot rolling dislocation density increases.
(xi) Very fine-grained metals detonned with slow strain mtes show super-pl&1ic behaviour.
(xii) Magnetic particle inspection can be adopted to detect surface and sub-surface
flaws in austenitic stainless steels.
(xiii) Stress-strain curves for solid and hollow cylinders are identical when tested in torsion.
(xiv) When iron is worked at 800 K (dull red hot) it is hot working.
(xv). Higher is the radius of curvature of flaw, higher is the stress concentration factor.
2. Fill in the blanks with appropriate answers. Write only the missing word,
statement or expression as your answer. (20 x 1 = 20)
(ii) The ideal entropy of mixing for a metallic solution containing n components is
n
given by ASM '= -- R L -------------------
i =l
50 ~lite Academy GAIQB!Mf-1 ,
(iii) The difference in the activation energy for the forward and reverse reactions is
equal to -------------------
(iv) The chemical potential of oxygen shown on the Ellingham diagram for oxides
correspond to unit activity of metal and oxide.· For the reaction, M + o 2 · .__. M0 2 ,
and -------------------
(viii) In the zinc blast furnace---------------- is used for shock cooling of the zinc vapours.
(ix) 'fhe monotectic reaction is-------------------
(x) · Higher order .reflections give ------------------- error m the lattice parameter
determined using X -rays.
(xi) The driving force for the recovery of cold worked metal stems from the-----------------
of cold work.
(xii) Annealing twins are not observed in pure aluminium because it has higher ··--------------
energy.
3. Select the correct answer(s) for each of the following questions. There may
be more than one correct answer. Full marks will be given only when all the
correct answers have been identified. There is no partial marking. Usc only
capital alphabets A, B, C and D for your answer. (15 X 2 = 30)
where E is the Intemd Energy, H the Enthalpy and G the Gibbs' Free energy.
(ii) The limiting condition for the appearance of a miscibility gap in a binary solution
IS
( oaxG) laxJG) = o
ra 3
=0
2
(A) (B)
2
(C)
where G is the Gibbs' force Energy and X is the mole fraction of component 2.
. . .
(iv) In the commercial production of which of the following metals, metallothermic
reduction is used?
(A) Copper (B) Zinc (C) Zirconium (D) Nickel
(viii) A binary alloy system A-B shows the peritectic reaction, L + u ~ p. An alloy
of the peritectic composition when cooled tmder natural cooling conditions will
show coring in
-----,----~-- ---,...----..-..,---------,...-----~---~--
••.•• c-. --~--
(ix) When the wave length of the incident X-ray increases, the angle of diffraction
(A) decreases (B) mcreases
(C) remains constant (D) shows no systematic variation
(xii) For preparation of porous bearings by powder metallurgy preferred particle shape
lS
(xiii) With increase in annealing temperature the following defect density decreases
(A) Vacancy (B) Dislocation
(C) Grain boundary (D) All of them
(xv) Solme atoms which cause yield point phenomenon in mild steel are/is
(A) Aluminium (B) Boron (C) Carbon
54 Elite Academ_v GA/QBIMT-1
(ii) In the Bayer process, bauxite is digested with NaOH. What are the conditions
under which this is done? Explain.
(v) What is the effect of humidified blast on the reducing potential of the gas in the
iron blast furnace?
(ix) Sketch ~chematic stress-strain Ct!rves for single crystals of pure (a) Mg, (b) AI
and (c) a-Fe
(x) Why are aluminum castings not prone to reaction unsoundness (due to reaction
between two solutes)?
copper? Explain.
(ii) Determine the packing density of {111} plane of the fcc: !auice (in number of
atoms/m 2 ).
GA/QBIAFF-i Elite Academy 55
(iii) The growth of a and Fe 3 C phases leads to the formation of lamellar structure of
pearlite in steel. With the help of the concentration-distance profile for the
growth of the two phases explain the cooperative growth mechanism.
(vi) Sketch the schematic curves indicating dependence of (a) fracture toughness
(Kc) with thickness, (b) plain strain fracture toughness (K IC) with strain rate.
Calculate the minimum temperature at which the reaction can take place.
(3)
Also compute the Pco I Pco ratio in the gas phase at this temperature when the
2
total pressure ( Pco + Pco = Ptotal) is equal to (a) 1.0 and (b) 1.50 atmosphere.
2
(ii) At 1200 K Fe-Ni austenites are found to exhibit regular solution behaviour and
the integral molar heat of mixing at this temperature follows the relation:
(iii) Pure copper sheet· is exposed to an oxidizing atmosphere at 1273 K. Given the
variation of the thickness (x/cm) of the oxide layer with time, deduce the rate law and
suggest amechanism for the growth of oxide layer. Also calc:.ulat:e the rate constant.
1.10 1
1.50 2
1.90 3
2.20 4
2.45 5
(iv) In a binary eutectic system, metal A melts at 1000 K and B melts at 800 K. An
alloy containing 30% B shows 60% primary a under equilibrium cooling. The
remaining liquid decomposes by the eutectic reaction at 600 K into a and ~ phases
in the ratio 2 : 5. Another alloy containing 70% B shows 50% primary ~under
(v) ~ phase particles in the shape of a spherical cap nucleate on a flat impurity
surface(s) from the patent phase a. The three interfacial energies y aB, y u.s and
Y~s are equal. Given ~G 0 ~~ =-100 J mol-l, Yap =50mJm-2 and molar
volume = 10-5 m3 mol- 1 , calculate the size of the critical nucleus and the
activation energy.
GA/QB/MT-1 Elite Academy
(viii) A copper single crystal has a Critical Resolve Shear Stress (C.R.S.S.) of 1 MPa.
It is subjected to a tensile load along [1 00] direction; determine the tensile yield
strength of the crystal. Given slip system is (111 ), [1 1 0].
Determine true tensile strength, U.T.S. and strain hardening exponent of material.
(x) (a) For 800 mm diameter roll. initial height of 200 mm, coefficient of friction
is 0.4; detem1ine the angle of bite.
58 Elite Academy GA/QBIMT-1
********************
GAIQB/1\ff-I Elite Academv
SOLUTIONS I ANSWERS
1.
(i) True
Substituting (3) in 2
dG=VdP-SdT
00
at constant temperature ( ) =V
oP T
rca\
at constant pressure i ---~ i =- S
'cr )p
(ii) False
(vi) False
(vii) False
(viii) False
(xi) False
Unless temperatures are also high (~ 0.5 Tm) superplastic behaviour is not seen.
2.
(i) (;;) p = - s
M n
(ii) ~S =- R "'
L..., N.I /n N.I where N.I = mole fraction of, component i
i=l
----------------------- -··--
3.
(i) C,D (ii) A,B (iii) B (iv) ·c
(v) A (vii) B,C (viii) B (ix) B
(x) A (xi) A,B,C (xii) A,B (xiii) B,C
(xiv) A,D (xv) C,D
4.
(i) Fine gold, difficult to separate from gangue, is selectively dissolved using sodium
cyanide. The relevant reaction is
4Au + 8 NaCN + 2H 2 0 + 0 2 ~ 4 Na Au(CN) 2 + 4 NaOH
This gold solution is brought into contact with zinc dust to precipitate out the gold
2 Na Au (CN) 2 + Zn ~ Zn Na 2 (CN) 4 + 2Au
The crushed bauxite is once again ground with caustic soda in a ball mill to yidd
a slurry, which is fed to a digester which is an autoclave. Here, the alumina in the
bauxite is dissolved in caustic soda in the temperature range of 200,· C und.;r <'
r,,·::_~.;;surc of 25 atmespheres. This lreatm.:nt dissolves the alumin:.:: and k
62 Elite Academy GAIQB/MT-1
(iii) Anodizing: It is anodic oxidation of aluminium and certain of its alloys, carried
out purposely to obtain a thick tenacious oxide film which provides protection
against abrasion and corrosion. The article is made anode in a bath of chromic or
sulphuric acid and the nascent oxygen evolved when a current is passed results in
the thickening of the oxide film. The electrical resistance of the film sets a limit
to the thickness which can be developed, and this is normally of the order of
0.025 mm. Anodizing is also capable of providing decorative finishes since the
coatings can be dyed to give an attractive finish.
(v) Steam can be used to get high blast temperatures because of its endothermic
nature of reaction with carbon ~ C + H" 0 = CO + H,
- "-
Since moisture gives double the volume of the reducing gas (CO + H 2 ) per mole
of carbon, the both gas volume will increase per unit of blast volume according to
the amow1t of steam injected. Hei1ce with steam addition. although the amount of
blast oxygen and nitrogen will decrease slightly, the oxidizing power per unit
volume of blast will increase. since oxygen composes about 89 perccm H 2 0.
Therefor~, the both gas volume will increase per unit volume of blast but it wi:!
decrease per unit weight of ..:arbon burnt. Moisture increr:scs the cc.~c bti<nm~:
GA/QB/MT-1 Elite Academy 63
rate, the tuyere gas is enriched ¥.i.th reducing gases (CO+ H 2 ) and there is a
(vii) During solidification of gray irons, carbon precipitates out in the form of graphite
which has lower density than iron and therefore higher specific volume than iron.
It partly compensates for the volumetric shrinkage of iron that occurs during
solidification.
(viii) Tin sweat is inverse segregation of tin in copper based alloys i.e. tin bronzes.
Normally tin is expected to segregate towards the centre of the casting due to low
m.p. of tin. But in tin sweat tin is found to exude on the surface.
5.
(i) The solubility of SO 2 in high purity copper would increase with pressure in
·/3
Area=- a 2
2
. 2 4
~ =
v 3j
Number of atoms/unit area= ~a 2
2
(" 3 /2) a
=1.4xl019 atoms/m 2
· = (1.4 x 10 15 atoms I em 2 )
64 Elite Academy GAIQB/MT-1
Basic units are Tundish for guiding and controlling the metal flow, watercooled
mould, water spraying arrangement on moulds, withdrawal rollers, bending roller
for changing the direction, and shearing arrangement for billets.
(v)
....
.....
m•••
Slivhtlr oaidisifte
Hearth
4metres ..... _____ _ outer tuyere zone:
COa +CO+Nz
--------
Fig. Soln. 5-(v): Diagrammatic represem:Jtion of the distribution of tempe.·ature of tf.··:l !:!/:1st
furnace gas for the reductwn of iron ore in an ungraded burden cnarge.
GA/QB/MT-1 Elite Academy 65
(vi) (a) Refer to Fig. Solution 5-(vi). Since the fracture touglmess of a material
will depend on the volume of material capable of plastically deforming
prior to fracture, and since this volume depends on the specimen
thickness, the fracture toughness K c will vary with thickness as shown in
J./t,
Fig. Soln. S-(l·i): Variation in fracture toughness with plate thickness
6.
(iii) The general laws governing the growth of oxides are
(a) Parabolic law Y 2 =Dt where Y is thickness, tis time and Dis constant
A closer look at the data give (particularly for time = 1 X I 0 3 and 4 X 10 3 sees)
y2 = o.[t
66 Elite Academy GA/QBIMT-1
y2
the rate constant D = -
t
A
·f.B
Fig. Soln. 6-(vi)
% primary a = be x 100%
ac
%primary {3 = cd x 100%
ce
(v) Hint: As the three int~rfacial energies are equal (Y uP , y as and y l3s) it can be
shown that the spherical cap will form with a contact angle of 90 o (co~() = 0) .
2y o:p 50 mJ m 2 10 x 10-6 m
Critical radius r * = ---- = = ----·~·--~-
~G o:-13
= 5 X w-6 ffi
- 2 -3cos0-- cos3 G
Activation energy for homogeneous nucleation x
4
,, 2 -- 3 cos e + coo;.) e
Ya!.l! x -------1-----
. ! ~
Substitute
T'·
I i
;.;-Q k.T
(2)
D and t are the only two variables. Using (1) find out the value of D at
~P ~Hv
=
~T T~y
~Hv = 18 KJ mo!- 1
(viii) Hint: Plot a cubic structure. Show [100] direction along which the load 1s
applied. Show the ( 111) plane and [ll 0] direction in the cubic structure.
GA/QB/MI'-I Elite Academy 69
't crss
u =
Y (cos+ cos A.)
tcrss = 1 MPa
+ is the angle between the normal to slip plane (i.e. ( 111) plane) and the direction
of loading (i.e. [100] direction) and /., is the angle between the slip direction (i.e.
[l 1 0] direction) and the direction of loading (i.e. [100] direction). Substitute the
(ix) Hint: Cross section ofthe sample is 100 mm 2 and gauge length= 10mm
(1)
where a is true stress
E is true plastic strain
n is strain hardening coefficient
k is material constant, defined as the true stress at a true strain of 1.0
75 KN
True stress 75 KN = ---- {3)
1000 mm-)
----
104.4
1
At <J45 KN E45KN = 100 = .01
Using cr and t values from (2) ar.d t3) in (1) Yalues of K and n can be dctennined.
V.T.S. cannot be determined as the load at fracture is not gi\en. · Similarly tru~
a= ~~/R
'f.
t·
0 1h .
T
0
GA/QBiMr-1 Elite Academy 71
0.4 = ~200-h
400
200-h
400
h=2oo- (0.42 x4002) = 136mm
and also.
.
13 = ~200-136 =
164 =0.4 radtans
V400 .
400
-
angle qfbite = 22.9r
********************
72 · Elite Academy GA/QBIMT-1
GATE-1993
MT : METALLURGICAL ENGINEERING
. PART- I (core)
Section A: 25 marks
Section G: 25 marks
..
Section E: 25 mf.!r/cs
PART- II (saecialization)
Ml': 125 marks
PART-I'
Note: Part - I consisting of three core· sections (A, G, E) must be answered in the first
nine pages ofthe answer book in the same order in which they appear in the question
paper.
SECTION-A.
1. In questions 1.1 to 1.7 below, one or more of the alternatives are correct.
Write the code letter(s) A, B, C, D corresponding to the correct alternative(s)
in the answer book. Marks will be given only if aU the correct alternatives
have been selected and no incorrect alternative is picked up.
.
1.1.
. (0 0 a.J , a.
The eigenvector(s) of the matrix 0 0 ~
-
:t: 0 is (are) / (1)
. 0 0
(A) (O,O.a) (B) (a,O,O) (C) (0, 0, 1) (D) (O,a,O)
··~
-----~------------~ ---~--~-~ ~~---- ---
.ff. . l . d2v dv . 0 .
1.2. The d 1 ~erentla equatton 2
+ -· + sm y = IS (1)
dx dx
(A) linear (B) non-linear
(C) homogenous (D) of degree two
1.3. Simpson's rule for integration gives exact result when f(x} is a polynomial of
degree (l)
(A} I (B) 2 (C) 3 (D) 4
(A) 1t 2 /4 (C) 1t 2 /8
I
(C)
ex;
J ----dx
X (0)
f-1--cosx
--X
d
• X 512
o l + x2 0 .
•
00 ("' ) •
. o f convergence o f the power senes
Tl1e ra d· ms · "£... -'ill' :
---::.- x ··~m IS ---------- (r. )
0 (m!).i
2.3. If the linear velocity Vis given by V =x 2 yi + xyz]- yz 2 k, the angular velocity
2.4. Given the differential equation y' = x - y with the initiai condition y(O) = 0. The
value of y(O.l) calculated numerically upto the third place of decimal by the
second order Runge Kutta method with step size h - 0. J is ------------ (1)
I L'"
2.6. The value of the double integral f f -- x ., dxdy is------------ (2i
• • 1 + ).-
0 X
GA/QB/MT-1 Elite Academy 75
~~l
1 0 0
0 -1 0
2.7. If A= the matrix A4, calculated by the use of Cayley-
0
0
0
0 0
iJ
-1
2.8. Given V = xcos 2 yi + x 2 ez] + zsin 2 yk and S the surface of a unit cube with
one comer at the origin and edges parallel to the coordinate axes, the value of the
2.9. The differential equation y" + y = Ois subjected to the boundary conditions
In order that the equation has non-trivial solution(s), the general value of A. is
(2)
2.1 0. The Laplace transform of the periodic function f(t) described by the curve below,
. {sint if (2n-l) 1t $; t $; 2nrt(n=l,2,3, ...... ).
le. f(t) = IS--------- (2)
' 0 otherwise ' ·
f(t)
---- - - - -~----
SECTION-G
3. Choose the correct answers from amongst the alternatives given in each of
the following questions and enter in the answer book the appropriate letters
(A, 8, C, etc.) against each part number. There could be one or more choices
for your answer and all are to be indicated. No marks will be given for
partially correct answers. Answers must be in the same sequence as the
questions. (l )( 9 =9)
(i) The atom positions in a given cubic unit cell are (0, 0, 0) and (~·~·~). The
(ii) The sixth reflection in an X-ray powder pattern of a diamond cubic crystal is
(A) (2 l l) (B) (2 2 2) (C) (400) (D) (4 2 2)
(iii) On sl<J\V c0o!ing the liquid fi·c11n the point Pin the phase diat-~mm sh(v,q; h::;i,w,, its
GA/QB/MT-1 Elite Academy 77
L+A
AB+B
A+AB
(v) Some of the processes which have the same activation energy in a given material
are
I
I
I
•
I
I . .,.
I ,,
ol ,,,"""
~--------
''
·-·
,/
, /
I' '
','
,
,, ' '
b
GA/QBlMT-1 Elite Academy 79
(b) Calculate the dislocation spacing in a symmetric 2'' tilt boundary in copper,
which has an FCC structure with lattice parameter 0.361 nm.
(c) A steel can be carburised at 900oc to a skin depth of 0.5 mm in a given time.
Find the temperature at which the carburisation can be achieved to a skin depth of
1.0 mm in the same time. Diffusion coefficient of carbon in the steel is
(e) Mild steel with a grain diameter· of 0.03 nun has a yield strength of 200 MN
m - 2 and that with 0.005 mm has 400 MN m - 2 . Estimate the yield strength of
mild steel single crystaL
(t) A brittle material has been found to contain surface cracks of depth ranging tiom
0.1 ~tm to 1~tm. Estimate the minimum stress at which the material will fracture.
(g) Total dipole moment of tetragonal BaTiO 3 is 1.06 x ro-29 Cm per unit cell. The
lattice parameters, a and care 0.399 mn and 0.403 mn respectively. Calculate ~he
polarization.
(h) At room temperature, the mobilities of el~ctrons and holes in purr.;: silicon ar-.:
(a) A body of weight 100 N falls freely a vertical distance of 50 m. The atmospheric
drag iorce is 0.5 N. Forth~ bod.y. the work interactkm is
(A) +5000J (B) -5000 J (C) -25 j (D) + 25 J
(b) An insulated rigid vessel contains a mixture of fuel and air. TI1e mixture is
ignited by a minute spark. The contents of the vessel experience:
(A) Increase in temperature, pressure and energy
(B) Decrease in temperature, pressure and energy
(C) Increase in temperature and pressure but no chang~ in energy
(D) Increase in temperdture and pressure but decrt!aSe in energy.
(c·) The first law of thermodynamics takes the form W .:: ··· AH w·hen ~pf'h'=J to:
(A) A closed system undergoing a reversible adiabatic pmctc:.ts
(B) An open system undergoing an adiabatic pro1:ess with n<;gligible changes in
k\netic and pot::ntial energies
(C) A closed system undcrgomg a revcr;;;ibh: ~~unstant vnlurt!·~ ph)O!S8
(e) Which among the following relat~ons is/are valid ONLY for reversi:bfie process
undergone by a pure substance?
(A) oQ = dU + BW (B) T dS = dU + oW
(A) An ideal gas at any state (B) A real gas at its critical state
(C) Any gas at its critical state (D) Any gas at its inversion point
(i) At the triple point of a pure substance, the number of degrees of freedom is:
(A) 0 (B) 1 (C) 2 (D) 3
6.1. Th:r;; Figure below shows a thermodynamic cycle undergone by a certain system.
p
5
J
ll
0.01 3 0.03 v
;a. m.
6.2. A vertical cylinder with a freely floating piston contains 0.1 kg air at 1.2 bar and a
small electrical resistor. The resistor is wired to an external 12 Volt battery.
When a current of 1.5 amplifier~ is passed through tht> resistor for 90 sees, the
6.3. Figure below sho-..vs a reversible heat engine ER having heat interactions with
three constant temperature systems. Calculate the thermal efikkncy of the he,l.t
engine.
GA/QB/MT-1 Elite Academy 83
6.4. Air expands steadily through a turbine from 6 bar, 800 K to 1 bar, 520 K. During
the expansion, heat transfer from air to the surroundings at 300 K is 10 kJ/kg air.
Neglect the changes in kinetic and potential energies and evaluate the
irreversibility per kg air. Assume air to behave as an ideal gas with
CP = l.OkJ /kgK and R = 0.3 kJ /kg K.
6.5. In problem 6.4, find the actual work and maximum work per kg air.
6.6. A vessel of volume 1.0 m 3 contains a mixture of liquid water and steam in
equilibrium at 1.0 bar. Given that 90% of the volume is occupied by the steam,
find the dryness fraction ofthe mixture. Assume, at 1.0 bar and v ,.,o = L7m 3 /kg.
6.8. In the vicinity of the triple point, the vapour pressures of liquid and solid
ammonia are respectively given by
/np = 15.16 -3063/T
and lnp =18.70-3754/T
PART-II
Instructions:
1. Answer all questions.
2. Answers to the sub-questions of a question must be answered in the sequence in
which they appear in the question paper.
3. There will be no negative marking.
7. Select the correct answer(s) for each of the following questions. There may
be more than one correct answer. Full marks will be given only when all the
correct answers have been identified. There is no partial marking. Use only
capital alphabets A, B, C and D for your answer. (2 x 15 = 30)
(i) For a two phase equilibrium in a binary A-B alloy, the conditions to be fulfilled arc
(A) the free energies of the two phases should be equal
(B) the chemical potential of A in both the phases should be equal.
(C) the chemical potential of both A and B in a given phase should be equal
(D) the chemical potential of B should be the same for both the phases.
(iii) The predominant modes of heat transfer to ingots in a soaking pit are
(A) conduction (B) forced convection
(C) radiation (D) free convection
(v) The reductants used for industrial production of sponge iron are
(A) non-coking coal (B) metallurgical coke
(C) natural gas (D) graphite
(vii) State which of the toll owing elements are ferrite stabilizers in alloy steel:
(A) W (B) Cu (C) Ni (D) Si
(viii) The basic features of martensitic transformation ~;ommon to ferrous and non
ferrous alloys are
(A) significant increase in hardness
(B) no change in composition during transformation
(C) atomic motions promoted by shear
(D) carbon remaining in solid solution
(xv) In a discontinuous fibre metal matrix composite the fibrt' \\ill iractun; m tb.:
middle portion if
(A) the. length of the i:ibre is less than half of1he critical fibre length
(B) the length of the fibre is more than double the critical tibre length
(C) the Jength of the iibre is nearly same as the critical fibre kt1f!,th
(D) the fibre surface contains stress raisers.
Ill IIIII ~ i
. .,.. ...
~
8. Write down whether the following statements are TRUE or FALSE (do not
write T or F). Justify your answer in two or three sentences. No marks will
be awarded for answers without proper justifications. (2 )( iO = 20)
(i) Sulphide ores are generally concentrated by floatation and not by gravity :-tparation.
(ii) The operating voltage in industrial electro-winning cells is lov.c:- than the
decomposition voltage calculated from thermodynamic consideratio:-ts.
(iii) Carbon blocks are used for lining the blast furnace hfarth, but such Jin~ng can rw:
be us,~d in the open hear~h furnace.
(iv)
from metal..:
(ii) What are the sources of inclusions in steels? How do you control tundish nozzk
blocking during continuous casting of killed steel?
88 Elite Academy GAIQB;?vfT-.J
(iii) Zn is removed from molten lead by allowing droplets of impure lead to pass
through a molten salt mixture containing 10 3 g moles I m 3 of PbC1 2 according to
Calculate the rate of removal of Zn from molten lead droplets assuming that the
rate controlling step is mass transfer of PbC1 2 from the bulk ofthe salt mixture to
(iv) Controlled roasting of copper concentrate containing Cu 2 S, FcS and silica has to
be carried out in a fluidized bed roasted such that the resulting product can be
easily leached in dilute H 2 SO 4 . Determine the temperature range at which the
roaster should operate with the help of data given be low. Justizy your choice.
Further, assume that the refractory lining in the roa...;;ter limits the maximum
~m ~ Temperature °C
~s r 25-500 5
StablePhasel
675-900
___ j_ I
GA/QB/MT-1 Elite Academy
(Vl
. I (a) Why is it ncce~'sary to carry out double tempering of high speed steels?
(b) How can you produce a duplex ferrite-martensite structure in a medium
carbon steel.
(vi) Define Pilling-Bcdworth ratio. Calculate the Pilling-Bedworth ratio for the
following oxides:
1 (gm/cc) ! ! (gm/cc) ·
l Na -,0 , 2.27 · [ 23.0 I 0.97
c~-~~
:
-- ---~-7(:-----+----~,-8---
·'. } I - ·'.
:-
I
7.87
--+---··---~----- -~~- r--~--------~~7---;------~-- --~~~-----~--
! Al203 I 3. ,.o
L - . - , _ _ _ _.1______________
I ~ •• J : ·-· /l!
_l_________ -- ----·-- _______)_ ___________________ ,_]
Suggest on the basis of your calculativns whk~h of ~i1e above ment;. ;··H~d oxides
will provide a protecti\e coating?
(vii) Construct a phase diai_•ram for the system A-B from the fi-Jl!owing d::\:~:
Label the phase diagnu.n. Calculate fractions of pr,oeutectic phase and eutectic
mixtun: at the eutectic temperature for the alloy containing 15 at. % R
(viii) A low carbon steel can be carburised at 920" C to atta.in a ctmcentmtion of 0,6!:--Q
C at a depth of2 mm in lhour. lfthc case de?~t has to be doubled by carbursing
90 Elite Academy GA/QB/Mf-1
(ix) An aluminiun:t solid solution having a l~ttice parameter of0.4 nm.is subjected to a
high pressure experiment. The powder specimen suffers an uniform compression
of one percent. The diffraction pattern is recorded in a Debye-Scherrer camera.
Find out the shift in (422) reflection in the pattern in terms of Bragg's angle(A8)
in case of CuKa radiation {A.= 0.154run) . State whether the line will shift
(x) In which group of alloys docs one observe yidd point phenomenon? Briefly
explain the mechanism responsible for this phenomenon.
(xi) A 3 meter wide steel plate has a residual axial tensile stress of the order of
(xii) In a tensile test on a copper alloy with a gauge diameter of 12 mm, the load at
J5% and 30% elongation was recorded to be 3.1 KN and 3.6 KN respectively.
Assuming that the tlow curve can be represented by a equation of the typ~
(xiii) A spheroidal graphite cast iron analyzing 3.5% C, 2,8% Si, 0.02% S. 0.04% P.
0.05% Mg is prepared from a base iron melt ofthe composition 3.5% C, 1.4% SL
0.04% ~. 0.04~o 1'. Calculate the amount of Fe-Si-MJ.! alloy (40% S>. W';u Mg,
GA/QB/MT-1 Elite Academy 91
balance Fe) required for treatment of 1OOOKg melt. Assume 30% recovery of
magnesium.
(xiv) In a power drop hammer with a 50 Kg ram the cylinder has a diameter of 50 mm.
The ram is accelerated by steam pressure of 600 MPa. If the drop length is
200mm,
(a) What is the total energy supplied to the below?
(b) If friction is neglected, what will be the effect of the section thickness of
the job on the forging load?
(xv) In the rolling of a slab, the friction force between the rolls and the slab is 1.5 KN
per mm width. Tbe radial force on the roll is 5 KN per mm width. Calculate the
critical angle for unaided entry of the slab into the rolls.
********************
Elite Academy GA/Q.8/MT-1
SOLUTIONS I ANSWERS
PART-I
SECTION-A
1.
1.1 (B), (D)
t.e. 'A=O
0
0
0
Note: sin y is linear in y. It is homogeneous in the s.:nse that the right hand side
1.5 (C)
----------
•
f(x)
4
1t
l 7tn2
"'ll
'Xi r
1
=-- + L... --(cosnn -l)cosnx- -cosnn
n
. nx 1I at x = n:
sin
_j
-1
1t
2
= -·-
1t
4
L...l___
-t·. " 'f 1 (cos n1t- 1) cos mr--! cos nn sm- niT
nn2 ' ' n
sm nn = L
· · cn~ n n: = (-1) n
1 1 n2
= + --"\- + -~- + ... '····· = --
3"· s.: 8.
Consider
;"_ ;-~m x dx . 1
.. sin x dx
! = ,) . -----·-- -- = 1Jnl 1--------
; ' -- ~:os x
0
t -70 :- : l - cos x
1
Put i -- cos x = t,
I---eos l
lf------
sin x
- == 1n(t)
._
= ln (1-cosl)- ln{l-c.~ost)
1-· cos x
' t ~-l-cost
94 Elite Academy GA/QBIMT-1
11
= J cosxdx
M'
0
l+x
1
Let U = ---, -dV = COS X
l+x dx
du ··- - - - 1- , V = sin x
dx (l + x)2
Integrate by parts
l
-sin x M M sin x dx
I
I = [
L I+ ~-Jo + l (l + x)2
I = lim 11
\1 ~oc ·
GAIQB/MT-1 Elite Academy 95
Next, consider
00
1
IM
I= f-
ol+x2
X
dx = .lim -ln(l + x
M-+oo 2
2
)j O
= _!_ lim ~n (1 + M 2 ) ] does not exist
2 M-+oo
Next, consider
l I
I = J1 - COS X
"?
d
X
= l'
liD
f1 - S COS X
I
d.
X
X S:- t-+ o+ X 2
0 t
= lim -1 f-X"'- dx
1 2 I ! ..,
2 lim J--dx
I <- X 1 · dx
=- lim j -
- 4 t-+0+ t "'"
x·'- .:."' r-
t-+0+ t '\}X t-+0+ 2 t X-''~
(/'?
ar
- = 2xv -- 3y + l,
ax .
Of =x2 - 3x + 2
fJy
Of
af =0 and -=0
ax Dv
"
2xy - 3y + 1 = 0 and (X·-2)(x-l)=0
96 Elite Academy GA/QB/A1T-1
Of
Now 8 = --=2x-3
OxOy ,
P is a saddle point
2.
2.1 0
(eX - 1) (1 - COS X)
------ 2 -·---·----
. x(ex -1).+ 2(cosx-1) . X x2
llffi = 1lffi
x_.o x(l- cos x) x~O 1- cosx
1-]
= --·--· =0
1/2
2.2
GAIQB/MT-1 Elite Academy }7
1
R=-
. f~
2.3 1
At P (1, 1, -l)
- A A
Vp=i~j~k
l ..z-. . r:3-
Vp=t"pl""'"
Nnw
'11:
2.4 l--
4
98 Elite Academy GAIQB/Mf-/
1 iy=l/x -~
1
I = Jx !l
0
J --., dy Jj dx
y=x l+y~
0 X J
1
= Jx [cot- 1 x- tan- 1 x] dx. tan ·-I -~ = cot ·-t x
X
0
1
, ,
=..!!. x _!_ - 2 Jx tan- 1 x dx
- - 0
= rx2
IL .... ,
tan -1 X l'J - -~, tf-···__1-
l+ "
.... 0
dx
x-
0
l f~.: . ::+-J..:-.!. dx
1
::.o l tan -t 1-
.,- ..,~ 0; ' x2
1...
l .
::.:·
1 " 1 ·rr1 I-·---·:.-
-- · - - -·-
1 dx
?-i- •jJ·., 1..;.~-.!
- -· 0' • ' ·"
;'[
--- -· -
1 "! 1t
.... ..... :
it
..... ·- ....
8 2 . 4 4 ..,
GA/QB/MT-1 Elite Academy 99
I= ~- 2[ ~ - ~] = ~ - ~ + 1 = 1- ~
i.e. A 4 = 14
2.8 l
· By Gauss theorem,
I= JIJt dS = l
s
Solution of y" + y =0 is
y(x) =A cosx + Bsinx
y(O) = 0 ~ A. 1 + B. 0 = 0 ~ A = 0
y(A.) = 0 ~ B sin/. = 0
1
2.10.
1 2TI:
L{f} = ___:__ j" e-St sin t dS
(1- c ·-27tS) rc
2n
1 -St
= 7
s [ e -;. (-Ssint- cost)
(1-e--n) (l+S-) ]
1t
=l
\e2nS -1) (1. + s2 ) [(-1) - c nS ]
l+u u = e~s
=- where
1+ u
= ---
(u -l)(u + 1)(1 + s2)
1
= = - -11 -l - - 2-
(u-l)(l+S2) (1-e s)(l+S )
GA/QB/MT-1 Elite Academy 101
SECTION-G
3.
(iii)
t
T L __.,-
/ L+a
I
A+ f:..:
phase before the onset of eutectic (i.~.:,, procutectic AB) and then A and Air'
during eutectic transformation. Hence the statement D is also correct
(iv) The question is somewhat ill defined. At a certain temperature during coolh;.g of iR
liquid glass, the glass undergoes a sharp change from a viscous to a rigid and hrit1h-;
material This is known as glass transition temperature. Below this tempemture the
102 Elite Academy GAIQB/Ml'--J
(v) The climb occurs by diffusion of vacancies. The diffusional creep, which is a low
strain rode, high temperature deformation process supposed to occur by the
diffusion of vacancies to grain boundaries. Hence both these processes will have
some activation energy as that of diffusion by vacancy mechanism.
(vii) Some of the corrosion protection methods are: use of anodic inhibitors, metallic
coatings and alloying.
(ix) Materials used should have easy direction of magnetization parallel to the coil
axis, a narrow hysteresis loop, and high saturation magnetization.
4.
(a) Take intercepts of plane OPQ on abc axis (do not take origin at 0 in figure).
The slip distance (I b !) is the repeat distance between the atoms along the slip
direction, which for FCC metals (such as copper) tends to be along the face
diagonal [110] of a unit cell. This is also a line of contact for atoms in FCC
structure.
I
, r
Tt-
J. ~
-
-1
I
I
I
I .I. ~
-- " j
;-
+-
r-
-
t
r
\ J..
....
1
I
r "T-
-
Referring to the above figure, we sec that the separation distance D of dislocations
D = jb I= 0.361 nm = 10.31 nm
e 2° (l rad /57.3)
(c) The relationship showing the concentration with diffusion coefficient (whic>1
varies with temperature) and time is given as
GA/QB/MT--1 Elite Academy 105
where C 0 is the initial bulk concentration of the diffusing species. C x is the concentration
We have to find temperature at which carburization uph1 i mm depth take rl1ct f; ,. the
same carburization time.
5xl0-4 lxi0- 3
=
z.,JD;i 2~D 2 t
_K -k 2 /t273
At 900°C, DI - Ie
Therefore,
In [• . l
~ J: ~ In 4 - In~e ·gR:~?j
5
J
I l
L
lI
.J
-· 15 7000 = In 4 _ ____!22~00 .
8.314T 8.3l4xl273
or
106 Elite Academy GAIQB!k!T-l
H CH 3 H H H CH 3 H H
I I I I I I ' '
-C-C=C-C- -t-c-6--t-
H
1 I
H h sI sI h
+ 2S - - - +
H H
I I ~ II Y
-C-C=C-C- -c-c-c-c-
1 I I I 1 I I
H CH 5 H H H CH 3 H H
equation constants.
(f) According to the Griffith criterion the stress required for fracture.
r,., E\1/2
cr = l4:e)
where y = surface energy= 1 J m -2
E =Young's modulus= 70 GNm- 2
e =Half crack tip length (max)= 1 J.lrn
., Jl/2
a=(-----------
2 x 1 Jm-- x 70 GNm-2
1t
= xl ~tm
140 GNm
_2
In intrinsic semiconductors n n = n P
SECTION -E
5.
(a) D Hint: Work= mgh = 0.5 x SO= 25 J
6.
6.1
L---------------------------.-
0'0 I
= 2 + .J(3)
2
== 2 + 1.5
6.2 Data: Air= 0.1 kg, p = 1.2 Bar, V = 12v, l = 1.5 amp,
GAIQBIMT-1 Elite Academy 109
kJ
t = 90 sec, c v ==0.7 - -
kgK
Now ~Q = AU + ~W
~U= AQ :-. ~W = 1620-1200=4201 = m Cv ~t
420
At= X 0.1
700
~t = 6" c
6.3
lT.:- t~o~l
Q1=tooi<J Q -: 50t(1
a
Qi l ... ...
---- :::: '· - U. I = 0"
.,,.:;
100
Q} ::::30 KJ
110 Elite Academy GAiQB/MT-1
nR =[1- T3.]
T 1 2
= [t- 300]
SOO
= 0.4
Q~ Q~
=l--=l--
Q2 so
Ql
2
=> - =0.6
so
=> Q~ = 30 KJ
Q3 = Q1+ Q~ = Jo + Jo = 60 KJ
W = (QI- Q2) - Q 3 = 100 + SO- 60 = 90 KJ
Thennal efficiency
WD 90
nth=- = - x 100 = 60%
Qs ISO
6.4 o.tapn:
Pt =6 Bar p 2 = 1 Bar
T1 =800 K T2 =S20 K
kg KJ
R=0.6- c Pkgk
=1-
kgk
kJ
Cv = CP - A = I - 0.3 =0. 7 kgk
Q surrounding = I0 ~ air
·kg
AS = _g_ = _!Q_~
SUIT T2 S20 kgk
. ',
GAIQB/MT-1 Elite Academy 111
I= 5.79 ~air
kg
Max work
= 370.5 kJ air
kg
X=0.0053
N2 C0 2
v, v2
M=28 M=44
P, T P,T
--------~--'---~---
RITI
VI=--
. pl
R2T2
v2 = --=-=-
P2
Vl RI R M2 M2
-=-=-~=-
V2 R2 MI R M1
VI = 44 = 1.57
v2 28
~ v = v1 + v2 = 1.57 v2 + v 2 = 2.57 v2
VI
2.57 - = 1.64 V1
1.57
v v
AS = R ln - + R ln -
VI V2
= -Rl nV- -
R V
ln-
MI V1 M 2 V2
1 1
= . 8.314[- ln 1.64 + - in 2.57]
28 44
= 8.314 (0.01706 + 0.02145)
= 8.314 (0.03911)
kJ
AS= 0.3251-
kgK
6.8 In the vicinity of triple point we have equal vapour pressures for liquid and solid ammonia
PART-II
7.
(i) A,B,D (ii) .B,C (iii) B,C (iv) B,D
(v) A,C (vi) A (vii) A,D (viii)· A,B,C
(ix) A (x) D (xi) B,C (xii) A,C
(xiii) B (xiv) D (xv) c
8.
(i) True
Flotation can separate· gangue from sulphides as well as separate the suphides by
selective flotation. Gravity separation is not effective in separating the sulphides
from one another.
(iii) llrue
In the b.f. hearth conditions are not oxidising. In O.H. conditions are oxidising.
So carbon is not a good refractory in O.H. furnace.
(iv) False
(v) True
·' .............·~..
114 Elite Academy GA/QB/MT-1
(vii) False It is the screw dislocations that may bypass an obstacle by cross slip
(viii) False They are used for degassing the melts
(ix) False
It consumes less power. Since the roll separating force depends on the radius of
the drive cells, these area always kept small in size. The backing rolls are
provided with a larger radius to increase the rigidity.
9.
(ii) (a) Nonmetallic rejected from solution during cooling of the liquid metal. (mtrinsic)
(v) (a) The first tempering is carried to eliminate internal stresses and to remove
1
Specific volume of Na 2 0 = --
2.27
(vii) The equilibrium diagram is shown in Fig. Soln. 9-(vii). It has a eutectic
transformation. Above the eutectic temperature
\
\
A tro 8
Proeutectic a =
40 - 25 = 15%
40-25
Eutectic mixture = 25%
(viii)
116 Elite Academy GAIQBI.MT-1
D = 49 exp- 18300
T
2mm 4mm.
--;======= = -;:=======
2)0 9200 C X 3600 SeC 2 Jo 9700 C X t
Values ofh, k, l are 4, 2, 2. I..= 0.154. Find out the values of e for two values
of a. The difference between them is £\9 .
(x) Yield point phenomenon: The stress at which plastic flow initiates in short-time
loading is known as yield point. At this value the dislocation movements begin.
In some materials containing impurities, e.g. iron containing c, molybedenum,
cadmium, brass and zinc each containing nitrogen, there is a sharp yield point at
which plastic deformation occurs without an increase in applied stress. If the
tensile straining frame used is 'hard' enough, i.e. deflects little under the stress
applied to the specimen, a pronounced drop in stress occurs at th~ y~~id point as
shown at AB in Fig. Soln. 9(x).
GA/QB/Mf-1 Elite Academy 117
atmospheres of impurity atoms where upon their continued flow can occur at lm.ver
temperature. Support for this view is provided by unloading and immediately
re-straining, when the yield point is found to be suppressed as shown in curve 2.
Unloading and ageing permits the diffusion of the impurities to the dislocations and
re-eStablishment of a yield point on subsequent as shown in curve 3.
(xiii) Though Si. content of the final c<?mposition is 2.8% compared to 1.4% of the
charge, the entire Si need not rome from Fe-Mg-Si alloy. The alloy is primarily
toaddMg.
********************
-~-~--~------------------------------- ·------------ ------- -----
GATE-1994
MT : METALLURGICAL ENGINEERING
t. IIICiiaate tile cornet daoiee by wl'idq dowa tile correspoadiac letter (A), (B),.
(C), (D) or (E) u *e cue may be ill die aauwer script. Each qaestion carries
I •ark. (lS x I = lS)
1.3. In BOF, desiliconization is a first order reaction. So the silicon content of metal
decreases
(A) Linearly with time
(B) Exponentially with time
(C) Logarithmically with time
(D) In proportion to the square root of time
1.7. The best method for detennining the averag~ hardness of an alwninium casting is
(A) Rockwell A (B) Rockwell C (C) Knoop
(D) Brinell (E) Vickers
proportional to
(A) d 11 2 (B) d- 1i 2 (C) d (D) d- 1
1.13. The maximum axial compression stress during cold upsetting of a cylindrical rod
of radius r, occurs at ·
(A) .The outer edges of the rod (B) r/3 from the centre
(C) r/2 from the centre (D) The centre
1.14. As the % reduction increases, the flow stress during hot isothermal forging of a metal
(A) increases linearly (B) decreases exponentially
(C) decreases linearly (D) remains almost constant
1.1 7. The single most important requirement for a turbine blade material is
(A) Damping (B) Resilience
(C) Creep resistance (D) DBTT
1.2J. The ratio of the shear stress to the principal stress on a principal plane is
(A) 0 (B) 1 (C) 112 (D) 113
1.24. The usual energy consumption in electric arc furnace steel making is
(A) 60-100 kWh/ton of steel (B) 400-700 kWh/ton of steel
(C) 1200-1500 kWh/ton of steel (D) 2000-2300 kWh/ton of steel
2. . Indicate the correct answer by writing down the letter (A), (B), (C) or (D), as the case
may be, in the answer script Each question canies two marks. (5 x 2 = 10)
2.1. A material is loaded elastically under plane stress condition given by the
. tensor [12 0
followmg ] . The modulus of rigidity is 25 MPa. The maximum
0 10 .
aperture (N.A.) of 1.5 and uses the radiation of 4500 A. The minimum
0
2.3. In a single crystal of copper (lattice parameter 3.615A) the distance between
0
2.4. One face of a furnace wall is at 1030° C and the other face is exposed to room
m- 1k- 1 and the wall thickness is 0.3m the maxif!tum heat loss (in W/m) is
· (A) I 00 (B) 900 (C) 9000 (D) 10000
1
2.5. For a binary solution A-B, the a ftmction is given by a = exp(X)- , where X is the
X
mole fraction of component A. The limiting value of alpha when X approaches zero is
(A) l (B) infinite (C) indetenninate (D) 0
3. Answer True or False. Give brief justification in one or two sentences. Each
question carries 2 marks. No marks will be awarded for answers without
correct justification. (10 X 2 = 20)
~
) .'1
.:.. Match the commonly used manufacturing process for the following products:
(A)
. Thoriated nickei wire (1) Single crystal grov\'·ing
5.3. !\fatch the microst.ructural state of the following steels with their respective heat
treatment
126 Elite Academy GA/QBIMI'-1
room temperature
(B) A 0.4% C steel soaked at 750° C (2) Pearlite and carbide
CaO + C0 2 = CaC0 3
AGO = -168,400 + 144 T J. (5)
Calculate the total work done per unit volume for doubling the gauge length of a
sample under tensile stress conditions. cr is true stress and s is true strain. (5)
10. A fluid of viscosity f..l is flowing through a horizontal pipe of radius R and length
Lin laminar flow. The axial velocity, v, at any radial point R is given by
~p_: R
2
V = [1 - (r I R) 2 ]
4J.tL
11. Using Gibbs-Duhem equation show that if solute B obeys Henry's law, solvent A
follows Raoult's law. (5)
12. A tensile stress of 15 MPa applied along [1 T0] axis of a single crystal of silver is
just sufficient to cause slip on the (11 1) [0 T1] system. Calculate the critical
resolved shear stress for silver. (5)
13. A sample of brittle material has a central crack of 4 J.tm. The elastic modulus of
the material is 70 GPa and the specific surface energy is 1 Jm-2 . Estimate the
fracture strength of the material. (5)
14. Iron undergoes allotropic transformation from BCC to FCC phase at 910° C. At
this temperature the atomic radii of the iron atoms in the two stmctures are
1.253A and 1.292A respectively. What is the percent volume change as the
structure transfoims? (5)
15. Flow curve of annealed 7075 aluminium alloy at room temperature is given by
cr = KE 0 , where K = 400 MPa and n = 0.21. Calculate the tensile strength of the
alloy. (5)
16. High top pressure operation of blast fumace increases productivity and leads to
low silicon hot metal. Explain why? ( 5)
18. Using NeWton-Raphson method calculate the value of the root of the t~;llo\\:ing
equation after one iteration:
f(x) =0.5lx -sin x
19. Determine the principal stresses cr 1 , cr 2 , cr 3 for the stress components gi1.·en below:
/ o'\
i -'"' -1
..,
I
I
1-! .) o!I
MPa
l 0 0 tj
Also caiculate the magnitude of the maximum shear stress for the above stress
state. (5)
20. What -.vou1d be tlw r: 'aximan1 nitrogen content of a liquid iron tnclt after i-: is
bubbled \\ith an argon--nitrogen gas mixture containing 50% (by volume) of
21. A steel plate (50 em x 25 em x 2 em) has to be sand cast. Calculate the dian1eter
of a suitable cylindrical riser with H : D = 1.5. Assume appropriate modulus for
the riser. (5)
22. A 5 em diameter steel shaft has endurance limit of 260 MPa at R = -1. What is
the largest effective maximum stress which can be applied safely? Assume that
the fatigue strength reduction factor is 1.8 and factor of safety is 2. (5)
24. For a chemical reaction at 700 K, the chemical rate constant is 1.5s- 1 and the
25. Yielding begins in a high strength low alloy sted undt:r the follovdng strc:.>::,
conditions: .
SOOMPa
Calculate the uniaxial yield strength of the above steel usml,! (a) von Mi <>u:
-\ '.
''
26. For a binary dilute solution of carbon in iron, express /n y c as a function of the
27. A floatation mill treats 16,000 toimes of ore per day containing 0.75% Cu and
discharges 15,640 tonnes of tailings per day containing 0.075% Cu. Calculate:
(A) % Cu in the concentrate
(B) Copper recovery(%) (5)
28. Enumerate primary and secondary bonds with two examples of e.ach. (5)
29. List the steps involved in age hardening process. Schematically show the
hardness versus time curves during age hardening of Al-Mg-Si alloy at
30. (a) List the parame1ers which determine the heat input requirement for fusion
welding. (2)
(b) Schematically show (i) a well-formed bead, (ii) a bead with lack of fusion
underfilling and (iii) a bead with melt-through/overlapping. (3)
********************
132 Elite Academy GAIQBIA!T-!
SOLUTIONS I ANSWERS
l.
1.1. A 1.2. c 1.3. B 1.4. D
1.5. B 1.6. c 1.7. D 1.8. B
1.9. B 1.10. D 1.12. B 1.13 D
1.14. A 1.15. B 1.17. c 1.18. B
1.19. B 1.20. B 1.21. c 1.22. A
1.23. A 1.24. B 1.25. c
2.
2.3. B ~{hkl} = {111}
0
a= 3.615 A
d=
w a
+ k2 +12) (12
3.615
+ 12 + 12)1/2
2.087
2.4. D
q= kd~ Furnace
dx Inside wall outside
(room
k = 3Wm -l K -l (Thennal conductivity) 0
30 C temp.)
dT = (1303-303) (13031:) (303K)
dx=0.3 m
. q = 3 xlOOO =lOOOOW /m
0.3
--.o. 3m ...-
2.5. A
GAIQB/MT-1 Elite Academy 133
3~
3.5. . False
3.6. False
3.7. True
The hot working temperature of lead is room temperature. Due to the action of
stresses for a prolonged time, lead can creep, under its own weight at room
temperature.
Define: Creep occurs when plastic flow occurs due to a constant stress applied to
a metal for a prolonged period of time.
3.8. True
3.9. False
3.10. False
lt is not a valid direcrion cosine matrix because, the deter:ninant of this matri\ ;,
zero. It can be seen from the question that the elements in one ro\v and orw
column is zero.
4.
4.1. Anode
de
4.3. activator 4A. J = -D--·
dA
4.5. Higher than 4.6. 0.6- 0.7 (close to unity)
4.7. cross-slipping 4.8. Increase
4.9. Right 4.10. Smaller
5.
5.1. A - 4 B - 3 c - 2 D 1
5.2. A
·'"' B 4 c 2 D
5.3. A - 3 B 1 c - 2 D -· 4
5.4. A 3 B 4 c D - 2
5.5. A - 4 B -- c -- D -- 2
GAIQBIMT-1 Elite Academy 135
6. CaO + C0 2 = CaC0 3
~Gc = -168,400 + 144T J
Decomposition Temperature of time=?
6G: -- 0 at equilibrium
It is of the form
b 1 ~ b 2 + b 3 (in tenns of Burger's law vector vectoring feasible-?
Testing
x components of LHS = x components of RHS
y components of LHS = y components of RHS
z components of LHS = z components of RHS
---------------------~-------~-
136 Elite Academy GA QB J!T-f
Energetically feasible?
Test- b 2l > b 22 + b23
8.
1500
Liquid
X - point of study
X=80%A 20%B
Teap
C - eutectic point
opl
8 C=40%A 60%B
Solid A u Solid B
+ T +
Eutectic E Eutectic
A 80A c B
T 40A
208
~ I
c 608
60 - 20
. .
% ofsohd A=-· xlOO
Xc
=- - - = -40x 100 =-2 = 66.67%
tc 60 60 3
Vis given
SECTION-8
a2 =K N2 (2)
a2 = activity of component 2
N2 = concentration of component 2
K =constant (deviation from ideal behavior)
This is valid for a solution so dilute that Henry's Law holds good for solute. Rearranging
5 we get
-N..,
d In a 1 = --~ d /n N 2 (6)
Nl
dN
and utilizing the relation d In N 1 =~ & dN 2 = - dN 1 ; we get
I
(7)
a1 = CN 1 (8)
The integration constant C is seen to be unity, since, from the definition of activity.
a1 =1 when N 1 = I , hence,
(9)
This is Raoult's law and it is seen that Raoult's law holds good for the solvent 1.
Soln.: p
TR
,.
'
Slip ' '
disection ..
The angle between the tensile axis [1 T0] and normal axis N = 1TT is
2 2
=.fi..[j=../6
The angle between tensile axis (1 T0) & slip direction 0 TTis
'tR
0:::::: ---·····--··-- (1)
co; q, cos /,_
• :. ' - ·~. ~ <
Substitute in ( 1),
tR 2 1 15
15 = = 15 X - X-= tR = - = tR
_]_ X _!_ .[6 2 .[6
J6 2
tR = 6.12 MPa or R! 6 MPa
y 5 = 1J m - 2 = surface energy
(1)
l/2
Fracture strength=
70 109
x
( 4 X 2 X 10
:1 )
= (8.75 x 10 15 ) 112 = 93.5 x 106 Pa
=93.5 MPa
4r
InBCC =:::>a=- a = 2.9 x lo- 10 m
.{3
a = - interatomic distance (vol) v = 2.45 x 10-29 m3
4r
In FCC =:::>a=- a = 3.65 x 10- 10 m
.[2
(vol) v = 4.88 x 10-29 m3
GAIQB/MT-1 Elite Academy 1-11
But BCC has 2 atoms per unit \:eH 4 f<CC has 4. Hence if total number of atoms
remain unchanged.
l
Volscc (or) VBCC = ~ Vrcc
,{..
15. !I,
K =400 MPa
n = 0.21
€ = :r "" 0.11
'-'
) = exp(0.21)
Su
'1'1>: 'Y
=_'::~::::: '8~,.,
~ =---~
. MPa
'"·' 233.5
?Zl LJH
142 Elite Academy GA/QB/MT-1
16. To increase productivity in the blast furnace, more oxygen or air has to be
supplied. But by supplying more air, the gas velocity is increased which results in
hanging, ships of irregular furnace operation. In the conventional furnace, the top
is almost open to atmosphere. If the top pressure is increased blast pressure will
. . .
be needed at the bottom to maintain the same pressure drop. As a consequence,
for the same pressure drop from the hearth to the top, greater volume or mass of
blast can be blown which burns more coke thereby supplying more reducing gas
for the reduction of iron ore. This eventually increases productivity.
HTP introduces lower input of iron oxides in the hearth of the blast furnace and
improves the hearth temperature. These conditions result in lower· silicon in the
hot metal.
t.e. X new
= 2.0 _ (0.51 x 2- sin 2.0)
0.51 - cos 2.0
Substituting this x value in equation (1) and repeating the process, (when two
consecutive x values are same) we get the solution.
~1 ~]
-1
19. 3 MPa
[
0
of the fonn,
l O'x
- 't X)'
-t
0')'
yx - tzx
-t
zy =D
- txz -t O'l
yz
This is written as
0' z =1
"C
yx = 1
So ( l) becomes
----------~-- -~----~-
144 Elite Academy
(a-4) (a 2 -3a+2) = 0
0 iarge - 0 small
'tmax = ""
.)
(1)
Substitute we get
from (1), or
PN
2
= 0.5 atm i.e. 500/o by volume of gas
aN =0.0318
0 20 40 eo 80 100
BlowiDC t1... aiautee
146 Elite· Academy GA/QB/MT-1
EA
In K 1 = In A - -- (1)
RT1
E
In K.., = In A - _A_
~ RT
2
E E
/n K 1 -in K 7 =__A_--~
- RT.., RT1
/n l.S - /n K 2
__ _!±OOOQ_ .1 ~-1- ___1_11
8.314 Ll200 700j
In LS + 10.02 =In K 2
K 2 =33817 s- 1
_ 1 r
cro- -h l(crx -cry) +(cry -crz)
2 2
+(crz -crl) j
2 p12
(l)
""'.,..,.
cr 0 = ~=
.J2
[soo = (-200) 2 + (-200--500)2 + (500-800)2 t 2
We know that
log c ·y c = /n ·y,...
I ~" ~ •':.
law), the activi1y of carbon is. liquid iron can be computed at any desired
temperature.
148 Elite Academy GAIQB/Mf-1
Copper ore
Mass Balance
Input Olllput
ore- 16000 tons per day Tailings= 15,640 tons
Cu o/o = 0.75% Cu %=0.075%
0 75
Wt. ofCu = · x 16000 = 120 tons Wt. Cu = 11.73 tons
100
Concentrate = 16000 - 15640
- 360 tons
%Cu=?
108.27
(b) Copper recovery = --- x 100 = 90.225%
120
28. Pri•al1' bonding: Primary bonding are the strong bonds. These are covalent and
metallic bonds. It requires a high energy to break these bonds.
GAIQB/MT-1 Elite Academy 149
:o
o•
..... ~-
,.' 0
Secondary bonds: These are very weak compared to primary bonds. These are
normally referred to as 'VanDer Waais' bonds. The crystals with these kinds of
bonds are called 'Vander Waals' crystals.
~ VanderWall's forces
83 Q QSolid.
------------~----- -------~-
150 Elite Academy GAIQB/l\JT-I
ll VI = q /v
v
(Parameters are V, L 11 + V)
(iii)
Overlapping.
********************
152 Elite Academy GA/QB/MT-1
GATE-1995
MT: METALLURGICAL ENGINEERING
(iv) Section B has TWENTY questions. Answer any TEN questions from this se~tion.
Strike off the answers which arc not to be evaluated, else only the FIRST TEN
answers will be evaluated. Answers to this section should start on a fresh page
and should NOT be mixed with answers to Section A.
(v) Answers to questions and answers to the parts of a question should appear
together in the same sequence in which they appear in the questioi1 paper.
(vi) In all questions of 5 1~1arks, \\Titc clearly the i.mportant steps in your answer.
These steps carry partial credit.
1. Indicate the correct choice b)' writing down the corresponding lcUcr (A), (Hi,
(C) or (D) a~ the case may be in the answer script. Each qut•stion has ONLY
ONE correct answer. Each question carries 1 mark {15 x I = 15)
1.1. For a spont<:~neous. natural process at constant tt;mper ..:1tun: and pressure, the fi'>..":
energy of the system always
GA/QB/MT-1 Elite Academy 153
1.2. For a first order chemical reaction the concentration of the reactant decreases
(A) linearly with time (B) exponentially with time
(C) logarithmically with time (D) inversely with time.
1.3. The velocity- at which individual particles from a fluidized bed are-carried away
by the fluid passing through it is defined as
(A) minimum fluidization velocity (B) terminal velocity
(C) elutriation velocity (D) superficial velocity
(A) (B)
1.12. The ASTM grain size number N for a structural steel which shows 65 grains per
square inch at a magnification of 1OOX is
(A) 1 (B) 3 (C) 5 (D) 7
1.14. Basically (defined as (% CaO + % MgO) I % SiO 2 ) of the slag in Indian blast
2. Indicate the correct choice by writing down the corresponding lett~r (A)s {B),
(C) or (D) as the case may be in the answer script. Each question ha~ ONLY
ONE corrc~t answer. E11cb ~rsestion carrief '1, marks. (10 x 2 = 20)
2.1. The heat released by cooling one mole of copper from 400 K to room temperature
2.2. Consider an ideal solution of ccmpom:nts A and B. The entropy 'f mixir:g per
mole of an alloy containing 50 at '?o B is
(A) R Cn2 \B) - R :n:: (C) 3R tn2
2.3. Two electroiy1ic cells with CuSO 4 :L'ld AgN0 3 solutions are connected in series
to a power source. If after 10 mir.utes the weight of copper (atomic \\eight 63Si
deposited in the first ceil is 63 5 g. the corresponding weight of sir ver (atornic
weight 108) deposit.:;d in the second cell is
(A} 108 g (B) 54 g (C) 216 g (D) 81 g
parameter of 0.3608 m'R) taken with a Cu Ka radiation (A.= 0.154 nm), the Bragg
2.6. In a hcp single crystal, slip on the basal plane may occur, if the tensile axis is along
156 Elite Academy · GAIQB/MT-1
(A) <0001> (B) < 1120 > (C) < 1100 > (D) < 1121 >
2.8. The plane strain- fracture toughness (K IC) and yield strength of a material are
100 MN m- 312 and 500 MN m-2 respectively. The minimum plate thickness to
determine K IC is
2.9. Hot gases from a furnace are entering at the base of a 30 m high tubular verticai
temperatures are 1.165 and 0.405 kg m - 3 respectively. The static draft produced
by the chimney is
(A) 2.3 Pa (B) 22.8 Pa (C) 223.6 Pa (D) 2193.3Pa
2.10. A steel sample which has been deoxidized with Fe-Mn at 160<rc contains 0.51
wt % Mn. The equilibrium constant for the dissolution of MnO in steel with 1 \\1
3. State whether the following statements are true of false. Each question
carries t mark. (10 x 1 = 10)
.~.?. In a binary system at constant pressure, th..ree phases can coexist over a range of
temperatures.
1 3. If the contact angle between two phases is zero, one phase will spread over the
other.
3.4. The electrical resistivity of pure solid metals increases with increasing temperature.
3.5. The creep resistance of a material may by improved by decreasing its grain size.
:;•. 6. Earing in deep drawn products is caused by coarse grains in the blanks.
3.7. Friction is essential in rolling of metals.
3Jt Nitrided parts need no additional heat treatments for hardening.
3.9. Dephosphorization of steel is favoured at high temperatures.
3.10. L-D dust is pure iron.
.4.3. If cr E and E E are engineering stress and engineering strain respectively, the true
4.5. On a macroscopic scale, ductile fractures are slant ones; but on microscopic scale
fracture surface shows --------------------
4.8. Before casting, nitrogen, argon or chlorine is bubbled through molten aluminium
to relllOVe --------------------
158 Elite Academy GA/QB/}fT-1
5.2. The following reactions are written such that the forward reaction occurs during
cooling. Match the reactions to their names.
5.4. A 0.4 wt % C steel is austenitized at 90o·J C for 1 hour and heat treated to get
different microstructures. ~1atch the foilowing microstructures to the heat
treatments.
(A) Martensite+ retained austenite ( 1) Annealing
(B) Ferrite + fine pearlite (2) Quenching
(C) Ferrite +spheroidal cementite (3) Quenching +tempering at
600"C
(D) Ferrite +coarse pearlite (4) Normalizing
5.8. Match the corrosion phenomenon with the material in which they are conu:1c'r<·
observed.
(A) Season cracking (1) 70:30 brass
(B) Pitting corrosion (2) GI water line fitted with a brass tap
(C) Galvanic corrosion (3) Duralumin
(D) Caustic embrittlement (4) Boiler steel
6.2. (i) What is the crystal structure of aluminilJffi? Draw its unit cc1 L
(ii) Name the type~ ofinterstitial siies.
(ii1) Givt· the slip system.
(iv) Give the number of slip systems.
(v) What is the packing factor.
GA/QB/MF-1 Elite Academy 161
6.3. An isotropic material is subjected to uniaxial tension. Show with a sketch the
resolved shear stress on a plane inclined to the tension axis. Write an expression
for the shear stress on this plane. Show that the resolved shear stress has a
maximum value when the plane makes an angle of 45° C with the tension axis.
6.4. Ellingham diagram shows that the standard free energy of formation vs
temperature lines for the following two reactions intersect at 1700 oC .
Si (t~ + 0 2 - = Si0 2 (1)
(i) Sketch the standard free energy of formation vs temperature lines for the
above two reactions. Label the sketch.
(ii) What is the significance of 1700c C, a temperature less than 1700" C and
one above 1700' C .
6.5. Two sides of a thin strip of steel of thickness L are maintained at hydrogen
concentrations of C 1 and c2 . At steady state, the hydrogen concentration profile
-~-_( D dC) = 0 .
dx l dx
where D 0 and b are constants. Write the boundary conditions and solve the
cooled at 730° C , held there for a few hours and furnace cooled to room
temperature. Determine the weight fraction of pearlite in the final microstructure.
Also, determine the weight fraction of cementite in this microstructure.
8. Draw only the start of the transformation in a plain carbon eutectoid steel in its
TTT diagram.
(i) \Vhy does this transformation take a long time to statt at temperatures just
below the eutectoid temperature?
(ii) Why does this transformation take a long time to start at low temperatures
(i) Draw the free energy vs composition curves for the three. phases at TP .
(ii) Draw the free energy vs composition curves for the three phases at a
temperature slightly above TP showing two phase equilibrium.
10. In a ternary A-B-C system each of the binaries (A-B, B-C, C-A) has a eutectic
reaction. The three components also form a ternary eutectic at temperature
TABC . It is known that
section of the ABC phase diagram at temperature T1 is shown in the next page:
GA/QB/MF-1 Elite Academy 163
Dlt~
A
~,-------~--------~-- B
L+...f
Label the regions marked. I. II and III in the figure. Between which two of the
eutectic temperatures does T1 fall 0
600o C and an ordered structure belo\V 600c C. This alioy is quenched from the
12. 1be free energy of formation of a spherical liquid droplet from its vapour is given by
where AGv is the free energy change per unit volume of the liquid droplet for
unit area, and Vr and Sr are the volume and interfacial area respectively of a
droplet radius r.
(ii) Derive an expression for r * , the critical radius at which ~Fr is a maximum.
13. Sketch the plot of potential energy vs distance between two atoms in a solid. Also
sketch the corresponding force vs distance curve. Identify on the plots the
equilibrium distance between the two atoms and the bond energy. What factor
determines the stiffness of the bond.
14. Sketch the Frank-Read dislocation source of length I!. Under a certain minimum
applied shear stress, such a source will emit dislocations. Sketch THREE
signiticant stages in the operation of this source. Does the stress required for
~.~
···dislocation emission increase with increasing length of the source?
da = 10-10 (~Kl-+
dN
where a=-"' instantaneous crack length tin metres). N =number of cycics and .·\K-
16. Samples of a singic phase material show the following variation of )ielu stres _
cry . as a function of grain size, d:
GA/QB/MT-1 Elite Academy 165
Yield stress, cr 0 , of single crystal is 150 MPa. Perform a best fit (using least
17. Sketch and label a typical creep curve. Identify the normally used design
parameter from the above curve. Sketch the usually expected variation of log
(design parameter) vs log(applied stress) at a constant temperature. List two
mechanisms associated with the above behaviour.
18. Calculate the fracture stress of a thin steel plate containing a 24 mm long internal
crack along its width. The cntical strain energy release rate and the Young's
19. Obtain the reduction per pass in wire drawing, assuming that strain hardening and
friction in drawing are negligible. Drawing stress is given by
( i \
cr =Y {n i ----- J
I.J -· r /
where)' :md r art! the yidd stress anJ the reduction per pass respectively.
20. What arc the raw materials t(lr self-fluxing sinter? What are th~: bonds in
self-fluxing sinter? \\'hat arc th•: pref~tTed bonds and wh:i? Why is selt:.~1uxing
21. Based on Cr-C-0 equilibrium, identify the problem of stainless steel making.
How is this problem overcome in AOD process?
22. Give the flow sheet of production of liquid zinc by pyrometallurgical extraction,
starting from zinc ore. Properly label each stage and intermediate products.
23. Calculate the maximum size of the inclusion that can float up from the bottom or
- a liquid metal bath of 1 m height in 10 minutes. Assume that Stoke's law is valid.
Calculate the stoichiometric volume of air at STP required per kg of f'l~el for
complete combustion.
25. A 10 mm thick 500 mm x 500 mr:.1 size steel plate is being. heated from 30" C to
is 7900 kg m-3 ' and specific heat of the steel is 0.056 kJ kg- 1 ccr·i.
Calculate the heating time of the plate neglecting the temperature gradient in tk
plate. Derive the expression used for calculation of heating time.
26. Give typical structure of killed, semi-killed and rimmed steel ingots. Give th,::: ~
applications.
**~*****~**************
GA!QB11\1T-l f;iite Academ.v ]()7
SOLUTIONS I ANSWERS
1.
1.1. B 1.2. B 1.3. B 1.4. B
1.5. A 1.6. A 1.7. c 1.8. D
1.9. c 1.10. D 1.11. c 1.12. D
1.13. D 1.14. A 1.15. D
2.
2.1. A (Lili = mCP ~T)
3.
3.1. False 3.2. False 3.3. True 3.4. True
3.5. False 3.6. True 3.7. True 3.8. True
,., 9 ~
:.t@ True 3.10. False
168 Elite Academy GA/QB/MI-1
4.
4.1. Temperature 4.2. W/m.k
4.3. crT= crE(l+EE) 4.4. 400 MPa
4.5. voids 4.6. Surface
4.7. very thin 4.8. hydrogen
4.9. carbon 4.10. Cu 2 S,FeS
5.
5.1. A-3, B-2, C-4, D-l
5.2. A-2, B- 3, C-4, D-1
5.3. A-1, B- 3, C-4, D-2
5.4. A-2, B -4, C-3, D-1
5.5. A-2, B -3, C-4, D-1
5.6. A-4, B -3, C-2, D-1
5.7. A-2, B -4, c -1, D-3
5.8. A-4, B- 3, C-2, D-1
5.9. A-2, B -4, c -1, D-3
5.10. A-2, B-4, c -1, D-2
,.
o.
6.1
B
Tmp
A B
hypoeutectic comp. C1
t
eutectic
a
(,_) =--
'· .o..,'l,ffi"'X
h;._ •• 2
6.4.
T
At 1700° C, CO and SiO 2 are equally stable. Below 1700° C, Si0 2 is more
stable than CO, and the reaction 2CO + si(/) ~ 2C + Si0 2 is feasible. Above
1700° C, CO is more stable than Si0 2 and the reaction Si0 2 + 2C ~ 2CO + Si(/)
6.5. c
~
dx
(n dxde)= o
B.C. I atx=O,C=C 1
B.C.2 atx=L , C= C 2
D de= k
1
dx
(J:?o + bc)dc =k 1 dx
be2
DoC + 2 k --
= 'tX + K2
bc2
DoC 1 + - 1 = K2
2
GA/QB/MT-1 Elite Academy 171
bc 22 bc 2
1
and DoC 2 + - = K 1L + DoC 1 + -
2 2
c
c.
c.
X
X = 0 X : L
7. 0.5% C Steel
By Lever Rule,
01
;-o p ear1'1te = 0.5-0.008
- x 1000 = 62 .!20/
;ro
0.8-0.008
. == 0.5- 0.008 x 100
% cementite = 7.380/ 10
6.67 -- 0.008
172 Elite Academy GAIQB/MT-1
8.
y
•
ssac-
·~~~8~----------------------~
il«r-
logt
9.
1i
>----......-....oe~..-+Tp
T Peritectic reaction a + rJ -+ y
)(
@'•
~
~
<Jl t ot+Y
f
p-r-Y t I'
~ .I I 0( I o(-tp If l
t I
10.
12.
• 2cr
r =--
" ...,
uUy
174 Elite Academy GAIQB!},fi-!
13.
Pf r0 : Equilibrium distance
G
t =o 2 ~=> at maximmn energy state,
r
GA/QB/MT-1 Elite Academy 175
2G
't = __b => Increa'ie in I causes decrease in required stress.
I
15. a= O.OOlm
a max =50 MPa, a min =- SOMPa
I
K = <J"'/7ta
I
K= 50 M X 'V1t X 0.001
da
dN
= w- 10 (5.6
.
x(5.6) 4
.
=983.4 xl0- 10
N = 0.001
983.4 X 10-IO
N = 10170 cycles
400·= a 0 + 0.33 K
---~--- -~..-...._._ -- ~ -- --~---- -- _:__ ___ ----- --- --- ··-·-· --------- --------- ~--------- ,._.....,._
176 . Elite Academy GAIQBilt4T-1
cr 0 = 156.8, K = 686.0
.
los •
Mechanisms
.
Eac
AacDL
= h3.5 Ml/2 =
(crgJ
KT
y = 30000 JIm 2
GA/QB/MT-1 Elite Academy 177
cr f = 408.8 MPa
( y)
'\
1 '
19. cr =yrn _I
d 1-
_l_ =? !'")
1-y -··-
1=2.72-2.72y
y= 63.28%
20. Raw materials of self-fluxing sinter are ore, limestone and coke breeze (as a
fuel). The bonds in the self-fluxing sinter are partially ionic in nature.
21. Since Cr is more reactive than Fe, it is more prone tor oxidation in steel
decarburization process. The equilibrium,
(I)
-·
178 Elite Academy GA/QB/MT-1
is setup and due to oxygen blowing, Cr is oxidised. The carbon and chromium
compete for oxidation and the reaction set up is,
2Cr + 3CO(g) -+ 3~ + Cr2 0 3 (s)
h3
So, K~_f_
h~r
[o/oCr] = K'[%C] 312
So, during decarburization, % Cr also starts going down drastically. !io Cr is lost
to very high extent. because stainless steels require very iow carbon.
I Mining,
!
Fine
Size reduction by crushing, rolling mills.
sized Zn or~;s
•
i
I
'
ZnO is mixed with coke and heated at HX.!IJ' C in rdorb .,.,.b~-n
rcdu.::tion take.; place to fonn Zn ~md en vapr11urs
.
'
't
GA/QB/MT-1 Elite Academy 179
r--
Shock cooling of Zn vapours by passing in molten lead
CO(g)
Pb-Zn alloy
By substitution,
r = 29.16 x 10~ m =29.16 J.lm.
inclusion size = 58.32 f.lln
C+ 0 2 -+C02 (g)
12: 32 44
180 Elite Academy GA/QB/Aff-1
32
Oc =-x0.840 = 2.24kg
12
2 : 16 18
1
Air consumed = O_Q_ x 3.19 = 15.19 kg I kg fuel
21
mC T dT t
_P
hA
J
T Tr -T
= Jdt
o
1
t =- - In l( Tf -1})
mCP pdCP
· =- - / n (Tr -Tl)
hA Tr - T h Tr - T
87 800 ·-750
t = 139 sec.
GA/QB/MT--1 Elite Academy 181
26.
... :-....... .
. .
... ..... .
.. . ,·
. .. ·....
•
.-
•
. .. . ..
• Iii
...
• • •
(i) very sound and (i) Descent reiiability (i) Properties very
reliable properties in properties reliable
(ii) Structural application (ii) General purpose use (ii) general purpose
(iii) Costlier material (iii) more cost effective (iii) very cost effective
material
********************
------ ---------------
.
-----·----------~-----------
.
-----~--
182 Elite Academy GAIQBIMJ-1
ADDITIONAL QUESTIONS
(b) In the case of adherent oxide layer formed on a metal surface, the thickness of the
oxide layer is proportional to
(A) square root of diffusion coefficient
(B) time interval of diffusion
(C) square root of the product of diffusion co-efficient and time interval
(D) product for time-interval and diffusion coefficient
(c) The strain energy. per unit of dislocation of burgers vector 'b' is proportional to
Q.3- A fibre reinforced epoxy composite rod containing-75 wt% of 'E' glass fibres.
All the fibres are aligned longitudinally. Estimate the Young's modulus (E) of the
composite in the longitudinal direction of the fibres. Given
E(GPa)
lI 'E' glass
65.0
Epoxy
6.9
j
Specifk vavity
! 2.4 1.0
Q.S A steel can be ~urised at 900° C to a skin depth of 0.5 mm in a given time.
Find the temperature at which the carburisation can be achieved to a skin depth of
1.0 mm in the same time. Diffusion coefficient of carbon in the steel is 7.5 x 1o- 5
Q.6 Mild steel with a grain diameter of 0.03 mm has a yield strength of 200 MN m - 2
and that with 0.005mm has 400 :f\1N m - 2 • Estimate the yield strength of mild
steel single crystal.
Q. 7 A brittle material has been found to contain surface cracks of depth ranging from
0.1 ~tm to 1 ~m . Estimate the minimum stress at which the material will fracture.
184 Elite Academy GAIQBIJfi-!
Q.8 Ca!culate the equilibrium number of vacancies. per cubic meter for copper at
Q.12 Calculate the critical nucleus size r *. the number of spherical clusters of size r *,
the free energy changes between liquid and solid per unit volume L\G v • and the
free energy changes J.t the critical nucleus size (r") £\G; for rreezmg of
********************
186 Elite Academy GAIQBI.W-f
SOLUTIONS I ANSWERS
1.
(a) B (b) c
(c) D (d) c
(e) A (f) A,B,C
2.
(i) False
.., :.;
Volume of epoxv = ~~..:.:. ::: 25.0
. !0
V f -- -31.:25
- X '" ~6'0/
100 -- _,.,.,,:;"! 70 or O.S55t•
36.25
.1
. GA/QB/Mf-1 Elite Academy 187
and Vm=0.4444
4. The slip distance (j b !) is the repeat distance between the atoms along the slip
direction, which for FCC metals (such as copper) tend to be along the face
diagonal [ 11 0] of a unit cell. This is also a line of contact for atoms in FCC
structure.
2vDt 1
timet> 0.
C -C0
In the given problem ..::~ x is constant.
cs -Co
------------------------~--~-
188 Elite Academy GA/QBIJ..fl~J
At 900°C,
In [e -157000]
8.3147
= In 4 +In [e 8.314
-157000 ]
xl273
157000 = In 4_ 157000
83147T 8.314 X 1273
or . T ~ ( I ) ~ !403°K ~ 1130°C
_1_- 8.3!±_ /n4
1273 157000
K=23.9
and ai = 61.95
single grain ( d =co .'. d -l/ 2 = 6)
<>=(2:Er
where y = surface energy = 1 J m- 2
E = Young'smodulus=70GN m-2
C = half crack tip lengt&'l (max) = 1 !lffi
2 ,-1/2
a= 2
(
X um- 2
x70GNm- J = 140 GN m-2
1tX I~
N =NAp
Acu
3 6 3 3
{6.023x 1023 atoms/mole)(8.43g/cm }(10 cm /m )
=
63.5g/mole
190 Elite Academy GAIQBilrii-I
=2.2 x 10 25 vacancies/m 3
9. - The cadmium electrode will be oxidized and nickeltcduccd because cadmium i:,
lower in the emf series, thus, the spontaneous reaction will he
·')
Cd ~ Cd- + 2e-
when.~ F is the elastic modulus, a 1 the linear codlicicnt of thcnnal cxpan;:;,io:o i1i":i_~
T.-
' -
T() -~
t;' .:y
.L- ..___ i
=2(1" c + 86' c
== l06"C
J = -o _c..:,_:A:_-_c--=--s
XA -XB
3
-11 2 ) (1.2-0.S)kglm
=- (3 x 10 m 1sec
(Sxlo-3 -10-2 )m
• -2 'YsL T
(i) Critical nucleus size r = m
L\Hr AT
= 94.5nm
("")
,11 The number of spherical dusters of size r • is given by
• 4 *3 l
N = -7tr x-
r 3 Vo
=2.12xto 8
--·--·--·--~-·· · - - , - - - - - - - - - - - - - · -·
192 Elite Academy GA/QB/MI-1
Llli ~T
(iii) The value of ~G v = f
Tm
l.836xl09 J /m 3 x-lK
=---------------
933K
(iv) ~Or
• = 34 1tr-•3 ~
G v + 4m •2 'YsL
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