MG103 ENGINEERING MATERIALS

Assignment 1
Instructions
1. Answer all Questions
2. Do not use any software packages to plot graphs.
3. Due date is 15:00hrs Monday 08 June 2020 and late assignments will not be considered.
4. Submit your assignment to either sumcle@gmail.com or WhatsApp 0784741898
5. Your assignment will be considered submitted if and only if I have acknowledged receipt of your
assignment.

Question 1

a) Define the following;

(i) Amorphous materials and [1]
(ii) Dendritic structure. [1]

You can easily get a definition from the internet.

b) Explain the principle of slip in terms of BCC and FCC crystal structures [2]

The body centre cubic (BCC) structure is not a close packed arrangement while the face centre
cubic structure is close packed, which allows easier activation and movement of atoms across
each other. FCC metals are ductile while BCC metals tend to be more brittle. Crystalline
structure is important because it contributes to the properties of a material. For example, it
is easier for planes of atoms to slide by each other if those planes are closely packed.
Therefore, lattice structures with closely packed planes allow more plastic deformation than
those that are not closely packed. Additionally, cubic lattice structures allow slippage to occur
more easily than non-cubic lattices. This is because their symmetry provides closely packed
planes in several directions. A face-centered cubic crystal structure will exhibit more ductility
(deform more readily under load before breaking) than a body-centered cubic structure. The
bcc lattice, although cubic, is not closely packed and forms strong metals. Alpha-iron and
tungsten have the bcc form. The fcc lattice is both cubic and closely packed and forms more
ductile materials. Gamma-iron, silver, gold, and lead have fcc structures. Finally, HCP lattices
are closely packed, but not cubic. HCP metals like cobalt and zinc are not as ductile as the fcc
metals.

c) Mechanical tests are carried out to determine metal properties. Identify and
describe the metal properties under Izod test examination. [2]

A test for toughness which is a measure of the resistance to impact.

I was deducting marks for including strength, elastic constants etc

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 d) In the manufacture and maintenance of aircraft, a range of non-destructive testing
(NDT) is used to check for internal and external flaws. Identify two NDTs that
examine surface imperfections and two NDTs that detect internal flaws. [2]

Surface imperfections: visual inspection, penetrant test, Magnetic , Eddy Current

Internal flaws: radiography (x-ray) test, ultrasonics

e) With reference to the graph below Figure 1, outline the properties associated with
materials A, B and C and give an example of each material. [3]

Fig. 1 for Question 1 (e) Fig. 2 for Question 2 (c)

Material A. A small amount of elasticity is exhibited with little ductility. This is a

brittle material such as cast iron. Material B. This material displays good ductility
with a definite elastic limit. Low carbon steel exhibits these characteristics.
Material C. This is a very ductile material with stretching over a period with little
increase in load. An example is copper.

Question 2

a)
(i) Compare the indenters used in Brinell and Vickers hardness tests. [4]

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 I was awarding marks on an in-depth comparison of the two indenters. Full marks were
awarded if you include drawings and equation for calculating hardness using the two
indenters. You get these from your lecture notes Chapter 7 (Mechanical Properties)

(ii) Identify two factors necessary to prevent early fatigue failure in a

component. [2]
Factors necessary to prevent early fatigue include: • Make allowance for potential fatigue
during component design. • Removal of sharp corners. • Reduce vibration in service. •
Improve surface finish. • Prevent or minimise corrosion.

You were supposed to explain any two.

(iii) With reference to tensile testing, explain the elastic limit of a

material [2]

The point up to which the extension is proportional to the load applied and beyond which a
material stays stretched and therefore an increase in load produces a larger extension in the
material. This signifies the end of the elastic range for the material being tested.

b) Derive the formula for the lattice constant of a BCC structure. [4]

Lattice constant for FCC is derived on example 3.1 chapter 3. You were supposed to follow
the same procedure in deriving lattice constant for BCC structure. I deducted two marks for
deriving the lattice constant of a BCC structure without a diagram.

c) A simplified portion of the iron-carbon equilibrium diagram is shown in figure 2.

(i) Name the regions A, B, C and D. [4]
(ii) Identify and describe the significance of points X and Y. [3]

(i) A – Liquid B – Austenite + Liquid C – Austenite D – Austenite + Cementite.

[4]

(ii) X – Eutectoid point. Solid austenite changes to solid pearlite at 723 oC for the alloy
containing 0.83% carbon.

Y – Eutectic point. A solid to liquid change takes place at 1140 oC for the alloy with 4.3%
carbon. Liquid steel changes to solid austenite and cementite. [3]

Question 3

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 The results shown below were obtained from a tensile test of a 0.505 cm diameter
aluminium alloy test bar, with an initial length of 20mm.

Load (kg) 0 1.00 3.00 5.00 7.00 7.50 7.90 8.00 7.95 7.60
Change in 0 0.001 0.003 0.005 0.007 0.030 0.080 0.120 0.160 0.205
Length (cm)

(a) Plot a suitable graph and determine for the aluminium alloy the: [8]

Calculations and table [5]

You were supposed to show how the values in your table were calculated. At least one for
strain and one for stress.

Graph [3]

(i) the ultimate tensile strength (UTS) and [1]

(ii) elastic stiffness [1]
(iii) 0.2% offset yield strength [2]

Refer to Chapter 7 slides.

(b) You are required to design an aluminum rod to withstand an applied force of
45,000 Kg. The engineering stress–strain curve for the aluminum alloy to be used
is the one you plotted in (a) above. To ensure safety, the maximum allowable
stress on the rod is limited to 25,000 Pa. The rod must be at least 150 cm. long
but must deform elastically no more than 0.25 cm. when the force is applied.

(i) Give a reason why the maximum allowable stress on the rod is limited
to 25000Pa. [2]
(ii) Design an appropriate rod.
(N/B Calculations and explanations are required in this question; 3b(ii)) [6]

Part B will not be examined.

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