Semester 1 Examinations 2018/2019: Programme (S)

SEMESTER 1 EXAMINATIONS 2018/2019
MODULE: MM409 - Adv Eng Materials & Manufacturing Processes

PROGRAMME(S):
CAM B.Eng. Mechanical & Manufacturing Eng
MWB BSc Manufacturing Eng with Business
YEAR OF STUDY: 4
EXAMINER(S):
Nicholas Dunne (Internal) (Ext: 5712)
Dr. Gerard Ryder (External) External
Prof. David Kennedy (External) External
TIME ALLOWED: 2 Hours
INSTRUCTIONS: Answer 4 questions. All questions carry equal marks.
PLEASE DO NOT TURN OVER THIS PAGE UNTIL YOU ARE INSTRUCTED TO DO SO.
The use of programmable or text storing calculators is expressly forbidden.
Please note that where a candidate answers more than the required number of questions, the
examiner will mark all questions attempted and then select the highest scoring ones.
Requirements for this paper:

1. Statistical Tables
MM409 – Adv Eng Materials and Manufacturing Processes

Semester 1 Examinations 2018/2019 Page 1 of 7
QUESTION 1 [TOTAL MARKS: 25]
Q 1(a) [8 Marks]
Briefly describe four advantages and four disadvantages of advanced composite
materials.
Q 1(b) [4 Marks]
Outline the four fibre factors that contribute to the mechanical performance of
advanced composite materials.
Q 1(c) [4 Marks]
Briefly describe the four principal roles of the matrix in an advanced composite
material.
Q 1(d) [9 Marks]
Calculate the surface/volume ratio for a cylindrical reinforcement for a range of values
of the ratio of radius to length r/l. Show that the surface/volume ratio is greatest when
r/l is either very small or very large. What does this suggest about the most efficient
types of reinforcement?
[End of Question 1]

Q 2(a) [12 Marks]
Using an annotated diagram, describe the ultrasonic welding process. Also include in
your answer two advantages, two disadvantages and outline three applications where
the process of ultrasonic welding is applied.
Q 2(b) [6 Marks]
A 15 mm thick lap joint was produced by joining two sheets of Nylon using ultrasonic
welding. The ultrasonic welding process operated at a frequency of 20 Hz for 4
seconds. Calculate the minimum electrical energy produced during the welding. Note
the Vickers hardness is approximately three times the ultimate tensile strength. Use
ultimate tensile strength of Nylon = 68 MPa and k = 1.82 x10-7.

Q 2(c) [3 Marks]
Briefly describe how an oxide layer affects the quality of a weld if not removed.
Q 2(d) [4 Marks]
Briefly outline four of the main defects associated with using an improper welding
procedure.
[End of Question 2]

Q 3(a) [9 Marks]
Zirconium dioxide is a ceramic based material that is used in sensor technology to
detect oxygen. Using annotated diagrams, briefly explain the principle, approach and
operation of zirconia dioxide as an oxygen sensor.
Q 3(b) [6 Marks]
A large particle composite consisting of tungsten particles within a copper matrix is to
be prepared. If the volume fractions of copper and tungsten are 0.80 and 0.20,
respectively, calculate the maximum specific strength of this composite given the data
in the table below (Table Q3.1.).
Table Q3.1.
MATERIAL SPECIFIC GRAVITY TENSILE STRENGTH (MPa) MODULUS (GPa)

Copper 8.90 200 110
Tungsten 19.30 425 400
Q 3(c) [10 Marks]

Cemented carbides are classified as a type of metal matrix composite because the
metallic binder is the matrix that holds the bulk material (i.e. carbide ceramic particles)
together. Using annotated diagrams, describe in detail the manufacturing route for
cemented carbide components. In your answer, also make reference to the sintering
process and possible secondary operations.
[End of Question 3]

Q 4(a) [3 Marks]
Increases in chain stiffness within a polymer structure can increase the melting and
glass transition temperatures. Briefly, list the three main grouping arrangements
responsible for increasing chain stiffness.
Q 4(b) [6 Marks]
Considering your answer from Q 4(a). Sketch a graph showing the relationship
between specific volume (y-axis) versus temperature (x-axis) for glass, semi-
crystalline solid and crystalline solid polymers. On the graph indicate the melting and
glass transition temperatures for the aforementioned polymer systems.
Q 4(c) [7 Marks]
An example of an advanced polymer material is ultra-high molecular weight
polyethylene (UHMWPE). Briefly outline four of the key features and three main
applications of UHMWPE.
Q 4(d) [9 Marks]
A polymer with viscosity 250 N.s/m2 is to be extruded using a screw extruder, with
details as follows: Diameter of barrel D = 100 mm, screw speed, N = 60 rev/min, screw
helix angle = φ = 15°. The metering zone has: length L = 350 mm, and flight depth H
= 3 mm.
(i) Calculate the volumetric flow rate of the polymer if the screw were operated
under open discharge conditions.
(ii) Calculate the maximum pressure that can be generated in the event of a
blockage at the die.
[End of Question 4]

Q 5(a) [10 Marks]

Using an annotated sketch, briefly describe the continuous ingot casting process. In
your answer indicate two advantages and four disadvantages of the process.
Q 5(b) [6 Marks]
Briefly describe the single crystal casting process. In your answer indicate the main
advantage and two applications of the process.
Q 5(c) [9 Marks]
Fluxes are regularly used during various casting process. Describe the compound
type, principal role and four of secondary functions of fluxes and give examples of
three typical compounds used.
[End of Question 5]
Q 6(a) [12 Marks]

Electromagnetic Forming Ltd wish to reduce the amount of electrical power that they
use in the electromagnetic forming process. In order to do this they devised the design
of experiments shown in Table Q6.1. The three processing parameters varied were
the diameter of the sheet formed (parameter A), the distance between the sheet metal
and the forming coil (parameter B) and the thickness of the formed sheet metal
(parameter C). A high and low level of each of these parameters was examined in a
23 factorial design. The resulting values of power recorded from these experiments
are shown in Table Q6.1. Quantitatively determine and then describe the influence of
the three parameters on the power consumed.

Table Q6.1.
Power
Experiment A B C
(W)
1 - - - 120
2 + - - 110
3 - + - 105
4 + + - 100
5 - - + 90
6 + - + 50
7 - + + 95
8 + + + 55
Q 6(b) [8 Marks]
Figure Q6.1. shows different responses for y as a function of x1 and x2. With this in
mind, for each case, briefly describe the extent of the effects of x1 and x2 on y and if
any interaction is occurring between x1 and x2.
Figure Q6.1.

Q 6(c) [5 Marks]
Describe the simplest and most common type of factorial design. What is the main
disadvantage associated with this type of factorial design, and a process used to
reduce the extent of this disadvantage?
[End of Question 6]
[END OF EXAM]


Semester 1 Examinations 2018/2019: Programme (S)

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SEMESTER 1 EXAMINATIONS 2018/2019

MODULE: MM409 - Adv Eng Materials & Manufacturing Processes

TIME ALLOWED: 2 Hours

INSTRUCTIONS: Answer 4 questions. All questions carry equal marks.

Requirements for this paper:

MM409 – Adv Eng Materials and Manufacturing Processes

QUESTION 2 [TOTAL MARKS: 25]

MM409 – Adv Eng Materials and Manufacturing Processes

QUESTION 3 [TOTAL MARKS: 25]

MATERIAL SPECIFIC GRAVITY TENSILE STRENGTH (MPa) MODULUS (GPa)

Q 3(c) [10 Marks]

MM409 – Adv Eng Materials and Manufacturing Processes

MM409 – Adv Eng Materials and Manufacturing Processes

Q 5(a) [10 Marks]

QUESTION 6 [TOTAL MARKS: 25]

Q 6(a) [12 Marks]

MM409 – Adv Eng Materials and Manufacturing Processes

MM409 – Adv Eng Materials and Manufacturing Processes

MM409 – Adv Eng Materials and Manufacturing Processes

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