DMX5204 Final 2021

The Open University of Sri Lanka
Faculty of Engineering Technology

Department of Mechanical Engineering
Study Programme : Bachelor of Technology Honours in Engineering

Name of the Examination : Final Examination
Course Code and Title : DMX5204 - Materials Engineering
Academic Year : 2020/ 21
Date : 22nd January 2022
Time : 0930-1230hrs
Duration : 3 hours
General Instructions
1. Read all instructions carefully before answering the questions.

2. This question paper consists of Eight (8) questions.
3. Answer any Five (5) questions only. All questions carry equal marks.
4. Answer for each question should commence from a new page.
5. Relevant charts/ codes are provided.
6. This is a Closed Book Test (CBT).
7. Answers should be in clear handwriting.
8. Do not use Red colour pen.
QUESTION 01 (20 marks)
(a) State the four factors that affect the solubility in formation of (4 marks)
substitutional solid solutions.
(b) The Fig. Q1 below shows the Hafnium-Vanadium phase diagram. Using
the phase diagram answer the following.
i. Label the phase/s in areas marked 1-8 in the phase diagram. (8 marks)
ii. For an alloy containing 60 wt% Vanadium and 40 wt% Hafnium, (3 marks)
describe the process of solidification from 2000°C.
iii. Calculate the amount of liquid and vanadium present at 1600°C and (5 marks)
at 60 wt% Vanadium.
Page 1 of 6
Fig. Q1
(a) What is a copolymer? Discuss the types of copolymers available. (6 marks)
(b) Differentiate between Addition polymerization and Condensation (6 marks)

polymerization.
(c) A copolymer of ABS (Acrylonitrile-Butadiene-Styrene) contains equal (8 marks)

weights fractions of each polymeric component. What is the mole fraction
of each component? Monomer structures of ABS copolymer are given
below. Atomic weights are C-12, H-1, N-14.
Fig. Q2
Page 2 of 6
(a) Explain the effect of following failure mechanisms on materials.
i. Fatigue (4 marks)
ii. Creep (4 marks)
(b) A shaft with a diameter of 30 mm is to be carry a load of 35 kN at a

temperature of 250°C. The experimental data showed that the steady state
creep rate of the material follows the Norton equation given by,
𝒅𝜺⁄𝒅𝒕 = 𝑪𝝈𝒏 Where 𝐶 = 4.43 × 10−15 and 𝑛 = 4.2 when stress is given
in MPa and strain in m/m/hr.
Calculate the following.
i. Strain rate at 250°C. (6 marks)
ii. If the maximum tolerable strain is to be 0.1%, useful life expectancy (6 marks)
of the shaft.
(a) With the aid of Iron-Carbon phase diagram, explain the effect of following
heat treatment processes on plain carbon steel.
i. Annealing (3 marks)
ii. Normalizing (3 marks)
(b) i. Briefly describe the most popular 18-8 stainless steel. (18 Cr - 8 Ni). (4 marks)
ii. Why does stainless steel have corrosion properties? (4 marks)
(c) Discuss the types of fibers and matrix materials used in composites. (6 marks)
(a) Derive an equation for Elastic modulus of a lamellar continuous fiber and (8 marks)
matrix composite for isostrain condition.
(b) A continuous and aligned carbon fiber-reinforced epoxy matrix composite

is to be produced consisting of 64 vol% carbon fibers and 36 vol% epoxy
matrix. Mechanical characteristics of these two materials are as follows.
Page 3 of 6
Tensile modulus Tensile strength
of Elasticity (GPa) (MPa)
Carbon fiber 372.6 2136
Epoxy matrix 3.65 63.5
Compute the following
i. The tensile modulus of elasticity of the composite. (4 marks)
ii. The tensile strength of the composite. (4 marks)
iii. Fraction of the load carried by the carbon fiber. (4 marks)
(a) Describe the edge and screw type dislocations with illustrations. (6 marks)
(b) What types of strain fields are surrounded both types of dislocations? (6 marks)
(c) “Smaller the grains size higher the strength of a material.” Explain this (8 marks)
statement with the help of Hall-Petch equation.
(a) Distinguish between traditional and engineering ceramic materials and (6 marks)
give examples of each.
(b) Describe the steps in the slip-casting process for ceramic products. (6 marks)
(c) Explain the types of bonds present and resultant properties in ceramics. (8 marks)
(a) What is the difference between Hardness and Hardenability? (4 marks)
(b) A cylindrical component of diameter 62.5 mm will be made with alloy

steel. The candidate materials are 8660, 8640, 8630 and 8620 alloys. The
component will be Austenized and quenched in moderately agitated water
or oil and the surface and center hardnesses must be at least 50 and
40HRC respectively.
i. What is the carbon content in each of these 4 alloys? (4 marks)
ii. Determine the hardenesses of these alloys at the surface and center, (6 marks)
if they were quenched in moderately agitated water. Comment on
which of the alloys satisfy the requirements. (Show your
calculations. Refer Fig. Q8(a) (i) & Fig. Q8(b)).
Page 4 of 6
ii.
Fig. Q8(a) (ii) & Fig. Q8(b)).
Page 5 of 6
(i) Water quenching (ii) Oil quenching
Determine the hardness of these alloys at the surface and center, if
they were quenched in moderately agitated oil. Comment on which
of the alloys satisfy the requirement. (Show your calculations. Refer
Fig. Q8(a) – Cooling rate as a function of diameter at surface, three-quarter radius (3/4R), mid radius (1/2R) and center positions for
cylindrical bars quenched in moderately agitated (i) water and (ii) oil. Equivalent Jominy positions are included in bottom axis.
(6 marks)
Fig. Q8(b) –Hardenability curves for four 8600 series alloys
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The Open University of Sri Lanka

Faculty of Engineering Technology

Study Programme : Bachelor of Technology Honours in Engineering

1. Read all instructions carefully before answering the questions.

QUESTION 01 (20 marks)

QUESTION 02 (20 marks)

(a) What is a copolymer? Discuss the types of copolymers available. (6 marks)

(b) Differentiate between Addition polymerization and Condensation (6 marks)

(c) A copolymer of ABS (Acrylonitrile-Butadiene-Styrene) contains equal (8 marks)

(a) Explain the effect of following failure mechanisms on materials.

ii. Creep (4 marks)

(b) A shaft with a diameter of 30 mm is to be carry a load of 35 kN at a

Calculate the following.

i. Strain rate at 250°C. (6 marks)

QUESTION 04 (20 marks)

ii. Normalizing (3 marks)

ii. Why does stainless steel have corrosion properties? (4 marks)

QUESTION 05 (20 marks)

(b) A continuous and aligned carbon fiber-reinforced epoxy matrix composite

ii. The tensile strength of the composite. (4 marks)

iii. Fraction of the load carried by the carbon fiber. (4 marks)

QUESTION 06 (20 marks)

QUESTION 07 (20 marks)

QUESTION 08 (20 marks)

(a) What is the difference between Hardness and Hardenability? (4 marks)

(b) A cylindrical component of diameter 62.5 mm will be made with alloy

Fig. Q8(a) (ii) & Fig. Q8(b)).

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