Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

First Semester 2022 -2023

Comprehensive Examination
(EC-3 Regular)

Q.1. (a) Explain the main reason why aluminum and its alloys are widely used in motor vehicles? What are the
advantages of using aluminum alloys compared to conventional steel materials for the production of parts
and vehicle assemblies?
(b)What is specific strength? Why fibers have very high specific strength?

Answer
Aluminium and its alloys are widely used in many manufacturing industries, these are used in various industries
due to several reasons. These reasons are the advantage of this where it can increase the efficiency of the
automobiles. The reasons are as:

- It can increase the fuel efficiency of the automobile.

- The weight of aluminum is very less , therefore this can decrease the weight of the automobile.
Therefore when the weight is decrease it will increase the efficiency of the vehicle.
- Aluminum and its alloys are the strongest material available.
- Aluminum is very light weight and durable.
The above mentioned are the advantages as well as reasons why aluminum and its alloys are
widely used in vehicle assemblies when comparing to conventional steel material.Conventional
steel is having many disadvantages comparing to the steel alloys. It includes the weight of the
material, cost of the material, manufacturing methods, change in properties in different
temperature.

Specific strength is defined as the yield strength of the material. This is calculated uisng the ratio of the
material towards the strength of the material. When the material have high specific strength it will have
higher the weight carrying capacity.
Fiber is one of the strongest material . This is because the strength of aluminum is very high. This is
because the arrangement of atoms inside it. When the atoms are closely packed inside , this can
cause increase in the specific strength as well. The type of fiber which has higher specific strength are
carbon fiber , different type of fiber polymers ......

• Explanationfor step 2

Fiber is one of the strongest material due to higher specific strength

- Aluminum and its alloys are used in automobile industries due to its various advantages.It
includes the hardness of aluminum as well as the weight of the material as well.

Q.3. (a) Sketch an isomorphous phase diagram of AB alloy and determine the weight fraction of liquid in an
alloy of 73% B, if α of 82 % of B and liquid of 57 % B are in equilibrium. What would be the degree of
freedom in such a case?
(b) Explain briefly the concept of true stress and strain against engineering stress and strain with a help of stress-
strain diagram.
Q.5. State the treatment processes must be performed on eutectoid steel to obtain transformation from:
[2 M]
(a) Martensite to Pearlite
(b) Pearlite to Bainite, and
(c) Austinite to Ferrite
Q.6. (a) Sketch and explain the iron-iron carbide equilibrium diagram, and show their salient feature. Indicate the
significance of this diagram for the heat treatment of steel. [4 M]
(b) For a brass alloy, the stress at which plastic deformation begins is 345 MPa, and the modulus of elasticity
is 103 GPa. [4 M]
i. What maximum load may be applied to a specimen with a cross-sectional area of 130 mm2
without plastic deformation?
ii. If the original specimen length is 76 mm, what is the maximum length to stretch it without
causing plastic deformation?
Salient features are :

(1) Its a plot between the iron and iron carbide

(2) At different temperature and carbon percentages it can exists in different phases called as
polymorphism which are shown by alpha , delta , austenite and iron carbide .

Significance of this diagram for heat treatment of steel :

(1) It gives us the data related to the phases that will be present upon heating the steel which helps us
in speculating the properties of the steel.

(2) we can easily select our desired temperature and composition of steel required for heat treatment
to get the desied properties in it for a particular application.

• Explanationfor step 1

Iron and iron carbide diagram is the basis for the heat treatment which is used along with the TTT
diagram.
(b)

Plastic deformation stress = Syt = 345 Mpa

Modulus of elasticity E= 103 Gpa = 103000 Mpa

i. Area of cross section = A=130 mm2

Maximum load to avoid plastic deformation = Pmax = Syt * A = 345 * 130 =44850 N

Maximum load to avoid plastic deformation = Pmax = 44850 N

ii.

Original length Lo= 76 mm

Final length to avoid plastic deformation = Lf

we have

(Syt / E) = (Lf-L0)/Lo

(345 / 103000) = (Lf-76)/76

Lf=76.25 mm

Final length to avoid plastic deformation = Lf =76.25 mm

• Explanationfor step 2

use formula of hookes law stress is proportional to strain and also

stress= load/area
a)

Sketch is drawn and explations provided already .

(b)

i.Maximum load to avoid plastic deformation = Pmax = 44850 N

ii.Final length to avoid plastic deformation = Lf =76.25 mm

Q.7. Draw the tensile stress-strain diagram of the following materials in Table below and locate the yield and
ultimate stress value. Also compare and make a ranking on the following mechanical properties, Toughness,
Hardness, Ductility, Ultimate Tensile Strength and Plasticity of these materials. [5 M]

S.No. Materials
1 Pure Copper
2 Steel
3 Pure Aluminum
4 Magnesium
5 Diamond
Q.8. Explain the following BRIEFLY to the point: [5 M]

S.No. Fatigue Creep

1. Define it Define it
2. Discuss the mechanism of fatigue Discuss the mechanism of creep
failure failure
3. Suggest methods to improve the Suggest methods to improve the creep
fatigue life of materials life of materials

FATIGUE:
Ans.1) Fatigue is the failure condition formation and propagation of cracks due to repetitive or cyclic
load, which is below the burden that would result in the yielding of the material.

Ans.2) The primary mechanism of fatigue failure is the slip condition. The failure occurs when there is
an irregularity on the surface, which becomes high concentration points.

Ans.3)surface treatments, and heat treatment of the materials are some of the methods which can be
done.

CREEP:

It is commonly known as a time-dependent permanent strain under stress and is known as creep.

Ans.2)It is a deformation mechanism it might not be a failure mode but, it relieves tensile stress. Creep
deformation does not take place suddenly like brittle fracture it occurs slowly at higher temperatures.
Ans.3)Increasing the grain size, diffusivity and precipitates use higher melting point metals. Body-
centered cubic (BCC) metals are less creep resistant in high temperatures. FCC based super alloys
are less prone to creep.

Q.4. (a) Mention the enabling materials properties for each labelled item in the figure given below.
[2.5 M]

(b) Briefly describe the importance of temperature, corrosion, fatigue, and strain rate behaviour of materials in
engineering design applications.

A) material properties of each item

1.polymer frame :
polymer frame has high strength (light weight but comparetively stiff and strong) , toughness resillience
resistance to corrosion lack of conductivity , color, transperance , processing and low cost
2. woollen sweater :
wool fiber is soft durable , shafe in nature and has hifh wear and tear resistance it has good
chatacteristics such as elasticity resillience poor resistance to alkalies with good resistance and good
insulation properties
3. polycarbonate lenses:
these are strong stiff hard tough transparent engineering thermoplastic method can maintain rigith upto
140and toughness down to -20C
4.wooden table:
wood has high strength in tensile and compression in axial and shear , cleavage hardness static
bending and shock
5.stainless steel fork:
having high tensile strength very durable teperature resistance easy formability and fabrication low
maintainnance attractive appearance corrosion resistance
6.ceramic cup:
high hardness hieg elasti modulus low ductility good dimensional stability good wear resistance high
resistance to chemicals