UNIT 3 - METALLIC AND NON-METALLIC MATERIALS - ANSWERS

2 Marks
1. Discuss the effects of alloying carbon and aluminium elements on steel.
(i) Carbon determines the level of hardness or strength of the steel. It increases tensile strength and
hardness. It decreases ductility and machinability.
(ii) Aluminium is used as a deoxidizer. It combines with nitrogen to form hard nitride, which is responsible
for increasing the hardness of steel.

2. Discuss the effects of alloying antimony and arsenic elements on steel.

(i) Antimony is harmful to steel as it decreases the toughness of steel.
(ii) Arsenic is also harmful to steel as it decreases toughness and increases brittleness.

3. Discuss the effects of alloying boron and calcium elements on steel.

(i) Boron increases the hardenability of steel when added in small amounts (0.03%). The advantage of using
boron over other elements is that boron increases the hardenability without decreasing the ductility or
machinability of steel.
(ii) Calcium is used for the deoxidization of steel in the combination of silico calcium.

4. Discuss the properties and applications of stainless steel.

Properties: Steels have good machinability due to low carbon content. They can be cold rolled to 80-90%
without cracking and have good weldability.
Applications: Steel has very little dimension change on heat treatment, hence it is used in buildings, ships,
and weapons.

5. Discuss the properties and applications of tool steel.

Properties: Tool steel possesses high hardness, strength, and wear resistance. They are cheap, brittle, and
have relatively low hardenability.
Applications: It is used in chisels, hummers, drills, and razors.

6. Discuss the advantages and disadvantages of Gray cast iron.

Advantages Disadvantages
Very high damping capacity Very Brittle
Good dry bearing qualities and resist corrosion Higher-strength gray cast iron is expensive

7. Discuss the advantages and disadvantages of White cast iron.

Advantages Disadvantages
High Hardness: White cast iron is extremely hard due
Brittleness: White cast iron is highly brittle.
to its microstructure, which consists of iron carbide
Its lack of ductility and malleability means it
(light phase) and pearlite (dark phase). This hardness
cannot be easily bent, rolled, or worked at
makes it suitable for applications where wear
room temperature.
resistance is crucial.
Lack of Ductility: Unlike other materials,
Wear Resistance: White cast iron exhibits excellent
white cast iron lacks ductility, making it
wear resistance, making it ideal for components
unsuitable for applications requiring
subjected to abrasive conditions.
deformation or flexibility.

8. How Copper alloys are classified?

Copper and High Copper Alloys, Brasses (Cu-Zn Alloys), Bronzes, Phosphor Bronze, Aluminium Bronzes,
Silicon Bronzes, Cupronickel, Leaded Copper.
9. Enumerate the different kinds of Brasses.
Gliding Metal (<5% Zn), Commercial Brass (10% Zn), Jewelry Brass (12.5% Zn), Red Brass (15% Zn), Low Brass
(20% Zn), Cartridge Brass (30% Zn), Yellow Brass (35% Zn), Muntz Metal (40% Zn).

10. Enumerate the different types of alloy steels.

Nickel steels, Nickel-chromium steels, Molybdenum steels, Chromium steels, Chromium-vanadium steels,
Tungsten-chromium steels, and Silicon-manganese steels.

11. Discuss the properties of polymers.

Great strength, Self-extinguishing, High durability, Low water absorption, and High resistance to aqueous
chemical environments

12. Discuss the commercial uses of poly vinyl chloride (PVC).

50% of PVC is used as rigid resins.
30% is used in building construction including pipes, windows, and wall coverings.
Used in wire and cable insulation, medical tubing, and floor coverings.

13. Discuss the four loads which applied and tested on composites.
Tension: Tensile load applied to composite. It depends on the tensile strength of the reinforcement fibres.
Compression: Depends on the adhesive and stiffness of the composite which is responsible for maintaining
straight columns.
Shear: Adjacent layers of fibre slide over each other. The resin plays a major role in transferring the stress
across the composite.
Flexure: Combination of tensile, compression, and shear loads. The upper face exhibits compression, the
lower face exhibits tension and the central portion exhibits shear.

14. Discuss the most common man-made composites.

Polymer Matrix Composites: Also known as FRP - Fibre Reinforced Polymers (or Plastics) – these materials
use a polymer-based resin as the matrix, and a variety of fibres such as glass, carbon, and aramid as the
reinforcement.
Metal Matrix Composites: Increasingly found in the automotive industry, these materials use a metal such as
aluminium as the matrix, and reinforce it with fibres such as silicon carbide.
Ceramic Matrix Composites: Used in very high-temperature environments, these materials use ceramic as
the matrix and reinforce it with short fibres, or whiskers such as those made from silicon carbide and boron
nitride.

15. What is composite materials?

A composite material is created by combining two or more constituent materials with notably dissimilar
chemical or physical properties. These materials are merged to form a new material that exhibits properties
distinct from those of its components.

16. Discuss the properties of Silicon Carbide.

High hardness, Low density, Low porosity, Good wear resistance, Excellent corrosion resistance, Low
thermal expansion, High thermal conductivity.
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16 Marks
1. Discuss the effect of alloying elements on steel.
CARBON: Present in all steel and determines the hardness attainable by quenching. Increases tensile
strength, hardness, resistance to wear and lowers ductility and machinability.
ALUMINIUM: Mostly used as a deoxidizer and de-gasifier. Helps in fine-grain formation. Aluminium-killed
steel exhibits high toughness.
ANTIMONY: Harmful to steel as it reduces toughness.
ARSENIC: Injurious to steel as it increases brittleness, and decreases toughness.
BERYLLIUM: Sacrifices toughness for hardenability. Strong affinity to sulphur, hence used very less in alloying.
BORON: Increases the hardenability of steel. Does not affect the ferrite strength of steel, hence
hardenability can be attained without sacrificing ductility or machinability.
CALCIUM: Used for deoxidization, and enhances nonscaling properties of heat conductor alloys.
CHROMIUM: The best element that can be used to increase hardenability. Reduces critical cooling rate
required for martensite formation, therefore improving aptitude for heat treatment.
COBALT: Increases hardenabilty at high temperatures, hence used it high speed steels. Encourages the
formation of graphite.
COPPER: Improves corrosion resistance. But it's considered harmful to steel as it concentrates under an
oxide layer, making steel surface liable to suffer in hot working operations.
HYDROGEN: Harmful to steel, decreases strength, and reduces the area of steel. Also acts as a decarburizing
agent.
LEAD: Improves machinability when added in small amounts and helps in the formation of clean surfaces.
MANGANESE: Increases hardenability, tensile strength, resistance to wear, and increases rate of carbon
penetration.
MOLYBDENUM: Reduces critical cooling rate and improves hardenability, toughness, and strength at
elevated temperatures.
Helps prevent brittleness and promotes fine-grained structures. Increases yield point and tensile strength.
NICKEL: Increases impact strength, hence used for case hardening. It broadens the temperature range for
heat treatment. Increases strength without decreasing ductility and toughness.
NITROGEN: Increases hardness, tensile, and yield strength, but decreases toughness and ductility.
OXYGEN: Injurious to steel, as it weakens mechanical properties like impact strength, and brittleness.
PHOSPHORUS: Increases strength and hardness of hot rolled steel, but sacrifices ductility and toughness.
SILICON: Enhances resistance, hence used for alloying in high-temperature steels. It impairs workability and
machinability.
SULPHUR: Shows the strongest tendency to segregate. To remove its disadvantages, it is mixed with
manganese for manganese sulfide has a high melting point which increases the melting point of steel.
TIN: Can render steel susceptible to temper embrittlement and hot shortness.
VANADIUM: Increases the hardenability of medium carbon steel, and improves red hardness and dimension
overheating.
TUNGSTEN: Improves toughness, and increases wear resistance at high temperatures. Used in high-speed
and high-temperature steels.

2. Discuss the classification, properties, and application of copper and its alloys.
Classification of Copper Alloys:
1. Pure Copper:
o Composition: Contains at least 99.9% copper.
o Properties:
 Excellent electrical conductivity.
 Good corrosion resistance.
 Malleable and ductile.
o Applications:
 Electrical wiring and conductors.
 Busbars.
 Roofing and architectural elements.
2. Brass:
o Composition: Copper alloyed with zinc.
o Properties:
 Varies based on the zinc content.
 Yellowish color.
 Good machinability.
 o Applications:
 Musical instruments (trumpets, saxophones).
 Decorative items.
 Plumbing fittings.
3. Bronze:
o Composition: Copper alloyed with tin (and sometimes other elements).
o Properties:
 Harder than pure copper.
 Excellent corrosion resistance.
 Used for bearings, gears, and sculptures.
4. Copper-Nickel Alloys:
o Composition: Copper alloyed with nickel.
o Properties:
 High resistance to seawater corrosion.
 Used in marine applications (shipbuilding, heat exchangers).
5. Beryllium Copper:
o Composition: Copper alloyed with beryllium.
o Properties:
 High strength.
 Excellent spring properties.
 Used in electrical connectors and tools.

Key Properties of Copper Alloys:

 Heat Conductivity: Excellent for heat exchangers and electrical applications.
 Electrical Conductivity: Essential for wiring, busbars, and electrical components.
 Corrosion Resistance: Suitable for outdoor and marine environments.
 Machinability: Easy to work with for various manufacturing processes.
 Biofouling Resistance: Resists biological growth in water systems.
 Mechanical Properties at Cryogenic Temperatures: Retains strength even at low temperatures.
 Non-Magnetic: Useful in applications where magnetism is undesirable.

Applications of Copper and Copper Alloys

1. Building Industry:
o Roofing, cladding, rainwater systems.
o Heating systems, water pipes, and fittings.
o Electrical wiring.
2. Electronic Products:
o Connectors, circuit boards, and switches.
3. Transportation:
o Automotive radiators, heat exchangers.
o Busbars for electric vehicles.
4. Consumer Products:
o Cookware, utensils, and decorative items.
5. Industrial Machinery:
o Bearings, gears, and hydraulic systems.

3. Discuss the classification, properties, and application of aluminium and its alloys.
Classification of Aluminium Alloys:
1. Wrought Alloys: These alloys are extensively used for various applications. They can be further
categorized into:
 o Heat-Treatable Alloys: These alloys can be strengthened by heat treatment. Common
examples include the 2XXX, 6XXX, and 7XXX series. They find applications in aerospace,
automotive, and structural components.
o Non-Heat-Treatable Alloys: These alloys do not respond significantly to heat treatment. The
1XXX, 3XXX, and 5XXX series fall into this category. They are widely used in applications such
as cooking utensils, electrical conductors, and architectural components.
2. Cast Alloys: These alloys are primarily used for casting processes. They can be further divided into:
o Heat-Treatable Cast Alloys: These alloys can be heat-treated after casting. They belong to the
2XX.X series and are employed in aerospace and automotive applications.
o Non-Heat-Treatable Cast Alloys: These alloys retain their properties after casting. The 3XX.X
series falls into this category and is commonly used for castings like engine blocks and
housings.

Properties of Aluminium and Its Alloys

1. Pure Aluminium (1XXX Series):
o Soft, ductile, and corrosion-resistant.
o Excellent electrical conductivity.
o Used for foil, conductor cables, and lightweight applications.
2. Aluminium Alloys:
o Strength-to-Weight Ratio: Superior to steel.
o Formability: Easily shaped into various forms.
o Corrosion Resistance: Especially in marine environments.
o Recyclability: Environmentally compelling due to efficient recycling.
o Lightness: Ideal for aerospace and transportation industries.

Applications of Aluminium and Its Alloys

1. Transportation:
o Aircraft components (wings, fuselage, etc.).
o Automotive parts (engine blocks, wheels, body panels).
o Bicycle frames.
2. Construction and Architecture:
o Window frames, doors, and curtain walls.
o Structural members (beams, columns).
o Roofing and cladding.
3. Electrical Conductors:
o Overhead power lines.
o Electrical cables.
4. Packaging:
o Foil for food packaging.
o Beverage cans.
5. Consumer Goods:
o Utensils, cookware, and kitchen appliances.
o Furniture frames.

4. Discuss the properties and application of engineering polymers.

Polypropylene: It serves as both plastic and fibre and does not melt before 160 C.
Properties: High melting point, Stress-crack resistant, Susceptible to strong oxidising agents
Applications: Used to make indoor-outdoor carpeting, swimming pools, and golf courses.

Polyethylene:
Properties: High molecular weight, Stress - crack resistance
Applications: Used to make bulletproof jackets, plastic films, and large storage tanks.
Polystyrene: Aromatic polymer. Transparent and can be converted into various colours
Properties: High thermal conductance, Lightweight
Applications: Used in toys, aerospace, and architectural fields, computers, insulation in buildings, and
kitchen appliances.

Polyvinyl Chloride: Bulk-free polymer of vinyl chloride. Unstable when compared to others.
Properties: Resistant to hydrocarbons, Very flexible to modify into desired product
Applications: Used as stabilizers, pipe fittings, floor coverings, and wall coverings.

Polymethyl methacrylate: Transparent, amorphous.

Properties: Hard and stiff, Brittle
Applications: Used in sinks, baths, displays, signs, lenses, and light covers.

5. Discuss the properties and application of ceramics.

Ceramics are inorganic, nonmetallic materials. The desired properties are attained through high high-
temperature heat treatment process called firing. Alumina is the most commonly used ceramic. It is readily
available and reasonably priced. It has a wide range of applications.

Properties:
Hard, wear-resistant
Excellent dielectric properties
Good thermal conductivity
Excellent size and shape capability
High strength and stiffness

Applications:
Used for making pottery, and decorative items.
Used in the production of bricks, tiles, and building materials.
Used in electronic components like capacitors, and insulators.
Used in the biomedical field for implants, dental, and medical devices.
Used in the aerospace field for turbine blades and shields.
Used in the automobile field as brakes.

6. Discuss the different types of composites.

Composite materials are fascinating because they combine the strengths of different constituents to create
materials with unique properties.
Composite Laminate:
Layered and versatile.
Consists of multiple layers (plies) of different materials bonded together.
Commonly used in aerospace, sports equipment, and structural applications.
Thermoplastic Composites:
Recyclable and remoldable.
Made from a polymer matrix (thermoplastic) reinforced with fibers.
Can be heated and reshaped without losing their properties.
Used in automotive parts, consumer goods, and industrial applications.
Thermosetting Composites:
Irreversible and rigid.
Polymer matrix (thermoset) reinforced with fibers.
Cured through heat or chemical reactions, becoming rigid and durable.
Widely used in aircraft components, boat hulls, and electrical insulators.
Fiber-Reinforced Polymer (FRP) Composites:
Strong and lightweight.
Polymer matrix reinforced with engineered, man-made, or natural fibers (e.g., glass, carbon, aramid).
Used in construction, automotive parts, and sporting goods.
Natural Fiber Composites:
Eco-friendly and biodegradable.
Combine natural fibers (such as jute, hemp, or flax) with a polymer matrix.
Used in furniture, packaging, and eco-conscious applications.
Metal Matrix Composites (MMC):
Reinforced with metallic or ceramic particles within a metal matrix.
Enhance strength, stiffness, and wear resistance.
Applied in aerospace, automotive, and electronic components.
Polymer Matrix Composites (PMC):
Reinforced with fibers (e.g., carbon, glass, or aramid) in a polymer matrix.
Lightweight, corrosion-resistant, and strong.
Used in aircraft, marine vessels, and sporting goods.
Ceramic Matrix Composites (CMC):
Ceramic fibers embedded in a ceramic matrix.
High-temperature resistance, low thermal expansion, and excellent mechanical properties.
Used in gas turbines, aerospace components, and brake discs.

7. Discuss the composition, properties, and applications of the following cast iron.
(i) Ductile cast iron and (ii) Grey cast iron.
Ductile cast iron, also known as nodular cast iron or spheroidal graphite iron, is a remarkable material with
properties that bridge the gap between traditional cast iron and steel.

Composition:
Carbon: Typically contains 3.2% to 3.6% carbon.
Silicon: Ranges from 2.2% to 2.8%.
Manganese: Approximately 0.1% to 0.2%.
Magnesium: Typically 0.03% to 0.04%.
Phosphorus: Usually 0.005% to 0.04%.
Sulfur: Typically 0.005% to 0.02%.
Copper: Less than 0.4%.
Iron: Constitutes the remaining 94%1.
Additionally, alloying elements like tin, chromium, and nickel can be added to enhance specific properties.

Properties:
Strength: Ductile iron exhibits mechanical properties comparable to steel.
Ductility: Unlike brittle cast iron, it has ductile characteristics due to its unique microstructure.
Elasticity: Retains high fluidity when molten.
Shock Resistance: Stronger and more shock-resistant than gray iron.
Corrosion Resistance: Improved by adding chromium and nickel.
Microstructure: Graphite is present in nodular or spheroidal form, enhancing ductility1.

Applications:
Automotive Industry: Engine components, crankshafts, camshafts, and gears.
Construction: Pipe fittings, manhole covers, and structural components.
Industrial Machinery: Pump housings, valve bodies, and hydraulic components.
Wind Power Industry: Machine frames.
Pipelines: Corrosion-resistant pipes.
General Engineering: Where strength, ductility, and cost-effectiveness matter
Grey cast iron Composition:
Grey cast iron, also known as gray iron, is primarily composed of iron (Fe) and carbon. Its carbon content
typically ranges from 2.5% to 4%. In addition to carbon, grey cast iron contains small amounts of other
elements such as silicon (Si), manganese (Mn), phosphorus (P), and sulfur (S).

Properties of grey cast iron:

Low Cost: Grey cast iron is an economical material.
Brittle: It is quite brittle due to the presence of graphite flakes.
High Compressive Strength: Grey cast iron exhibits impressive compressive strength.
Effective in Damping Vibrations: Its damping properties make it suitable for applications where vibration
reduction is essential.
Good Casting Characteristics: Grey cast iron is easy to cast.
Lower Melting Point Than Steel: Its melting point is lower than that of steel.
Excellent Machinability: Grey cast iron can be machined effectively.
Limited Malleability: Unlike some other materials, grey cast iron is not malleable at any temperature.
Less Ductility: It cannot be easily rolled, drawn, or worked at room temperature.

Applications:
Pressure Vessels: Used in the construction of pressure vessels.
Clutch Plates: Found in automotive clutch systems.
Pistons: Used for certain types of pistons.
Cylinder Heads: Commonly employed in engine cylinder heads.
Base Structures for Machines and Heavy Equipment: Provides a sturdy foundation for machinery exposed to
vibrations.
Fittings, Levers, and Valves: Used in various mechanical components

8. Discuss the properties and application of tool and die steels.

Tool and die steels are essential materials used in the production of tools, dies, and other components for
machining metals, plastics, and wood.

Properties of Tool and Die Steels:

Hardness: Tool steels exhibit high hardness due to their carbon content, typically ranging from 0.7% to 1.5%.
Some variants can even contain up to 2.1% carbon.
Wear Resistance: These steels are wear-resistant, making them ideal for applications involving cutting,
punching, drilling, and grinding.
Toughness: Tool and die steels possess toughness, allowing them to withstand mechanical stresses during
use.
Heat Resistance: They maintain their properties at elevated temperatures, which is crucial for tool longevity.
Alloying Elements: Chromium, vanadium, molybdenum, and tungsten are common alloying elements that
enhance specific properties.

Applications of Tool and Die Steels:

Chisels: Used for cutting and shaping materials.
Forging Dies: Essential for shaping metal components.
Hammers and Drills: Tool steels withstand impact forces during drilling and forging.
Cutters and Shear Blades: These steels provide durability for cutting operations.
Razors: Tool steels are used in the manufacturing of razor blades.
Additional Information:
Tool steels are heat-treatable, allowing for precise control over their hardness and performance.
They find applications in metal stamping, forming, shearing, and plastic forming.
Some tool steels are produced using powder metallurgy or specialized processes.