KAMPALA INTERNATIONAL UNIVERSITY

MEC1208 MATERIAL SCIENCE I

REVIEW QUESTIONS FOR ESE.
QUESTION 1 [25 POINTS]
1.1 The tensile test is a very important test used to evaluate the mechanical properties of engineering
materials. Give a brief description of the tensile test indicating the following:
1.1.1 Test piece [3 points]
1.1.2 Test procedure [2 point]
1.1.3 Data collected [3 points]
1.1.4 Definitions of derived values [5 points]
1.2 In a tensile test a test piece fractured at a stress of 860 N/mm2. The reduction in area (Z) was 37%.
Calculate the true stress and true strain at fracture. [12 points]

QUESTION 2a (25 MARKS)

The following data were collected from a 20-mm diameter test specimen of ductile cast iron (lo =
40.00 mm):

After fracture, the total length was 47.42 mm and the diameter was 18.35 mm. Plot the data and
Calculate: (a) the 0.2% offset yield strength; (b) the tensile strength; (c) the modulus of elasticity; (d) the
% elongation; (e) the % reduction in area; (f) the engineering stress at fracture; (g) the true stress at
fracture; and (h) the modulus of resilience.

QUESTION 2B [25 POINTS]

2.1 A Brinell hardness measurement, using a 10-mm diameter indenter and a 500-kg load, produces an
indentation of 4.5 mm on an aluminum plate. Determine the Brinell hardness number (HB) of the
metal. [4 points]
2.2 When a 3000-kg load is applied to a 10-mm diameter ball in a Brinell test of a steel, an indentation
of 3.1 mm is produced. Estimate the tensile strength of the steel. [3 points]
For questions 2.3 to 2.26 note down the correct answer out of the choices given. Each question is
worth 0.5 points (total 12 pts).
2.3 The measure of how a signal from a defect compared to other background reflections is called: (a)
Acoustic impedance, (b) Signal to noise ratio, (c) refraction (d) Reflection (0.5)
2.4 When a single element transducer is operating in the pulse echo mode, the element: (a) Can not
start receiving reflected signals until the element has stopped ringing from its transmit function, (b)

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 Needs to have a high pulse rate, (c) Should be used in the dual mode, (d) Can only be made with
lithium sulphate. (0.5)
2.5 In an angle beam testing, when the geometry of the parts is relatively uncomplicated and the
orientation of a flaw is well known, the length of a crack can be determined by a technique known
as: (a) Tip diffraction (b) Immersion (c) Surface mode diffraction (d) contact testing. (0.5)
2.6 What type of a set-up can provide information about the size of the flaw and the distance between
the flaw and the transducer? (a) Through transmission, (b) Pitch/catch with two transducers (c) Pulse
Echo, (d) paint brush transducer. (0.5)
2.7 Angle beam transducers and wedges are typically used to introduce a: (a) reflected shear wave into
the part, (b) Longitudinal wave into the part (c) Shear wave into the part (d) compression wave into
the part. (0.5)
2.8 Mode conversion, occurs when a sound wave encounters an interface between materials of
different acoustic impedance and (a) One of the two materials is a liquid, (b) The incident angle is
greater than first critical angle, (c) the incident angle is greater than the second critical angle, (d) the
incident angle is not normal to the interface. (0.5)
2.9 What is the correct formula for calculating the wavelength when the wave velocity and frequency
are known? (a) Wavelength = (Velocity)/(Frequency), (b) Wavelength = (Velocity) x (frequency), (c)
Wavelength = (Frequency)/Velocity, (d) Wavelength = (Frequency)/ (Velocity). (0.5)
2.10 The active element of most acoustic transducers used today is: (a) Lithium, (b) Piezoelectric ceramic,
(c) Sulphide, (d) Quartz. (0.5) 12
2.11 LPI developers come in a variety of forms and can be applied by: (a) Dusting (b) Dipping (c) Spraying
(d) All in (a), (b), and (c) (0.5)
2.12 The total time that the penetrant is in contact with the part surface is called the: (a) Soak time (b)
Baking time (c) Dwell time (d) Immersion time. (0.5)1
2.13 Penetrant can be applied by: (a) Dipping (b) Brushing (c) Spraying (d) All (a, b, and c) (0.5)1.5
2.14 Which emulsifier system is water based? (a) Hydrophilic emulsifier (b) Lipophilic emulsifier (c) Type
I emulsifier (d) Form A emulsifier. (0.5)2
2.15 A developer is required to: (a) Draw out the penetrant from the discontinuity, (b) Provide contrast
between the penetrant and the parts background color, (c) Increase the penetrant’s fluorescence,
(d) Both (a) and (b). (0.5)2.5
2.16 Post emulsified penetrants: (a) Are most often used in the field, (b) Should never be used in the field,
(c) Require a separate emulsifier to break the penetrant down and make it water washable, (d)
Require a separate emulsifier to break down the cleaner and make it solvent removable. (0.5)3
2.17 Once the surface of the part has been cleaned properly, penetrant can be applied by: (a) Spraying,
(b) Brushing, (c) Dipping, (d) All in a, b, and c. (0.5)3.5
2.18 Which of the following is an advantage to LPI? (a) Large areas can be inspected, (b) Parts with
complex shapes can be inspected, (c) It is portable, (d) All in a, b and c are advantages. (0.5)4
2.19 Developers are used to: (a) Make the penetrant fluoresce, (b) Reduce the dwell time, (c) Pull trapped
penetrant material out of the defect, (d) All in a, b, and c. (0.5)4.5
2.20 A penetrant must: (a) Change viscosity in order to spread over the surface of the part, (b) Spread
easily over the surface of the material, (c) Have a low flash point, (d) Be able to change color in order
to fluoresce. (0.5)5

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2.21 Dry developer can be applied: (a) To a wet part, (b) To a partially wet part but needs to be placed in
a dryer immediately, (c) To a dry part, (d) All in a, b and c. (0.5)5.5
2.22 Penetrants are designed to: (a) Perform equally, (b) Perform the same no matter who manufactures
them, (c) Shift in grade and value when the temperature changes, (d) Remain fluid so it can be drawn
back to the surface of the part. (0.5)6
2.23 The advantage that liquid penetrant testing has over an unaided visual inspection is that: (a) The
actual size of the discontinuity can be measured, (b) The depth of the defect can be measured, (c)
The cause of the impact can be seen, (d) It makes defects easier to see for the inspector. (0.5)6.5
2.24 A good cleaning procedure will: (a) Remove all contamination from the part and not leave any
residue that may interfere with the inspection process, (b) Remove a small amount of metal from
the surface of the part, (c) Should leave the part slightly flourescent in order to identify any
discontinuities, (d) Should etch the part slightly only if it is made from 4041 aluminium. (0.5)7
2.25 It is well recognized that machining, honing, lapping and hand sanding will result: (a) In a better
penetrant inspection, (b) In a longer dwell time in order to produce adequate penetration of the
penetrant, (c) Longer dwell times, (d) Metal smearing. (0.5)7.5
2.26 Which penetrant method is easiest to use in the field? (a) Fluorescent, post-emulsifiable (b) Visible
dye, water washable (c) Visible dye, solvent removable, (d) Fluorescent, water washable. (0.5) 8

2.27 A cylindrical acetal polymer bar 20 cm long and 1.5 cm in diameter is subjected to a vibrational load
at a frequency of 500 vibrations per minute with a load of 50 N. How many hours will the part survive
before breaking? (See Figure 7–29) [6 points]

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Figure 7.29 The S-N Curve a Acetal polymer.

QUESTION 3 [25 POINTS]

3.1 State at least five factors that can influence the impact strength and transition temperature of bcc
steels. [5 points]
3.2 If you had a choice between an aluminum alloy, austenitic stainless steel, a plain low carbon steel
and a plain high carbon steel alloy (all of which offer appropriate strength for the application) for a
structural steel application in the Arctic regions, which would you choose? Why? (6 pts)
3.3 Explain briefly why it is allowed to change the weight of the pendulum in the Charpy V-notch
impact test but not the fixed elevation from which the pendulum starts to swing. [7 points]
3.4 The following data were obtained from a series of Charpy impact tests performed on four steels,
each having a different manganese content. Plot the data and determine: (a) the transition
temperature (defined by the mean of the absorbed energies in the ductile and brittle regions); and
(b) the transition temperature (defined as the temperature that provides 50 J of absorbed energy).

QUESTION 4 (25 MARKS)

In a rotating bending fatigue test, five specimens were tested and found to have the following results:
Specimen S=a [N/mm2] Number of Cycles N Remarks
1 520 5x104 Broken
2 440 1x106 Broken
6
3 422 2x10 Broken
4 420 3x106 Not broken
7
5 420 1x10 Not broken
4.1 Estimate the endurance limit of the material by plotting a detailed graph. [5 points]
4.2 Calculate from the data given the number of cycles until fracture and the time to fracture for a
specimen with stress amplitude a= 500 N/mm2, if the testing machine is running at 5000
revolutions per minute. [10 points]
4.3 Distinguish clearly between the terms: endurance limit and fatigue strength as it is applied to
fatigue testing. [5 points]
4.4 Briefly explain the difference in endurance limit of steels under rotation bending and
tension/compression loading conditions. [5 points]

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QUESTION 5 (20 MARKS)
5.1 Non-destructive testing by Radiographic inspection is widely use for examining defects in welds
and castings. Sketch a schematic of a set up you would use in such an examination describing its
basic components. (10 pts)
5.2.1 Explain why in the compression test the ratio of the specimen height to diameter is kept to a value
less than 3. (3 pts)
5.2.2 Mention two types of bend tests and explain briefly why each is performed. (5 pts)
5.2.3 Why are brittle materials like concrete tested in compression? (2pts)

Question 6 (20 marks)

6.1 Name four types of material classes discussed in class during the discussion of type of materials.
[4 marks].
6.2 What would you consider the most important basic properties of metals (at least 4) [4
marks]
6.3 Use figure 8.14 to help you answer the following questions:
6.3.1 Estimate with justification the recovery, recrystallization, and grain growth temperatures.
[6 marks]
6.3.2 Estimate with justification the melting temperature of the alloy. [ 2 marks]

0 C

Question 7 (18 marks)

7.1 Sate Schmid’s Law. Apply with the assistance of a sketch, Schmid’s law to a situation in which the
single crystal is at an orientation so that the slip plane is perpendicular to the applied tensile stress.
[10 marks]
7.2 In most applications Human beings strive for order, harmony, and perfection; alas this is not the
case in the engineering materials realm. Briefly explain why imperfections (defects) are
sometimes desirable in engineering materials. [3 marks]
7.3 The yield strength of mild steel with an average grain size of 0.05 mm is 137.8 MPa. The yield
stress of the same steel with a grain size of 0.007 mm is 275.6 MPa. What will be the average
grain size of the same steel with a yield stress of 206.7 MPa? Assume the Hall-Petch equation is
valid and that changes in the observed yield stress are due to changes in grain size.
[5marks]

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Question 8 (10 marks)
8.1 Derive with the assistance of a sketch Bragg’s law by using a simple case of incident X-ray beams
being diffracted by parallel planes on a crystal and state what it is mainly used for. (6 pts)6
8.2 A sample of BCC metal was placed on an x-ray diffractometer using X-rays with a wavelength of
λ = 0.1541 nm. Diffraction from the (221) planes was obtained at 2θ = 88.838o. Calculate a value
for the lattice constant a for this BCC elemental metal. (Assume first order diffraction, n = 1) (4
marks)

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