UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___1_____________

Paper No: ________EG2101________ Page No: ___1__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

K c a 0.003
a) For the aluminium fuselage: = 400 =38.8 MPa m1/2,
which is lower than the fracture toughness of the alloy, therefore it wont fail by
fast fracture. [6 marks]

b) Miners Rule determines the fatigue failure under cumulative loading modes. If
there are k different stress levels of cyclic loading and the number of cycles to
failure at a stress is Nfi, then the damage fraction at this cyclic is Ni / Nfi, where
Ni is the number of cycles at this stress level. Failure occurs when the sum of
the damage fraction reaches 1. [4 marks]

c)
10 5 106
(I) + =0.12<1
10 6 5 107

therefore the alloy will not experience fatigue fracture under the
situation (I)
[5 marks]
4 5 5
10 10 10
(I) 6
+ 7
+ 4
=5.01>1
10 5 10 2 10

therefore the alloy will experience fatigue fracture under the situation
(II)
[5 marks]

Setter: __________HD________________

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 Co-ordinator: ________________________

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 UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ________2_________

Paper No: ___EG2101_________________ Page No: _____________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(a)

[3 marks]
Ceramic shows an elastic-brittle response. It has higher yield stress when it is under
compression
Metal shows elastic-plastic response with ductile necking to the final failure.
Polymer shows ductile response with considerable necking and alignment of polymer
before final extension and failure.
[3 marks]

(b)

(either of the above) - 3marks

3
 a2 + a2 = (4r)2

a=r 8 ; r=a/ 8 = 0.352/ 8 =0.1244nm.

X = a - 2r = 0.351-20.1244 = 0.1032 nm

So the radius of atom that fits into the largest hole is half of the X, = 0.0516nm
[3 marks]

c) Force at the horizontal plane is F, and the shear force (// to the plane) on the
plane at angle is Fsin. Area of the ellipse (plane at angle ) is A/cos.
Hence the shear stress on the plane at angle is

(Fsin)/(A/cos) = (F/A) sincos

when =45, sin cos is at a maximum value of . Therefore the shear

4
 stress on the inclined plane is at a maximum when is 45

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 UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___3_____________

Paper No: ________EG2101_________ Page No: ___1__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(a)

liquidus

Solidus

Max

Label 2 phase regions [3 marks]

(b) Max solubility, liquidus, solidus, Eutectic = 550 C, 33 wt.% Cu

[3 marks]

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6
 UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___3_____________

Paper No: ________EG2101________ Page No: ___2__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(c) reading from the phase diagram; solid forms at ~650 C and is ~ 1 wt.% Cu.
[2 marks]
(d) Draw in tie line on phase diag in Al + L phase field.
CS = 3 wt.% Cu
CL = 13.5 wt.% Cu
C0= 4 wt.% Cu

C SC 0 34
F L= = =0.10
C S C L 313.5

C 0C L 413.5
F S= = =0.90
C SC L 313.5

solid

liquid

[4 marks]

Setter: ___________DPW______________

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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

7
__________________ Year Examinations Solution No: ___3_____________

Paper No: ________EG2101________ Page No: ___3__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(e)

[2 marks]
(log time)
y
Initially solution strengthened. In region a of above figure, initially drops due
to Cu atoms out of solution, thus reducing solid solution strengthening. Then GP
zones are nucleated and grow. Strength increases due to coherency strains. (Under
aged)

In region b of above figure, GP zones dissolve and '' precipitates nucleate and
grow. As particles grow bigger, they are less easy to cut so strength increases.
(Peak aged)

In region c of above figure, particles grow further, and subsequent ' ,

particles form. Spacing increases and it becomes easy for dislocation to bow round,
so strength decreases

Setter: _____________________________

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8
 Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___3_____________

Paper No: ________EG2101________ Page No: ___4__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

Dislocations will cut though small hard particles and bow around large well dispersed
particles via Orowan bowing.

[8 marks]

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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___4_____________

Paper No: ________EG2101________ Page No: ___1__________________

Title of Paper: _____________________ Date: ________________________

9
Part: ____________________________

(a) A structure sensitive property is a property which is sensitive to the detailed

microstructure of the material, while a structure insensitive property is relatively
insensitive to the details of the microstructure. Yield strength, fracture toughness,
ductility, fatigue, corrosion and wear properties are sensitive to the structure of the
material, while the elastic properties, density, thermal expansion and specific heat
are structure insensitive properties. Structure sensitive properties can be controlled
by alloying and selection of an appropriate heat treatment.

[ 4 marks]

Setter: ___________DPW______________

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Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___4_____________

Paper No: ________EG2101________ Page No: ___2__________________

Title of Paper: _____________________ Date: ________________________

10
Part: ____________________________

t
2 a=t a=
(b) If the crack length is 2a and then 2

hence safety is ensured if the stress is always less than or equal to equation 1
C K lc
=

t
2
where C is a constant near unity,
The wall thickness of the pressure vessel is designed to contain the pressure P
without yielding
Pr
h=
t

hence to avoid yielding the hoop stress must be less than the yield stress. To
achieve this, set the thickness in equation 2
Pr
t
y

substitute this into equation 1

C K lc
y=

Pr
2y

Or
2

P ( )
2C 2 K lc
r y

So, the maximum pressure is carried most safely by the material with the greatest
value of
K lc2
M 1= ( )
y

y
This can be maximised by making very small, using say lead, but this would
make the vessel very heavy. Hence, use equation 2. The thinnest wall is the one
y
with the highest so maximise this.
M 2= y

[10 marks]

Setter: _____________________________

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11
 Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___4_____________

Paper No: ________EG2101/________ Page No: ___3_________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(c)
M2

M1

Suitable materials are carbon and stainless steels and low alloy steels most
favourably. Also, Ni alloys, Cu alloys and Al alloys. Ti alloys.
y
Ni and Ti alloys may be rejected on cost grounds. Al and Cu have lower than
steels and so may be rejected.
In a nuclear facility, stainless steel should be used as it resists corrosion. Corrosion
would be very dangerous. In fact, nuclear pressure vessels are usually made from
316 stainless steel.
[6 marks]

Setter: _____________________________

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 Assessor: __________________________

Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___5_____________

Paper No: ________EG2101________ Page No: ___1__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

a) Fracture strength of ceramics depends on the size of flaw it contains. The nature
of ceramic processing is such that defects of variable size are present in the
ceramic. Therefore there is an inherent uncertainty in the failure stress. The failure of
a ceramic component depends on the probability of there being a flaw of a critical
size. So the strength must be described as statistical terms.
[4 marks]

b) Ceramics are brittle because:

Atomic scale: (1) Strong directional bonding prevents plastic deformation; little or no
mobility of dislocations. Therefore individual grain is brittle. Any weakness in a grain
will cause the entire grain to fracture. (2) Also for ionic bonding, there is not enough
slip systems for plasticity even if the dislocation could move.
- Microstructural scale: there are several types of microstructural scale defects
(flaws) formed during processing.
(1) Weak gain boundaries due to the incomplete
(2) Porosity at grain boundaries
(3) Different thermal contraction causes grains to crush, leaving residual
stress at room temperature
These defects (flaws) act as stress concentration. When crack occurs, no plasticity
to absorb energy. Therefore the ceramics are brittle at the microstructural scale. [6
marks]

Setter: _____________________________

13
 Assessor: __________________________

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UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___5_____________

Paper No: ________EG2101________ Page No: ___2__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

c) For the bottle: d = 0.08m r = 0.04m.

l = 0.18 m
t =0.0025 m
Weibull Modulus m = 12
V =2 rlt=2 0.04 0.18 0.0025=1.13 104 m3

Max probability Ps (V) = 1-0.002% =0.99998

For the test specimen: d = 0.006m r = 0.003m

l = 0.06m
V 0= r l = ( 0.003 )2 0.06=1.7 106 m3
2

Ps (V0) = 1-50% =0.5

{[ ]}
12

Ps ( V 0 )=10.5=exp
0

The probability of survival for the test specimen: Ps (V 0) equation 1:

{[ ]}
12
50
Ps ( V 0 )=0.5=exp
0

The probability of survival for the bottle: Ps (V) equation 2

{ [ ]}
12
V max
Ps ( V )=0.99998=exp
V 0 0

Take logs and divide equation 1 by equation 2

ln 0.5
=
{ [ ]}
V 0 50 12
ln 0.99998 V max

6 3 12
0.693147
2.00002 1 0
5
=
1.7 10 m 50
1.13 1 0 m max
4 3 [ ]
12
34657=0.01504
50
[ ]
max

max =14.75 MPa

14
 Pr 14.75 MPa 0.04 m
h= = =236 MPa
t 0.0025 m

[10 marks]

Setter: ___________DPW______________

Assessor: __________________________

Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___6_____________

Paper No: ________EG2101________ Page No: ___1__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(a) label fine pearlite, coarse pearlite, upper and lower bainite, 0%, 50% and 100%
transformation. Austenite and unstable austenite. [4 marks]

15
 Setter: _____________________________

Assessor: __________________________

Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___6_____________

Paper No: ________EG2101________ Page No: ___2__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(b) (i) as above plus . A mixture of pearlite and ferrite, or normalised steel: laminar
structure of Fe3C and ferrite(bcc) with crystals of pre-eutectoid ferrite.

pearlite

ferrite

[3 marks]

b(ii)
(i). Martensite is formed. Martensite is formed when austenite is quenched at such
a high rate that the C atoms do not have time to diffuse and form Fe3C. It forms
lenticular grains of a highly strained body centred tetragonal structure with a high
dislocation density. This gives very high hardness but very low toughness.

[3marks]

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 Setter: _____________________________

Assessor: __________________________

Co-ordinator: ________________________
UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___6_____________

Paper No: ________EG2101________ Page No: ___3__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

b (iii) In tempering the martensite is heated to over 200 C and Fe3C begins to
precipitate out of the martensite producing a fine dispersion of cementite
nanoparticles in ferrite

[3 marks]

b(iv) pearlite/ferrite is ductile and can readily be hot worked allowing the shape of the
helmet to be beaten to shape due to a low yield stress. This is too soft to be of much
use as armour. Martensite is hard with high yield stress but very brittle and will
shatter readily making it of little use as armour. Tempered martensite has a lower
yield stress than martensite but higher than pearlite, the nano dispersion hinders
dislocation motion. Toughness is significantly higher than martensite.
[3 marks]

17
 Setter: ____________DPW____________

Assessor: __________________________

Co-ordinator: ________________________

UNIVERSITY OF LEICESTER ENGINEERING DEPARTMENT

__________________ Year Examinations Solution No: ___6_____________

Paper No: ________EG2101________ Page No: ___4__________________

Title of Paper: _____________________ Date: ________________________

Part: ____________________________

(c)
Mo, Mn, Cr and Ni all shift the bainite nose to longer time. This increases the
HARDENABILITY of the steel. (i.e. Jominy test). This allows thicker sections may be
quenched to martensite.

Elemental content / wt.%

C M Si Ni Cr M V
n o
0. 0. 0. 2. 0.76 0. -
33 61 18 82 56
0. 0. 0. - 2.0 - 0.
5 67 27 1

18
 In C In In Incr Fo st
cr o cr cr ease r ab
ea m ea ea s m le
se bi se se hard s ca
s ne s s ena st rbi
st s st to bilit ab de
re wi re ug y le s.
ng th ng hn ca In
th S th es rb cr
bu to s id ea
t m es se
re ak an s
du e d yi
ce le in el
s ss hi d
du br bi str
cti itt ts es
lit le gr s
y ai wh
n ile
gr ret
o ai
wt ni
h. ng
Si du
gn cti
if lity
ca .
nt Hi
to gh
ug te
he m
ne p
r to
ug
hn
es
s.

The German and British armours are of comparable thickness and hardness. The
German armour contains no Mo and this makes the steel less tough. The Germans
had run out of Mo by the end of the war and had increased the C, Cr and V content
of their steel to compensate. While it is possible to heat treat the steel indicated to
give impact resistance, this is not the case and in fact the armour contained
tempered bainite indicating a slack quench.

[4 marks]

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19
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20