DEPARTMENT OF MECHANICAL ENGINEERING

ME6403 - Engineering Materials And Metallurgy

1. What are the two types of Deformation in metals?

Plastic Deformation
Elastic Deformation
2. What is plastic deformation?
When a body is subjected to a force, it will tend to deform. When the deformation
exceeds the elastic limit it will not regain to its original form
3. What is Elastic deformation?
When a body is subjected to a force, it will tend to deform. When the deformation with in
the elastic limit it will regain to its original form
4. In what ways plastic deformation takes place?
Two methods
1.Slipping
2.Twinning
5.Define slipping.
It is defined as the shear transformation, which moves the atoms over a number of
interatomic distances relative to their initial position.
6.Define Twinning.
It is the two plastic deformations which takes place along two planes due to set of forces
acting on a given metal.
7.Define fracture.
Separation of Solids in to two Parts.
8. What are the two components of the p[process of fracture?
Crack initiation
Crack propagation
9. What are the different types of fracture/
Brittle
Ductile
Fatigue
Creep
10. What is the use of izod test?
To determine the impact strength of the material
11.What is the yield strength?
The material yield with out a change in the load
12.What are the tests conducted in the material?
Impact test,hardness test,shear test,tensile test,fatigue test,creep test
13. What is fatigue fracture?
It is the fracture that occurs under repeatedly applied fatigue stresses
14. What is Brittle fracture?
It takes place with minimum of plastic deformation and very rapid crack
Propagation.
15. What is creep fracture?
It is the fracture that takes place due to excessive creeping of metals under steady loading
and high temperature.
16. What is the need of mechanical test?
In order to determine which material is best by knowing the properties such as
hardness,ductility,Strength.

17.. Differentiate Toughness and Stiffness

Toughness is the property of a material by vi which it can absorb maximum energy before
fracture place. resists deformation. virtue of which it Stiffness is the property of a material by
f metals
18. What is creep?
Creep is defined as plastic flow under constant stress and although the majority of tests
are carried out under constant load conditions, equipment is available for reducing the loading
during the test to compensate for the small reduction in cross-section of the specimen.
19. Define slip.
It is defined as the shear transformation, which moves the atoms over a number of
interatomic distances relative to their initial position.
20. Name different types of facture.
Fatigue fracture
Brittle fracture
creep fracture
21. What properties are determined from tensile testing of metallic products?
22. Define toughness.
Toughness is the property of a material by vi which it can absorb maximum energy before
fracture place. resists deformation.
23. Define notch sensitivity
It refers to the tendency of some ductile materials to behave like brittle materials in presesnce of
notches
24. List any four technological properties
1. Machinability, 2. Castability, 3. Weldability, and 4. Formability or workability
25. What are the factors affecting mechanical properties?
1. Grain size, 2. Heat treatment, 3. Atmospheric exposure, and 4. Low and high
temperatures.
26.State the advantages of Rockwell hardness test over the Brinell and Vickers hardness test.
Advantages of the Rockwell hardness method include the direct Rockwell
hardness number readout and rapid testing time.
27.What is Charpy test
The Charpy impact test, also known as the Charpy v-notch test, is a
standardized high strain-rate test which determines the amount of energy
absorbed by a material during fracture. This absorbed energy is a measure of
a given material's toughness and acts as a tool to study temperaturedependent
brittle-ductile transition.
28.What is fatigue test S-N curve?
fatigue is the progressive and localized structural
damage that occurs when a material is subjected to cyclic loading. The
nominal maximum stress values are less than the ultimate tensile stress limit,
and may be below the yield stress limit of the material.
29. What is the effect of the grain size on the mechanical properties of the materials?
The materials having smaller grains (i.e., fine grained structure) have high yield strength, high
tensile strength, and more hardness. Also fine grain results in better resistance to cracking and
better surface finish The materials having larger grains (i.e., coarse grained structure), exhibit
better workability, hardenability, forgeability and creep resistance. But coarse grains result in
poor surface finish, less tough and have greater tendency to cause distortion
30.Define fatigue strength in fatigue test.
fatigue is the progressive and localized structural
damage that occurs when a material is subjected to cyclic loading. The ability of the material to
withstand this fatigue load without permanent deformation is called fatigue strength
31. What is the effect of heat treatment on the mechanical properties of the materials?
The heat treatment improves mechanical properties like tensile strength, toughness,
hardness, ductility, shock resistance and resistance to corrosion. It also improves forgeability and
mach inability of metals.
32. , Distinguish between elasticity and Plasticity .
Elasticity is the property of a matersialilc by virtue of which it is able to retain its original shape
and size after the removal of the load. Plasticity is the property of a material by virtue of which a
permanent deformation (without fracture) takes place, whenever it is subjected to the action of
external forces
33. Differentiate between ductility and malleability.
Ductility is the property of a material by virtue of which it can he drawn into wires before
rupture takes place. Malleability is the property of a material by virtue of which it can withstand
deformation under compression without rupture
34. Define the terms brittleness and hardness.

Brittleness is the property of a material by virtue of which it can withstand deformation under
compression without rupture. Hardness is the property of a material by virtue of which it is able
to resist abrasion, indentation (or penetration), machining, and scratching.

35.What is meant by creep fracture?

36.Sketch a creep curve explaining different stages of it.
Primary
Secondary
tertiary
37.Define endurance limit in fatigue test.
38. What properties are determined from tension testing of metallic products?
It describes the resistance of a material under slowly applied stress
39. In general, HCP metals are hard and brittle while FCC metals are soft and ductile. Why?
40. list mechanical tests
Impact
hardness
tensile
Shear
fatigue
creep
41. Define twinning.

42. What are the types of twins?

Mechanical twins

Annealing twins
43. Define hardness in a material.
Hardness is the property of a material by virtue of which it is able to resist abrasion,
indentation (or penetration), machining, and scratching.

44. What is the use of S-N curve?

Using S-N curve fatigue life of a material can be calculated
45. Define creep
It is defined as the time-dependent and permanent
deformation of materials when subjected to a constant load or stress, creep is normally

46.Write down the various mechanical test.

Charpy test
izod test
Brinell hardness test
Vickers hardness test
Rockwell hardness test

47. What is meant by fracture?

Fracture is the mechanical failure of the material which will produce the separation or
fragmentation of a solid into two or more parts under the action ol stresses.

48. List the stages of creep?

Primary creep
 Secondary creep

Tertiary creep

49.What are the tests conducted in the material?

50. What is ductile fracture?
Ductile fracture may be defined as the fracture which takes place by a slow propagation
of crack with appreciable plastic deformation.
51.What is Brittle fracture?
A brittle fracture may be defined as a fracture which takes place by the rapid propagation of
crack with a negligible deformation.
52.What is creep fracture?
It is a defined as property of a material by virtue of which it deforms continusuly under a steady
load
53. How can you prevent the ductile fracture?
In order to prevent the ductile fracture, the material should have the following characteristics:
The material should have fine grains. It should have higher hardness value. It should have higher
Young's modulus and cohesi4, energy. It should not have any defects/dislocations.
54.What are the two types of Deformation in metals?
plastic deformation
elastic deformation
55.What is plastic deformation?
Plastic deformation is a change of the material dimensions remaining after
removal of the load caused the deformation. Plastic deformations in metals
occurs by slip mechanism
56.What is Elastic deformation?
When a body is subjected to a force, it will tend to deform. When the deformation
with in the elastic limit it will regain to its original form

57. What is meant by fatigue fracture?

A fatigue fracture is defined as the fracture which takes place under repeatedly applied fatigue
stresses
58.Define slip mechanism
Slip occurs when the shear resolved stress along the gliding planes reaches a critical
value. This critical resolved shear stress is a characteristic of the material.
59.What is Twinning.
It is the two plastic deformations which takes place along two planes due to set of
forces acting on a given metal
60. What is S-N diagram? What is the significance of it?
The S-N diagram is a graph obtained by plotting the number of cycles of stress reversals (N)
required to cause fracture against the applied stress level (S). Using S-N diagram, the fatigue life
of a material can be determined
61. What are the factors affecting fatigue strength?
1. Fatigue strength is influenced by many factors such as chemical composition, grain
size, and amount of cold working. 2. Fatigue strength is high at low temperatures and gradually
decreases with rise in temperature. 3. Environmental effects such as corrosion of the product by
moisture decreases the fatigue strength. 4. The design of the product also influences the fatigue
strength
.62.What are the magnetic properties of materials?
Magnetic susceptibility
Diamagnetism and
paramagnetism
Ferromagnetism
Anti-ferromagnetism and
ferrimagnetism
63. How can you prevent the fatigue fracture?
The following methods can be adopted to prevent the fatigue failure. 1. Use of good
design to avoid stress concentration by eliminating sharp recesses and severe stress raisers. 2.
Control of the surface finish by avoiding damage to surface machining, punching, stamping,
shearing, etc. 3. Reduction of corrosion environmental effects by surface heat treatments like
polishings, coatings, carburizing, nitriding, etc. 4. The material should have fine grain structure
and also it should be free from residual stresses and dislocations.
64. What are the factors affecting creep?
I. Grain 2. Thermal stability of the micro-structure 3. Chemical reactions 4. Prior straits.
65. . How can you prevent the creep fractures?
The following methods can be adopted to prevent the creer failure. I . Use of coarse
grained materials will avoid creep fracture. 2. Strain hardening can be done to avoid creep
fracture. 3. The material should be free from any residual stresses and dislocations. 4.
Precipitation-hardened alloys can be used to avoid fracture.
66.Differentiate destructive and non- destructive testing

In destructive type of testing, the component or specimen to be tested is destroyed and cannot be
reused. In non-destructive type of testing, the component or specimen to be tested is not
destroyed and can be reused after the test..

67. List some important destructive tests carried out on a material.

Tensile test, Impact test, Bend test, Fatigue test, Torsion test, and Creep test.

68. List the main parameters which may be determined in a tensile test.

Limit of proportionality, Yield point or yield strength, Maximum tensile strength, Breaking

strength, Percentage elongation, Percentage reduction in area, and Modulus of elasticity.

69. How does the Rockwell test differ from that of the others?
The principle of the Rockwell test differs from that of the others in that the depth of the
impression is related to the hardness rather than the diameter or diagonal of the impression.

70. Why must Rockwell lest numbers always include a letter, such as Ay By or C?

The Rockwell scales such A, B, or C are used to denote the type and size of the indenter

used and the total indenting load to be applied.

71. What are the causes of twins ?

/. Mechanical twins: Twins that are produced by mechanical deformation are called

mechanical twins.

2. Annealing twins: Twins that are produced by annealing are called annealing twins.

72. What are factors affecting fatigue strength?

Cyclic stress state
Geometry
Surface quality
Material Type
 Residual stresses:
73. What is meant by creep?
It is defined as the time-dependent and permanent
deformation of materials when subjected to a constant load or stress, creep is normally
an undesirable phenomenon and is often the limiting factor in the lifetime of
a part.
74. What are the factors affecting the creep?
Both temperature and applied stress level influence creep behavior. Increasing
either of these parameters produces the following effects:
An increase in the instantaneous initial deformation
An increase in the steady-state creep rate
A diminishment of the rupture lifetime
75. What is the attractive feature of Vickers hardness test?
The advantages of the Vickers
hardness test are that extremely accurate readings can be taken, and just one
type of indenter is used for all types of metals and surface treatments.
76. How does the Rockwell test differ from that of the others?
Advantages of the Rockwell hardness method include the direct Rockwell
hardness number readout and rapid testing time
77. State the limits of Rockwell hardness test over the Brinell and Vickers hardness test
Disadvantages include many arbitrary non-related scales and possible effects from the
specimen support anvil (try putting a cigarette paper under a test block and take note of the effect
on the hardness reading! Vickers and Brinell methods don't suffer from this effect

78. Define the terms slip and twinning.

S Slip may be defined as the sliding of blocks of the crystal over one another along
definite crystallographic planes called slip planes. Twinning is the process in which the atoms in
a part of a crystal subjected to stress, rearrange themselves so that one part of the crystal
becomes a mirror image of the other part

79. State the Schmid's law.

The stress required at a given temperature to initiate slip in a pure and perfect single crystal, or a

material is constant. This is known as Schmid's law.