Engineering Materials and Hardware:

Collection of Revision Questions

Topic: Classification of Materials

1. (a) Engineering materials can be classified into: Ferrous, Non-Ferrous, Non-Metallic, and Composite.
Define each of these terms.

(b) Give some examples of Ferrous and Non-Ferrous materials.

2. (a) What is an Alloy Metal?

(b) Why are other materials such as Carbon, Nickel and Tungsten added to Alloy Metals?

(c) Explain the term ‘Heat Treatment’, and why it is performed on Alloy Metals.

Topic: Characteristics and Properties of Materials

1. Explain the following properties of materials: Hardness, Ductility, Malleability and Tensile Strength.

2. Briefly explain how each of the above properties can be Experimentally Tested.

Topic: Production of Iron Ore and Steel

1. Iron is extracted from Iron Ore deposits in the Earth. What process is used to extract this Iron?
 2. (a) List the raw ingredients in a Blast Furnace which produces Crude Iron.

(b) What elements are added to Crude Iron in order to produce Steel?

3. What is Casting process, and what is it used for?

4. Explain the difference between the Forging and Rolling process.

5. (a) Explain the Extrusion process.

(b) What common Cross-Sections are made using Extrusion?

Topic: Ferrous Alloys and Heat Treatment

1. (a) Explain how Carbon, Silicon and Manganese improve the properties of Steel.

(b) Describe the percentage of Carbon in Low, Medium and High Carbon Steel.

2. State one problem with Heat Treatment of metals.

3. (a) Describe the methods of Annealing, Tempering and Case Hardening of metals.

(b) Why are these methods applied to Steel?

Topic: Non-Ferrous Alloys and Heat Treatment
1. Discuss some properties of Aluminium and Copper Alloys.

2. Using a diagram, describe the process of Precipitation Hardening (Age Hardening).

Topic: Testing of Materials

1. (a) A cylindrical Aluminium sample has a diameter of 28mm. The Yield Stress of Aluminium is 400MPa.
Calculate the Tensile Force is needed to cause the Aluminium sample to yield.

(b) A hollow cylindrical Aluminium sample has inner diameter of 15mm and outer diameter of 25mm.
Calculate the Stress on the sample if a Force of 70kN is applied.

2. (a) Draw a typical diagram of the Stress-Strain Curve of Steel.

(b) Label the parts on the diagram: Elastic Region, Plastic Region, Elastic Limit, Young’s Modulus, Yield
Stress, Proof Stress, Ultimate Tensile Strength, Necking, and Fracture Point. Also give the definitions of
each of these points.
 3. (a) What material properties are measured using the Brinell Test, Vickers Test and Impact Test?

(b) Describe the difference between all of these Tests.

4. (a) Describe the difference between Low-Cycle and High-Cycle Fatigue. Use a diagram to help.

(b) Give an engineering example of Low-Cycle and High-Cycle Fatigue.

Topic: Composite and Non-Metallic Materials

1. What is the main reason Composite Materials are commonly used in engineering applications?

2. (a) Define the term ‘Composite Material’.

(b) Identify some commonly used Composites and give its properties.

3. Describe the difference between Delamination and Debonding in Composite Materials.

4. What are the Coin Tap Test, Ultrasonic and Radiography used for?

5. How is the damage in Composite Materials assessed?

Topic: Plastics, Wood and Fabric
1. Briefly discuss difference in manufacturing Plastic Materials by Casting and Extrusion.

2. Discuss some of the Advantages and Disadvantages of using Plastic Material.

3. What is Laminated Wood or Plywood?

4. (a) Give one reason why Fabric Material is used for aircrafts.

(b) What is the Maule Tester and Seyboth Tester used for? Discuss the difference.

Topic: Plastics, Wood and Fabric

1. Label all the parts 1-8 on the Screw, and give the description.

2. Describe the difference between a Screw, Bolt and Stud.

Topic: Corrosion of Metals
1. (a) Briefly explain what is meant by Corrosion of Metals.

(b) Write an Oxidation-Reduction reaction for the Corrosion of Iron.

2. Briefly explain the difference between Chemical and Electrochemical (Galvanic) Corrosion.

3. Describe the types of corrosion: Surface, Pitting and Intergranular.

4. How is the corrosion on Iron (Steel), Aluminium and Copper identified?

5. Discuss two factors that influence the Rate of Corrosion,

Topic: Positive Locking Devices

1. Describe the main purpose of Positive Locking Devices.

2. (a) What are Spring Washers?

(b) Draw a sketch of 4 types of Spring Washers.

3. Using a diagram, explain the use of Split Pins (Cotter)

4. Explain how Wire Locking is used.