Important notes:

The 2012 final exam consists of:

- Part A: 20 multiple choice questions (1 mark each)
- Part B: 6 short answer questions (5 marks each)

All questions in the 2012 exam should be answered.

The 2012 exam consists of:
- 1/3 of content is based upon weeks 1-6
- 2/3 of content is based upon weeks 7-13
ENGG153 Engineering Materials -2- Autumn Session 2011





Faculty of Engineering



ENGG153
Engineering Materials

This paper is for students studying at:

X Wollongong Batemans Bay Bega Loftus

Moss Vale Shoalhaven Sydney Distance


AUTUMN SESSION 2011 EXAMINATION


Time Allowed: 3 hours 15 minutes

Number of Questions: 48


DIRECTIONS TO CANDIDATES

1. There are three Sections: A, B and C, with C consisting of Multiple Choice questions.
2. Answer Sections A and B in the exam book.
3. Write answers to the Multiple Choice questions on the computer marking sheet.
4. Answer all questions in Sections B and C; and 3 questions of the 4 in Section A.
5. The examination paper is printed on both sides.


EXAMINATION MATERIALS/AIDS ALLOWED

Calculators, Drawing Instruments

EXAMINATION MATERIALS/AIDS TO BE SUPPLIED

Computer marking sheet

USEFUL INFORMATION

Relevant formulae are given on page 3.




Family Name .......................................................

First Name .......................................................

Student Number .......................................................

Table Number .......................................................
THIS EXAMINATION PAPER MUST NOT BE REMOVED FROM THE EXAMINATION ROOM
ENGG153 Engineering Materials -3- Autumn Session 2011


ENGG153 Engineering Materials -4- Autumn Session 2011

SECTION A: SHORT ANSWER QUESTIONS (24 marks)

NOTE: Answer any three of the following four questions. Each question
is worth 8 marks.

A1. (8 marks)
Figure 1 shows a typical S-N curve describing the fatigue behaviour of a material. Explain why
the number of cycles to failure increases when a smaller stress amplitude is used.


















A2. (8 marks)
Figure 2 shows the relationship between thermal conductivity and composition for copper
(Cu) zinc (Zn) alloys. Explain why a copper-zinc alloy having 30 % Zn has a lower thermal
conductivity than pure copper.






















Figure 1
Typical fatigue S-N curve.
(Reference: Fig. 9.3 from Ashby,
Shercliff and Cebon)
Figure 2
Thermal conductivity vs weight %
zinc for copper-zinc alloys.
(Ref. W.D. Callister, Materials Science and
Engineering, 6ed, Wiley and Sons,2003)

ENGG153 Engineering Materials -5- Autumn Session 2011



A3. (8 marks)
What are the differences between process energy and embodied energy? Which of these is
more useful for eco-scoping of a new product design? Explain why.


A4. (8 marks)
A materials theoretical strength can be related to the stress needed to break the inter-atomic bonds
holding the material together. The real strengths of materials are much lower than their theoretical
strengths. Explain why this is true for

a) brittle materials, such as ceramics (4 marks); and

b) ductile metals (4 marks).






ENGG153 Engineering Materials -6- Autumn Session 2011

SECTION B: CALCULATION / DESIGN PROBLEMS
(36 marks) Answer ALL questions in this section.



Relevant Formulae












|
|
.
|

\
|
A = A
ts
m
m
o
o
o o
o o
1
0
A
F
= o
0
l
l A
= c
z
x
c
c
v

=
V
m
= c o E =
oc
2
1
= U
c Y K
Ic
t
*
=o
E
K
G
Ic
c
2
=
2
min max
o o
o
+
=
m
2
min max
o o
= S
( )
2 1
T T E
l th
=o o
2 / 1
max
1
|
|
.
|

\
|
+ = =
sc nom
SC
c
K

o
o
o
n
ss Bo c =
-
p
C
a

=
dx
dc
RT
Q
D J
d
o
|
.
|

\
|
= exp
( )
initial final
initial
initial final
T T
L
L L
=

o
dx
dc
RT
Q
D D
d
o
|
.
|

\
|
= exp
(

=
100
(
exp
o
o
t t r
C C t D x ~
ENGG153 Engineering Materials -7- Autumn Session 2011


B1. (10 marks)
Using the stress strain curve given in Figure 3 for a polymer, determine
(a) Youngs modulus (GPa); (1 mark)
(b) the elastic energy stored in the polymer (kJ/m
3
) at a stress of 25 MPa; (2 marks)
(c) the rod diameter at a stress of 25 MPa, given v = 0.4 and the initial diameter =10 mm (3 marks)
(d) the yield stress (MPa); (1 mark)
(e) the tensile strength (MPa); (1 mark) and
(f) the permanent strain after fracture. (2 marks)






B2. (6 marks)
a) A material has a fatigue endurance limit of 45 MPa. What maximum stress
amplitude could be applied to this material to ensure that it will survive 10
7
cycles if
the mean stress is 30 MPa (the materials tensile strength is 150 MPa). (2 marks)

b) A material increases in length by 0.2% when heated from 25
o
C to 250
o
C. What is
this materials thermal expansion coefficient? (2 marks)

c) The diffusion coefficient of a metal at just below its melting point is 10
-12
m
2
/s. What
is the diffusion distance in m (1 m = 10
-6
m) if this material was held at this
temperature for 12 hours? (2 marks).


20.0
10.0
30.0
0.0
Figure 3
Stress-strain diagram for a polymer material.

ENGG153 Engineering Materials -8- Autumn Session 2011


B3. (10 marks)
A material is required for a cheap column that will support a compressive force (F= 15000 N) and has a
circular cross-sectional shape and fixed height (h=3 m). The column must not fail by buckling and the
critical load for buckling (F*) is given by:


where n is a constant of value 3, E is the materials Youngs modulus and I is the columns second
moment of area. The second moment of area for a solid, circular column is:
4
4
r
I
t
= where r is the column radius.

a) Complete the translation stage for this problem (2 marks)
b) Show that the materials index (M) in this case is given by (3 marks)
where is the material density and C
m
is the material price.
c) Using Figure 4 select the material that will give the cheapest column that will not buckle under
load F. Explain all your selection steps. (3 marks)
d) Determine the radius of the column needed to ensure that the column does not buckle for the
material you have selected in part c). (2 marks)


Density * Price
100 1000 10000 100000
Y
o
u
n
g
'
s

m
o
d
u
l
u
s

(
G
P
a
)
0.1
1
10
100
Pine
GFRP
CFRP
Magnesium alloys
Bamboo
Polyethylene (PE)
Polypropylene (PP)
Polystyrene (PS)
PVC
PET
Polyamides
Aluminum alloys
Titanium alloys
Copper alloys
Medium carbon steel

2
2 2
*
h
EI n
F
t
=
|
|
.
|

\
|
=
m
C
E
M

2 / 1
Figure 4
ENGG153 Engineering Materials -9- Autumn Session 2011

B4. (10 marks)
A company wishes to manufacture heat exchangers from corrugated pressed metal
sheets, keeping costs as low as possible. The steel sheet thickness (t) is 1.5mm and the
sheets are made from low carbon nickel steel alloy. The design requires that the steel
sheets be joined using lap joints as shown in Figure 5. The joints will be subject to low
levels of tension and shear during installation, and a tensile load of 420N applied normal to
the lap joint when in service (Figure 5). The joints must conduct heat, be watertight, and
withstand temperatures up to 538
o
C for a service life of six months without failing.

a) Write up the translation stage for selection of a suitable joining process.(6 marks)

b) If the overlap length is equal to two sheets thicknesses and the width (w) of the joint
is 1.7mm, and a safety factor of 2 is required, will the joints be able to meet the
required lifetime? Use calculations and the Stress vs. Rupture lifetime diagram
(Figure 6) provided to support your answer. (4 marks)







Figure 5 Lap joint with applied forces expected during service.




Figure 6 Stress vs rupture lifetime for a low carbon nickel steel alloy.



SECTION C: MULTIPLE CHOICE QUESTIONS
w
420 N
t
2t
ENGG153 Engineering Materials -10- Autumn Session 2011

(40 marks)

NOTES: Answer ALL questions in this section
There is only one correct answer for each question
Record the selected letter (a,b,c,d) on the computer marking sheet.
Record your name and student number on the marking sheet.

1 A ductile material is one that
a) shows a large elastic deformation before failure
b) shows a large plastic deformation before failure
c) does not fail
d) becomes brittle at low temperatures
2 On a tensile stress-strain diagram, the maximum point on the curve gives which material property?
a) the yield strength
b) the tensile strength
c) the Youngs modulus
d) Poissons ratio
3 Hooke's law involves which material property?
a) Young's modulus of elasticity
b) Yield strength
c) Tensile strength
d) Poissons ratio
4 The elastic section modulus is related to which material property?
a) none
b) Young's modulus of elasticity
c) Yield strength
d) Tensile strength
5 A materials toughness has the units of:
a) J/m
2
b) MPa.m
1/2
c) N
d) MPa
6 Hardness is a measure of:
a) Resistance to plastic deformation
b) Resistance to deformation by indentation
c) Resistance to fracture by crack propagation
d) Resistance to elastic deformation
7 In general, the magnitude of the density of the three main materials groups increases in the order:
a) ceramics , metals , polymers
b) polymers , ceramics , metals
c) metals , polymers , ceramics
d) polymers , metals, ceramics.



8 The Youngs modulus of a material is most strongly associated with:
a) the ability of dislocations to move
ENGG153 Engineering Materials -11- Autumn Session 2011

b) the atomic weight of its atoms
c) the stiffness of the bonds holding its atoms together
d) the material's density
9 The four types of bonds operating between atoms arranged in order of increasing average bond stiffness are:
a) secondary, metallic, ionic, covalent
b) secondary, ionic, metallic, covalent
c) ionic, secondary, metallic, covalent
d) ionic, secondary, covalent, metallic
10 Which one of the following materials has the lowest density?
a) silica
b) aluminium
c) fibreglass
d) polyethylene
11 Which one of the following properties is typical of a polymeric material?
a) high thermal conductivity
b) low creep resistance
c) high density
d) high elastic modulus
12 The melting temperature of a material is most closely related to which of the following material attributes?
a) The dislocation density
b) The crystal structure
c) The atomic mass
d) The inter-atomic bond strength
13 Elastic deformation of a material involves which of the following processes?
a) Breakage of inter-atomic bonds
b) Vibration of atoms about their equilibrium distance
c) Movement of dislocations
d) Stretching of inter-atomic bonds
14 Ceramics display very high yield strengths due to:
a) The presence of impurity atoms
b) The high stress needed to make dislocations move
c) The presence of many dislocations that entangle with each other
d) Crosslinking
15 The type of atomic bonding occurring in polymer materials is
a) a mixture of ionic and covalent
b) a mixture of covalent and secondary bonding
c) a mixture of ionic and metallic
d) only covalent
16 The type of atomic bonding occurring in ceramic materials is
a) a mixture of ionic and covalent
b) a mixture of covalent and secondary bonding
c) a mixture of ionic and metallic
d) only covalent



17 A solid material that displays a periodic and repeating three dimensional array of atoms is described as
a) amorphous
ENGG153 Engineering Materials -12- Autumn Session 2011

b) crystalline
c) pure
d) a solid solution
18 The definition of a dislocation defect is:
a) a missing half plane of atoms
b) the direction along which atoms are touching
c) the basic structural unit of a crystal structure
d) a classification scheme for crystal structures
19 A solid material that includes impurity atoms dispersed randomly within the host crystal structure is called:
a) amorphous
b) a glass
c) pure
d) a solid solution
20 A "crosslink" in a polymer refers to:
a) a covalent bond operating within a macromolecule
b) a secondary bond operating within a macromolecule
c) a secondary bond operating between macromolecules
d) a covalent bond operating between macromolecules
21 Atomic bonding in metals is:
a) relatively weak
b) based on a mobile sea of electrons
c) ionic or covalent
d) based on Van der Waals forces
22 An alloy is:
a) A diatom
b) A metallic material reinforced with a ceramic
c) A metallic material composed of two or more elements
d) Atoms bonded covalently together
23 A compound formed from magnesium and chlorine will have which type of bonding?
a) Secondary, van der Waals bonding
b) Covalent
c) Ionic
d) Metallic
24 A polycrystalline material is a material made up of
a) Many smaller molecules joined together
b) A mixture of crystals and amorphous material
c) Many different materials mixed together
d) A solid consisting of more than grain.
25 Glass can be strengthened by
a) adding rubber particles
b) annealing
c) tempered - cooling quickly
d) shot peening



26
Metals can be strengthened by which one of the following heat treatments?
a)
Tempering
ENGG153 Engineering Materials -13- Autumn Session 2011

b)
Annealing
c)
Age Hardening
d)
Cold Working
27
Polymer fibres are typically stronger than sheets made of the same polymer because
a)
the fibres are more heavily crosslinked
b)
the fibres have a smaller cross-sectional area
c)
the polymer chains are highly oriented in the fibre
d)
the fibres are thermosets and the sheets are thermoplastics
28
Slip and disentanglement of polymer chains is the process that causes:
a)
Fracture
b)
Elastic deformation
c)
Melting
d)
Yielding
29
High cycle fatigue is caused by
a)
cyclically varying stress with the peak stress exceeding the yield strength
b)
cyclically varying stress with the peak stress exceeding the tensile strength
c)
cyclically varying stress with the peak stress not exceeding the yield strength
d)
cyclically varying stress with the stress amplitude less than the endurance limit
30
The "endurance limit" during cycling loading is approximately equal to
a)
1/3 of the material's tensile strength
b)
1/2 of the material's hardness
c)
the material's fracture toughness
d)
the material's yield strength
31
If a material contains a crack larger than the transition crack length and it is subjected to a steadily
increasing stress, then it will fail
a)
by yielding
b)
by fatigue
c)
by brittle crack growth
d)
by creep
32
The thermal diffusivity of a material refers to:
a)
How much energy is needed to heat up a material
b)
How much a material expands / contracts when heated / cooled
c)
How long it takes for a material to respond to a change in temperature
d)
How quickly atoms can diffuse within a material when heated
33
A processing method suitable for making long lengths having a constant cross-sectional shape would be:
a)
Casting
b)
Forging
c)
Extrusion
d)
Conventional machining
34
A surface treatment that can increase the fatigue resistance of a metallic material is:
a)
Carburising
b)
Painting
c)
Vitreous enamelling
d)
Anodizing

35 For forming of glass products, it is important to
a) control viscosity
b) ensure temperature is kept below T
g

ENGG153 Engineering Materials -14- Autumn Session 2011

c) ensure the melt is cooled very slowly
d) promote solid state sintering by diffusion
36 To produce steel from iron
a) additional carbon is mixed with the iron
b) alloying elements are added to the iron
c) iron must be quenched and then cold worked
d) oxygen is blown into the iron to remove some carbon
37
In general, the magnitude of the thermal expansion of the three main materials groups increases in the
order:
a) ceramics, metals, polymers
b)
ceramics, polymers, metals
c)
metals, polymers, ceramics
d)
polymers, metals, ceramics
38
Annealing is performed on materials primarily to:
a) reduce grain size
b) increase density
c) reduce ductility
d) reduce stress
39 The creep resistance of polymers is increased by
a) increasing Tg and reducing the amount of cross-linking
b) decreasing Tg and adding fillers
c) increasing Tg and increasing the amount of cross-linking
d) decreasing Tg and decreasing the crystallinity
40 A full life cycle assessment is
a) essential for the design of new products
b) too expensive to be conducted
c) useful for analysis at the end of the product life cycle
d) required by law for all products in Australia.