Question 1 (25 marks)

a. Pure metal and metal alloys have different fluidity. Related to their freezing range and
their structures during solidification, compare the fluidity between pure metal and
metal alloys. Justify your answer.
(5 marks)

b. State TWO characteristics of molten metal and explain how they can affect the
fluidity of molten metal.
(4 marks)

c. Draw a cast-structure of a pure metal that solidified slowly in a square mold. Then,
propose and describe a modified casting process to obtain a product with columnar
grains structures that grow from the bottom to the top of the part. Incorporate with
suitable sketches.
(8 marks)

d. Select ONE product from the list below. State with justification, the suitable casting
process and with the aid of sketches, explain the process steps.
i. Car wheel rim
ii. Automotive piston
(8 marks)

Question 2 (25 marks)

a. i. Explain with the aid of sketches, the difference of microstructure between hot-rolled
and cold-rolled product
(4 marks)

ii. Relating to the microstructure produced in a(i), which method of rolling process is
suitable for producing a long plate that will be under uniaxial tension stress? Justify
your answer and include with suitable sketches
(4 marks)
 b. Describe and compare how residual stresses can be developed in rolling process using
small-diameter rolls and large-diameter rolls. Draw the stress distribution in the cross-
sectional sheet thickness produced from both processes
(6 marks)

c. With the aid of sketches, explain the fundamental differences between extrusion and
drawing processes. Show the process variables in the sketches
(6 marks)

d. Explain the function of welding chamber and the effect of lubrication in the process of
extruding hollow shape components
(5 marks)

Question 3 (25 marks)

(a) Explain the main difference between thermoplastic and thermoset polymers.
(3
marks)

(b) With the aid of sketches, describe FOUR types of common structure in polymers, and
explain why a particular structure has higher strength while the other structures have
lower strength and flexible.
(8
marks)

(c) List THREE additives in plastics and explain their function in polymers processing.
(6
marks)

(d) Select ONE product from the list below. State the suitable manufacturing process and
with the aid of sketches, explain the process steps.

i. 3-pin plug casing

ii. Plastic bag
iii. Plastic bottle
 (8
marks)

Question 4 (25 marks)

(a) With the aid of sketches, explain the detail steps in ceramics slip casting process.
(7
marks)

(b) Explain the drying and firing process in ceramics processing.

(4
marks)

(c) Explain with the aid of sketches the thermal tempering process of glass. Describe the
residual stresses developed by this process and what is its effect on the properties.
(6
marks)

(d) Select ONE product from the list below, state the suitable manufacturing process and
with the aid of sketches, explain the process steps.

(i) Telescope lens

(ii) Syrup glass bottle
(iii) Fluorescent bulb
(8
marks)