Sunday, February 11, 2024

Unit III: Ferrous and Non-Ferrous Metals - Self Assessment Questions

 Self-Assessment Questions - short answer type questions: Ferrous and Non-Ferrous Metals - Engineering Materials and Metallurgy

SELF-ASSESSMENT QUESTIONS

SHORT ANSWER TYPE QUESTIONS

On Ferrous Materials

1. What are metals? Classify engineering materials.

2. What are ferrous metals? Classify ferrous materials.

3. State three reasons why ferrous alloys are used extensively.

4. State three characteristics of ferrous alloys that limit their utilisation.

On Steels

5. How can you specify a steel? What is the difference between 4140 steel and 4340 steel?

6. What are the three primary groups of plain carbon steels and the characteristics of each?

7. What are the principal uses of (a) low-carbon, (b) medium- carbon, and (c) high-carbon steels? M

8. What are alloy steels? How are alloy steels classified?

9. List four important alloying elements added in alloy steels.

10. Why is alloying done?

11. What are the primary effects of nickel, chromium, and copper as alloying elements in steel?

12. What are the effects of lead and sulphur on the machinability of steels?

13. Which alloy elements are basically (a) carbide formers, and (b) graphite promoters?

14. What makes a stainless steel "stainless"?

15. Why do stainless steels lose their corrosion resistance when the chromium in solution drops below 12%?

16. What determines whether a stainless steel is austenitic, ferritic, or martenistic?

17. What are common applications of (a) austenitic, (b) ferritic, and (c) martenistic steels?

18. What are the required properties of a tool steel?

19. How can you classify tool steels?

20. What is meant by 18-4-1 high speed steel?

21. What are HSLA steels? Where are they used?

22. What are maraging steels? Give its composition.

23. What are heat resisting steels and free-machining steels?

On Cast Irons

24. What are the features that make cast iron an important material? 

25. What are the effects of carbon on the properties of cast iron?

26. What is the influence of cooling rate on the properties of a cast iron?

27. What is the effect of heat treatment on cast irons?

28. How can you classify cast irons?

29. What is the chemical composition of grey cast iron?

30. Where are white cast irons used?

31. What is the difference between malleable cast iron and ductile cast iron?

32. What are alloy cast irons?

33. What are the primary effects of adding Ni, Si, Mo in cast irons? 

On Non-ferrous Materials

34. What properties do non-ferrous alloys have that usually are not associated with ferrous alloys?

35. Write some characteristics of non-ferrous alloys that limit their utilisation.

36. List the outstanding properties of copper and some typical applications.

37. What is the main difference between a brass and a bronze?

38. List atleast four types of brasses used.

39. List some bronze alloys.

40. What are gun metals? Give its composition.

41. What are cupronickels? What is the use of monel metal?

42. What properties have made aluminium and its alloys the most important non-ferrous metal?

43. Why does the aluminium replace the copper as an electrical conductor?

44. What is the principal difference between wrought and cast alloys?

45. What are the two types of aluminium alloys?

46. What is duralumin? Give its composition and applications.

47. What is meant by precipitation hardening?

48. Differentiate between natural ageing and artificial ageing?

49. What are the effects of ageing temperature and time on the material strength?

50. What are the required characteristics of a bearing material?

51. List the bearing materials that are commonly used?

52. What are super alloys?

Unit IV: Non-Metallic Materials - Self-Assessment Questions

 Self-Assessment Questions: Non-Metallic Materials - Engineering Materials and Metallurgy

SELF-ASSESSMENT QUESTONS

SHORT ANSWER TYPE QUESTIONS

On Polymers

1. What are polymers?

2. List any four attractive characteristics of polymers.

3. Classify polymers.

4. Define the following terms: 

(i) Monomer, 

(ii) Homopolymer,

(iii) Copolymer, and 

(iv) Linear polymer.

5. What is meant by isomerism?

6. What is meant by the term 'unsaturated molecule'? State its significance in plastics.

7. What is polymerisation?

8. Define the term 'degree of polymerisation'.

9. What is the difference between addition polymerisation and condensation polymerisation?

10. Why are additives added to polymers?

11. Why are the fillers and plasticizers added to polymers?

12. What are the characteristics of plastics which account for their wide use as engineering materials?

13. What is the most common use classification of plastics? What accounts for this?

14. Differentiate commodity plastics with engineering plastics. 

15. Name any four commodity plastics and engineering plastics. 

16. Distinguish between thermoplastics and thermosetting plastics. 

17. Name any four thermoplastics and thermosetting plastics.

18. Why is it important to know whether a plastic is thermoplastic or thermosetting?

19. What advantages do thermoplastic polymers have over thermo- setting polymers, and vice versa?

20. What are the sources of raw materials for plastics?

21. What do the following ‘acronyms' refer: PE, PP, PS, PVC, PTFE, PMMA.

22. Name any three hydrocarbon thermoplastics. Also state their applications.

23. List the properties and typical applications of PVC.

24. What are acrylic materials? Name two of them.

25. Write short notes on nylons.

26. What do you mean by heterochain polymers? Name any four of them.

27. What are bakelites? Also state their applications.

28. List the characteristics and typical applications of urea- formaldehyde.

On Engineering Ceramics

29. What are engineering ceramics?

30. List some of the distinct characteristics of engineering ceramics.

31. What are the main classifications of ceramic materials?

32. Name any four engineering ceramics.

33. Compare the fracture toughness of alumina, silicon carbide, and silicon nitride.

34. What is meant by PSZ?

35. What are sialons? State their applications.

36. Why do most ceramics not have tensile strengths?

On Composites

`37. What are composites?

38. What are the constituents of composites?

39. How are composite materials classified?

40. What is the role of matrix material in a composite?

41. List the various matrix materials used.

42. List the various fibre materials used in the fibre-reinforced composites.

43. What are cermets? What are two common uses of cermets?

44. List the advantages and limitations of composite materials.

45. List the applications of composite materials.

Non-Metallic Materials

UNIT - 4

Non-Metallic Materials

Learning Objectives

While reading and after studying this chapter, you will be able to:

● Appreciate and relate the properties and engineering applications of non-metallic materials with the metallic materials.

● Understand the differences between thermoplastic and thermosetting materials and how they are formed.

● Gain some knowledge of the properties and applications of some important thermoplastic and thermosetting plastic ma- terials.

● Understand how to select an appropriate plastic for an application.

● Have the basic knowledge about the ceramic and composite materials.

● Understand the main characteristics and engineering applications of some important engineering ceramics.

● Understand the principles involved in both fibre and particulate composite materials.

● Appreciate the features and typical engineering applications of composite materials.

Introduction of Non-Metallic Materials

 In the previous unit, we have discussed about the ferrous and n ferrous materials that are widely used in engineering applications.

UNIT - 4

Non-Metallic Material

“The important thing in science is not so much tổ obtain new fi as to discover new ways of thinking about the.

- Sir William Lawrence Br

NON-METALLIC MATERIALS

1. Introduction

In the previous unit, we have discussed about the ferrous and n ferrous materials that are widely used in engineering applications. addition to these engineering materials, there are a number of n metallic materials which have substantial importance in engineer practices. The most important non-metallic materials include polym (such as plastics, rubbers, and adhesives), ceramics, and composites

In recent decades, there is a large increase in the polyn materials. Polymers are widely used in number of applicatio including toys, home appliances, structural and decorative iter coatings, paints, adhesives, automobile tyres, foams, and packagi In the same way, ceramic materials are used in varied engineeri applications, including tools for grinding and cutting, seals, bearir and other components for engines and pumps. The compos engineering materials are used to produce a wide range of produ varying from those used in high-strength aircraft components to ro: building tarmacadam and concrete. Therefore it is imperative for design engineer to have an understanding of their natures, properti advantages, and limitations. The knowledge of these materials v enable him to make the optimum selection of materials.

In this unit, we shall discuss about the following groups of non- metallic materials, one by one, in detail, in the following sections.

1. Polymers,

2. Ceramics, and

3. Composites.

Polymers

 Almost all biological systems are built of polymers which not only perform mechanical functions (like wood, bone, cartilage, leather) but also contain and regulate chemical reactions (leaf, veins, cells).

POLYMERS

1. Introduction

Almost all biological systems are built of polymers which not only perform mechanical functions (like wood, bone, cartilage, leather) but also contain and regulate chemical reactions (leaf, veins, cells). People have used these natural polymers for thousands of years now. Modern scientific researches have made possible the development of numerous polymers, which are synthesized from small organic molecules.

Many of our useful plastics, rubbers, and fibre materials are synthetic polymers. In fact, in some applications polymers replaced metallic materials. The use of synthetic polymers have increased largely during recent decades. This is due to their many useful properties, coupled with comparatively low cost.

2. Characteristics of Polymers

Some of the attractive characteristics of polymers are :

1. Low density.

2. Good thermal and electrical insulation properties.

3. High resistance to chemical attack.

4. Ease of fabrication.

5. Relatively low cost.

Some of the disadvantages of polymer materials are:

1. Low strength.

2. Low elastic modulus values.

3. Low softening temperatures.

However, the low strength and stiffness can be improved by fibre reinforcement of polymers.

3. What are Polymers?

The term polymer* is derived from two Greek words 'poly' and 'mers'. The term 'poly' means 'many', and the term 'mer' means 'parts or units'. Thus polymers are composed of a large number of repeating units of small molecules called monomers. 

Monomers: Monomers are the small molecules which combine to form a polymer. They are also called repeating units as they combine repeatedly to form a polymer. The number of repeating units in a polymer is known as degree of polymerisation or D.P. value.

Polymerisation is a reaction which involves the union of small molecules to form molecules having higher molecular weight called polymer.

Therefore, a polymer is made up of thousands of monomers joined together to form a large molecule.

Polymers may be defined as giant organic, chain-like molecules having molecular weight↑↑ from 10000 to more than 1,000,000 g.mol-1.

4. Classification of Polymers

The basic classification scheme of polymers is illustrated in Fig.4.1.

† In practice, the term polymer is used interchangeably with the term plastic.

†† Molecular weight: It is the sum of the atomic weights of all the atoms in a molecule. Molecule is a group of atoms that are bound together by primary interatomic bonds.


However, our study is limited only to thermoplastics and thermosetting plastics.

5. Terminology Used in Polymers

The important terms used in the study of polymers have been explained below :

1. Monomer: It is a small molecule consisting of a single mer i.e., a single unit/blocking block.

Natural polymers include proteins, cellulose, resins, starch, shellac, and lignin. They are commonly found in leather, furr, wool, cotton, silk, furr rope, wood and many others. Other than natural polymers are generally called as synthetic polymers.

2. Polymer: It is a macromolecule formed by the repeated linking of many monomers.

3. Polymerisation : It is the process of forming a polymer.

4. Homopolymer: It is a polymer made out of identical monomer.

In other words, when all the repeating units along a chain are of the same type, the resulting polymer is called a homopolymer.


5. Copolymer: It is a polymer which is obtained by adding different types of monomers.

6. Degree of polymerization : It is the number of repetitive units (or mers) present in one molecule of a polymer. It is a parameter used to designate the average chain size of a polymer. Mathematically,

Degree of polymerization = Molecular weight of a polymer / Molecular weight of a single monomer

7. High-polymers: Solid polymers which have very high molecular weights (ranging between 10,000 and 1,000,000 g/mol) are called high-polymers.

8. Oligo-polymers: Oligo-polymers or oligomers are liquid/gas polymers with very short chains (having molecular weights on the order of 100 g/mol).

Types of Homopolymers

9. Linear polymers: Linear polymers are those in which the mer units are joined together end to end in single chains, as shown in Fig.4.2 (a). For linear polymers, there there may be extensive Van der Waals boundary between the chains.


10. Branched polymers: Branched polymers are those in which side-branch chains are connected to the main ones, as shown in Fig.4.2 (b).

11. Cross-linked polymers: In cross-linked polymers, adjacent linear chains are joined one to another at various positions by covalent bonds, as shown in Fig.4.2 (c).

12. Network polymers: Network polymers have three active covalent bonds (known as trifur.ctional mer units), which form three- dimensional networks instead of the linear chain framework, as shown in Fig.4.2 (d).

Types of Copolymers

Consider a copolymer that is composed of two mer units as represented by ● and ● in Fig.4.3. Depending on the polymerisation process and the relative fractions of these mer types, we have different sequencing arrangements along the polymer chains. They are:

13. Random copolymer: In this, the two different units are randomly dispersed along the chain, as shown in Fig.4.3 (a).

14. Alternating copolymer: In this, the two mer units alternate chain positions, as shown in Fig.4.3 (b).


15. Block copolymer: In this, the identical mers are clustered in locks along the chain, as shown in Fig.4.3 (c).

16. Graft copolymer: In this, homopolymer side branches of one ype may be grafted to homopolymer main chains that are composed ›f a different mer, as shown in Fig.4.3 (d).

17. Isomerism: It is a phenomenon wherein different atomic configurations are possible for the same configuration. For example, here are two isomers for butane (C4H10) as shown in Fig.4.4.


6. Molecular Structure of Polymers

As we know, most polymers are organic in origin; many organic materials are hydrocarbons. In other words, most polymers are hydrocarbons.

In hydrocarbons, carbon and hydrogen combine in the relationship Cn H2n + 2, known as paraffins.

Theoretically, the hydrocarbons can be linked together indefinitely to form very large molecules, as illustrated in Fig.4.5. The bonds between the atoms are single pairs of covalent electrons. Because there is no provision for additional atoms to be added to the chain, such molecules are said to be saturated.

In other words, a compound in which all the valence bonds of the carbon atoms are satisfied is said to be saturated. Such saturated molecules have strong intramolecular bonds, but the intermolecular bonds are much weaker.


A bond between two carbon atoms may involve the sharing of two pairs of electrons. This is termed as a double bond. For example, in ethylene (C2H4), the two`carbon atoms are doubly bonded together, and each is also bonded to two hydrogen atoms, as illustrated in Fig.4.6 (a). In some cases, triple bonds also exist. For example, in acetylene (C2H2), there is a triple bond between two carbon atoms, as shown in Fig.4.6 (b).


In these double and triple covalent bonds molecules, each carbon atom is not bonded to the maximum other atoms. So these compounds are termed as unsaturated.

In other words, a compound in which the valence bonds of the carbon atoms are not satisfied is said to be unsaturated. Such unsaturated molecules are important in the polymerisation i.e., joining together of small molecules into large ones having the same constituents.