ye 1 ‘ few Sie # the following quentions: westion Ln axhich ont the dlvoatton of floes Gf riety banat cera Aces ects ict ay int flay haga face finial he hotter elmnonnlanual eecugeny ie hare Ie BO Gold working jaw | 0) HONG Of the abies z puftonnnd on 16ts b) to Improve the | shrongth of tho mnotal - Mechanical working process: ))19 achieve opiimum mechanieal Nom working process, whici is tho pl pep temperature and strain rato, Is porformed to olimin Cold working process |b) hot work | The volume of metal that enters the rolling b) should decrease 6) should remain same after rolling process__| afler rolling process” a opt nota) de | Gy unpreAZel | How does the ability of material to Withstand unpredictable loads change afer forging? b) The ability of material ¢) The ability of material | d) to withstand to withstand Unpre unpredictable loads unpredictable loads does decreases after forging _| not change after forging | ancrcrier [| What is the process, in which the create anéxtremely elongated str area, called? metal is caused to flow through a Testricted orifice to ip of uniform and comparatively smaller cross-sectional 1b) Extrusion ¢) Drawing [d) Spinning "Which of the following are not improved by old working of metals? jardness [b) strain hardening index | c) strength [d) ductility | Following are the advantages of hot working of metals, except E b) porosity of the ¢) grain structure of | d) no residual stresses : vaintained’ _[metalis minimize __| the metal is refined_| introduced In rolling, the point of maximum pressure is called ) slip point b) slip point c) neutral point d) extreme point E ef uring extrusion of steel, adequate lubrication around the billet is done by providing a ating of __[b) graphite c) powdered glass a) graphite & Scanned with CamScannerGqetaiion Wich of the following ati the scales ates forging Saas GRE Witlion Ha bat ie retacad oF shaped by passing it th 1 shaped grooves? : = | Ty Fal forging Le) Press forging [d) Upsetting I Fine folowing forging prowess na flash is formed? [¢) Impression dies. Td) None of the Mentic! 7 feducion in Cioes sectional area per pass IS? | ES Lo) 55% 1d) 67% v in reduction the drawing force? weizzee yinereases |¢) Does notchange 1d) First increases then decreases _ 7 Tha following angle influence the drawing force and the quality of dravn products? | le \byDiewngls | c) Relief angle [d) None of the Mantioned is given by the expression? Lc) (AAR IAL [oy Hedy ine following method is used for analyzing metal forming processes? “cA_|b) Upper bound method | ¢) Slip line method AlLof the mentioned uzstion steel slab 1160 mm wide and 62 mm thick is rolled to a maxi ue wide maxim eduction i ee pees, The sol radius is 725 mam, coefficient of friction 0.3, ari eae ze7it speed of the slab is 0-7mis. Caltulate the roll fores and the aaa steel ctress is 110 MPa. Power required in thi (4 ~ 4) w AER Scanned with CamScannerDRS aes Suez University He Faculty of Petroleum and Mining Engineering Rysers Final Exam 2"? Semester 2018/19 Materials Forming (MTE ...) Model: 4 Metallurgical and Materials Engineering (Grade IV) Duration: 3 hrs | Date: 9/5/2019 | Total Marks :90 | Prof. Rashad Mohamed Ramadan - Three Questions in 6 pages - E.T. : The estimated time for each question in minutes Answer the following questions: Question one: MCQ (E.T. = 90 minutes; 45 Marks) 7 Better . process. ..... of material are the main advantages of using the swaging | a) surface finish and | b) surface roughness [sy surface finish and | d) surface roughness grain size and hardness grain structure and isotrop) 2 ~_ are the forming procesess which are used for making slender tubes. | a) Blanking and deep | byDeep drawing and | c) Deep drawing and | d) Impact extrusion drawing rotary swaging forging and swaging 3 Which of the following processes is mainly used for making the connecting rods? a) Extrusion b) Thread rolling ¢) Rod drawing _|.d) Forgin 4 Worm working process, which is the plastic deformation of metal or alloy under conditions of temperature and strain rate, is performed to eliminate drawbacks of a) cold working process | b) hot working process _,| ofboth a and b_| d) none of the above 3] The main function of the lubricant is to reduce the tensile or. compressive stresses required in metal forming. aa) tensile or b) redundant work _],¢yLoad and power @) fraction compressive stresses a How does the ability of material to withstand unpredictable loads change after forging? ] | unp) a) The ability of b) The ability of material | c) The ability of material | d) material to withstand _| to withstand to withstand Unpredictable redictable loads unpredictable loads unpredictable loads does [increases after forging | decreases after forging _| not change after forging 7 ‘What is the process, in which the metal is caused to flow through a restricted orifice to create an extremely elongated strip of uniform and comparatively smaller cross-sectional area, called? "a) Rolling [by Extrusion ©) Drawing @) Spinning At the highest rolls speeds the value of forward slip become ... lich would lead to poor mill control. tive b) smaller ) higher Qbothaands indicating Skidding of \Pase Scanned with CamScannerg of metals, except [a [ Following are the advantages of hot wor a). close Tee a scos |b) porosity of the | c) grain structure of i no residual SES can be maintained _| metal is mi the metal is refined _| introduced __ 70_[In rolling, the point of maximum pressure is called_ = a) no slip point b) slip point ¢) neutral point ‘d) extreme point 71 | During extrusion of steel, adequate lubrication around th billet is done by providing a coating of a) vegetable oll b) graphite ‘p) powdered glass d) graphite _ Which of the following is true for hot extrusion? 72 a) less force is required in forward [b) more force is required in forward ©) same force is applied in both forward and backward @ not any of the previous extrusion as extrusion as compared to compared to extrusion | [backward extrusion backward extrusion 73] Removing the scales after forging operation by which of the following cleaning operation : “| @) Pickling in acid 1b) Shot peening _ cyBoth of the mentioned | d) None of the mentioned__| [14 | Which of the following defects results due to improper for jing? | (Ca) edge wrinkling | b) centerline cracking | c)Laps d) All of the Mentioned _| [15 | In which forgi a pair of rolls, a) Skew rolling ing process cross section of a bar is reduced or ‘Shaped by passing it through | with shaped grooves? \ Roll forging — | [@) Upsetting | _| of the | - | d) ) area, area, and | @) Press forging 16 Lin which of the following forging process a flash is formed’? a) Open die bj Closed die c) Impression dies [d) None of the Mentioned 77 | The actual shape factor calculation is relative to the ratio between the .. extruded cross section and the ... _... of a circle of the same perimeter, b) area, area, and | c) diameter, perimeter, and area_| perimeter diameter, and height height As speed increases the amount of oil entrained into the bite rises and the ratio falls. This leads to a in friction. area of contact | -byDrop c) Unchanged | Which ofthe following angle influence the drawing foree and the qualily of drawn products? | pyBie angle __|c) Relief angle d) None of the Mentioned | d) First increase then decrease c) (A-ARIAI fof the following method is used for analyzi it if lyzing metal forming proces b) Upper bound method | c) Slip line method San ote | Sy All of the mentioned Scanned with CamScanner22 | In circular drawing process, when the depth of drawing is more than the diameter of the die, then the process is called as P @) forced drawing | b) hollowdrawing 6) deep drawing | 4) all ofthe above 23 ] Which of the following processes of metal forming is widely used for making the raw material for the manufacturing of bolts? a) Rolling b) Forging o)_Wire drawing i) Rod drawing 24 | _Astrip of metal is reduced from 7.9 to 4.9 mm in thickness by rolls rotating at 100 rpm. The roll diameter and coefficient of friction are 350 mm and 0.1. The mean strain rate is: a) = 30st b) = 50s | c)-2 5457 [g) =62s" | 25_|_Which of the following process is called as high rate energy formin | a” Explosive forming | b) Hydroforming | c) Wire drawing _ @)_Shear spinning | 28 | Which forming process is used for bending continuous lengths of sheet metal and for | large production runs Roll forming b)_Stretch forming | ¢) Explosive forming | d) Bending 27_[ Which of the defect is eliminated by hot working process? | a) Cold shut b) Misrun [oy ) Blowholes | d) Fusion 28 | Homogeneous work is determined by ... _, and is essentially independent of the drafting and | b) reduction and drafting | 6) friction and @) ) approach angle and | Approach angle drafting drafting 36 |The work involved with the intemal shearing process due to non-uniform deformation is? | a) Kdealwork [bY Redundant work | c) Fricional work __[d) None of the mentioned_| 30 [in deep drawing, the metal at the botiom side of the punch undergoes | a)longitudinal b) hoop stress and | ¢) compressive d) non of the | erone ‘stresses and | compressive stresses | stresses and radial previous hoop stresses tensile stresses During rolling process, the thickness of workpiece squeezed is called what? | Shaft b) _b) Bore bat Draft d) Core | The cup to be drawn has diameter of 80 mm and 100 mm height ‘Allow 2% for earing. The blank diameter in mm and number of operations are: 196 and 2 b)_235 and 3 200 and 2 Ld) 208 and? “|The main factors affecting the rolling load are: ; The rolldiameter | b) The deformation] c) The deformation | gy All the previous ? resistance of the | process : metal parameters discuss the possible mechanism for such changes. ) b) An automotive valve is to be used at 650-800 °C with moderate stress. Taking in consideration the other design requirements, suggest a possible type of material for the valve. If a higher engine temperature is to be used, what kind of material modification is required ? 2.- a) Outline why the various materials charts can be useful in determining the type of material required for certain designs, give an example. b) A cylindrical pressure vessel is to be made of plane carbon steel in accordance with design requirements. Do you have any further specification to be added to the proposed type of steel in order to ensure a successful fabrication ? 3 - a) Ceramic materials are generally known to have high strength and both low density and ductility, explain why and indicate how it is possible to improve the ductility of ceramic materials. b) A ceramic fiber with thermal expanision coefficlent of x 10° c"! and elastic modulus of 72 GPa and fracture toughness of 0.75MPa ‘im is rigidly supported and is stress free at 25 °C. Calculate the ) maximum flow size and the stress which the fiber can tolerate if it must survive at 200 °C . If this fiber isto be used in making composite material, give your comment. 4-2) For the development of a high efficiency flame tube for gas turbine engine , temperature is above 1000 °C. Indicate the design requirement and suggest a possible alloy to be used with explanations of the various alloying elements role. : py Four types of sheet steel for car manufacture are recommended , they are : ; Yield stress (MPa) nevalue Mild-steel 170 0.22 HSLA 360 0.16 DP-steel 360 0.16 TRIP-steel 400 0.22 _ Give a short comment on each of the above steel and justify your choice for one of those types steel, Scanned with CamScannerFaculty of Petrol & Min. Eng. Department of Metallurgy & Materials.Eng, rH 4" Year Exam 23/5/2007 Alloys Design ‘Time: 3 Hours Answer the following questions: 1-a) You are working with a multi-component alloy that derives strength from three sources: 1) a fine grain size. 2) solid solution strengthening from a fine interstitial. 3) a precipitated dispersion of ~25nm intermetallic particles. During the processing, each of these conditions is deformed above the upper yield point, followed by thermal annealing. Describe the three major processes of structural evolution that take place to reach the final state, and explain how these changes affect the strengthening. b) Density and Young's modulus of various alloys depends on many factors, explain and indicate why both properties are important. 2- a) Discuss the concept of equal strain, &4 = & , used in design for certain applications when different materials are under similar stress and temperature conditions. b)A glass fiber with thermal expansion coefficient of 5x10 C7, an elastic modulus of 72GPa, and a fracture toughness of 0.75MPa ‘im is rigidly supported between two posts so that it is stress free at 25C . Calculate the maximum flow size this fiber can tolerate if it must survive a temperature increase of 200C. 3- a) Fracture toughness value is used to design against material failure and material thickness has a determining effect on fracture toughness value, discuss such limitation, b) A steel component with the yield stress of 800 MPa and Ky~20MPa Ym, the maximum flow size which could be found in this material ~ 1.4mm. If this material was to be used under cyclic stress loading condition 0- to 400 MPa, would you recommend this type of steel ? Justify your answer. The modulus and strength relation are very important in spring materials selection, explain why and derive the material index which can be used in this case. igh strength and formability as well as relatively high safety (crash safety) are among the rial design requirements for sheets to be used in car industry. You are required to jest a processing treatnient for this steel in order to meet such requirement. questions bear the same marks. Scanned with CamScannerSuez. University Faculty of Pet & Min. E: : Min. Eng. Department of Metallurgy & Materials Engineering 4-th Year Exam 3/6/2014 Alloys Design z ime: 3 Hours Answer the following questions: 4 ‘i 5 Aa » For 8 power plant using Steam at a maximum temperature of 565°C, a high strength and good 21 stability steel is needed; indicate the necessary requirements for this steel microstructure, pe A structure component is to be fabricated from plate 4340 steel. This steel exists in two different is after heat-treatment: the first with 0 =860 MPa and fracture toughness equal 98.9 MPavm and the second with o=1515 MPa and toughness equal to 60.4 MPavim . If the plate thickness is 10 mm. and toughness constant during service, indicate which of the two steels you would select and explain we Ifa minimum 3 mm flow size can be detected during inspection would you still choose this steel? Materials with very low thermal expansion are requiced for many applications, even zero- expansion materials. Discuss some of the different concepts which can be used to design such type of materials, give an example, br Conduction and strength are among the alloys requirement for a heat-exchanger design. Indicate how to estimate the material index in such a case, is 760 mm wide. Assume =0.3 and the plane flow stress is 170 MPa, The rolling load is: E2B4KN (b= 134KN ©) =3.4 KN d)=33.4 KN Scanned with CamScanner(20 points) the source of each defect and how can it be are ston: 5 t Second ete the roling defo? Whe ad to reduce the thickness of a plate from so jided? . ons is to be used to in, Roll diameter is 700 mm by A seres of cold rolling operations 6 of 30 m/min. Ro igh mill at ee rk material tum to 25 rain eversingtvo high mi) and workpiece is 0.15. The wont nn and the coefficient of friction between mllss in hardening exponent of 0.2. The ficient of sera) es, Determine! ee tat the draft isto be equal on each pass. D i) Draf for each pass. s ii) Minimum number of passes required. ii) The rolling load. G0points) piece is 75 Question: . i ion. The starting piec A cynical workpiees i subjected toa cold upset forging operation. 1 height of 36 mm. The in height and 50 mm in diameter. It is reduced in the operat SE soils hye ley cove deed by K=350 MPa and n= 0.17. Assume a coxfficien! friction is 0.1. Determine the force as the process begins, at intermediate heights o , mm, and at the final height of 36 mm. Fourth Question: (25 points) a) For steel sheet tensile width and thickness strains in different direction with respect to tolling direction are given below. Sy & ours o° | 45° | 90° | 0° | 45° | 90° ksi 0.8 | 0.75 | 0.82 | 0.65 | 0.58 [0.62| 62 Calculate-the average normal anisotropy and the average planar anisotropy. If the sheet thickness is 2 in. and the punch diameter is 10 in. Determine: i) The limiting drawing ratio if the efficiency is 70%, ii) Find the load required iii) — Thenitial blank’s diameter. - - ) Calculate the drawing load required to achieve 30% reduction in area on a 10 mm diameter copper wire, given thatthe yield stress ofthe metal is 235 MPa, the die angle ig 12° and the coefficient of friction is 0.08. If the wire is Passing through the die at 2.25 m/s, calculate the horsepower of the electric motor. assuming 90% efficiency, UPA 9 Sled sling go Rolling load = 1.1554, Shape factore (Ky) =1+ Sen, h Forging load = of Ky A Scanned with CamScannerSuez University Faculty of Petroleum&:M Materials Forming I (MTE 455) Dept. of Metall. Materia Fl Ee ; Allowed Time 3 Hours pele Date: 6/9/2015 Answer the following questions: irst Question rat F for false statement and T for true one. (yg points) |. Camber and crown can be used to correct the roll deflection at any roll force. 2. The starting material for cold-rolled steel sheet is pickled hot-rolled breakdown coil from the continuous hot-strip mill. 3. In rolling free engagement will occur when p< tan a. 4, The maximum possible reductions for rolling increasing with increasing roll diameter and decreasing coefficient of friction. 5, High friction results in high rolling load, a steep friction hill and great tendency for edge cracking. 6. Extrusion is the process by which a block of metal is reduced in cross section by forcing it to flow through a die orifice under high tension. 7. Mill spring causes the thickness of ‘the sheet exiting from the rolling mill to be greater than the roll gap set under no-load conditions. 8. The maximum reduction per pass a strip drawn from thickness h, to final thickness he with coefficient of friction 0.03 and die angle 12° is 58%. . 9. The limiting thickness in metal rolling is nearly proportional to p, R, o, but inversely proportional to E. 10, Cracking. at the: flash- of. closed-die forgings is more prevalent the thinner the flash in relation to the original thickness of the metal. 11, Gauge control through control of strip tension has faster response time than ‘control through change in roll setting. 12, - Limiting Drawing, io is increased by reducing the friction coefficient; a more ample die corner radius, in ing the bend ratio; and higher normal anisotropy. 13. Reverse redrawing has an advantage is that there is only one bend and one unbend operation. 14. The drawablity of a metal is measured by the ratio of the diameter of the cup drawn to the initial blank thickness. 15. The change in fractional reduction from 0.90 to 0.98 corresponds t ‘extrusion ratio from 20:1 to pends to « chatage fa Second Question : (25 poi ° Briefly explain the different types of rolling mills eee) termine the rolling load when steel strip 185 mm wide, 2.54 i reduced 30% in a mill with 650 mm diameter rolls. Given that the coefficient af Seton of the rolls is 0.15 and the mean yield stress of the steel for the uction is 675 N/mm”, taking into account roll flattening, if the rolls made of cast iron (E = 1.005 MN/mm’, y =0.35). ” a Scanned with CamScannerird. Question ; Acylindrical workpiece is subjected to seat is 75 mm in height and 59 25 36 mm. The work material hee iameter, tt T redetine eration, The startin Assume a coefficient of Pie RBH 4 L6uV Rab - 1284] w. hath . cP )). Aor? wer(i+(3)): c=16 ZTE cose Scanned with CamScannerSuez University Materials Faculty of Petroleum& Mini Parsing a ig (MTE 455) Dept. of Metall.& Materials Eng, &)s = os ; ‘Allowed Thine 3 Hons erm, 23/05/2016 Answer following questions: First Question: Put F for false pene) ie Statement and T for ‘true one. Note: A wrong choice will cancel a right choice 1. The maximum possible draft in a rolling operation depends on the following parameters: coefficient of friction, roll velocity roll diameter. . A 40-mm-thick plate is to be reduced to 30 mm in one pass in a rolling operation using roll radius of 300 mm. The coefficient of friction that would make this rolling operation possible is 0.183. 3. A cylindrical billet that is 100 mm long and 40 mm in diameter is reduced by indirect extrusion to a 15 mm diameter. The extrusion ratio is 2.67 4, Formability is a measure of the relative ease with which a bulk metal can be plastically deformed. 5. A steel plate is to be reduced in one pass in a rolling operation from 12 to 6 mm. Entrance speed = 12 m/min. Roll radius = 250 mm, and rotational speed = 10 rpm the neutral point at 0.0.11 rad. from the exit. — cy eesti 6. The flow pattern in extrusion is very complex and continuously changing due to friction. 7. In the slab-method solutions no mention is made of friction that operating in-internal shearing; the only considered is metal-tool interface friction. 8. The tendency for orange peeling can be reduced by increasing the grain size. 9. With a large die angle the friction load is decreases whilst the redundant work load is increased. 10.Hot working is a working at such a temperature only that recrystallisation keeps pace with deformation. 11.Flash in impression-die forging serves no useful purpose and is undesirable because it must be trimmed from the part after forming. 12.The minimum thickness that can be reduced on a given mill is directly related to the coefficient of friction. 13.In the homogenous-method solutions no mention is made of friction that operating in internal shearing, and metal-tool interface Scanned with CamScannerin diameter is 0 mm icti i ong and 4 14. re tindrical pillet that is 100 mn ‘mm diameter. If the oe A eed by indirect extrusion f0 21" C trucion strain is 3.78%. ation hasa=0.8and b= 15. TPE tayo alloys. The ims be Tensile type samples are machined tensile samples are st zn “dimensi ion of is dimensions of the eaves ie tensile test of both seme eeeied sefore the UTS and the dimensions © measured as follows: Alloy A: length = 60 mm, width = 5.2 mm Alloy B: length - 62 mm, width - 5.4 mm sons a Second Question: (20 points) imensions of the A continuous hot rolling mill has six stands. The starting slab are thickness =8 mm, width = 40 mm, and length = sooo The final thickness is to be 0.8 mm. Roll diameter at each stand = 91 mm, and rotional speed at stand number 1 = 30 rev/min. It is observed that the speed of the slab entering stand 1 = 72 m/min. Assume that no widening of the slab occurs during the rolling sequence. Percentage reduction in thickness is to. be equal at all stands, and it is assumed that the forward slip will be equal at each stand. The work material has a strength coefficient = 600 MPa and a strength coefficient = 0.22. Determine (a) percent reduction at each stand, (b) rotational speed of the rolls at stands 2 through 6, and (c) forward slip. (d) What is the draft at stands-t and-6? -(e)- What is the length-and-exit speed-of the final strip existing stand 6? (f) roll force, roll torque, and power required for this operation at stand 6 (u=0.2) . Patiso{ (2-1) ARB aie oe aie Third Question: (20 points) 1. A cylindrical part is warm upset forged in an open die. D) = 50 mm. and hy = 40 mm. Final height = 20 mm. Coefficient of friction at the die-work interface = 0.20. The work material has a flow curve defined by: K = 600 MPa and n = 0.12. Determine the force (a) 0.002 strain (b) at h = 30 mm, and (c) at h=20 mm. 2. A cylindrical billet that is 100 mm long and 40 mm in diameter is reduced by indirect extrusion to a 15 mm diameter. Die angle = 90°. If the Johnson equation has a = 0.8 and b = 1.5, and the flow curve for the work metal has K = 750 MPa and n = 0.15, determine (a) extrusion ratio (b) true strain (homogeneous deformation) (c) extrusion strain (d) ram pressure, and (e) ram force. 2 Scanned with CamScanner5.6 A smooth discontinuity . NU crac 1 with a rough surface (incl Will reflect more energy than a discontinuity 5.7 The terms “intensity” and ‘ Ht § . . 5.8 On the typical Bee and ‘impedance’ do not mean the same thing. = , the verti m . deflection re epresents amplitude sweep represents time and the vertical 5.9 The vertical pi di contig, Pip on an A-scan can be used to compare the relative size of a 50 ame C-sean Gisplay wil indicate length and wid of isontinsty but it 5 a calibration of a UT instrument for sound path distance can be performed 5.12 A reference block should be made from the same basic material as the part being tested. 5.13 Blocks which provide a size reference and are used to check the system’s linedtity are known as area amplitude block. 5.14 The exit point of an angle beam transducer should always be determined before the angle of the transducer is checked. 5.15 A focused transducer has better resolving power than a conventional transducer. Sixth Question: [10 marks] Solve the following problems: | 1. If you wanted a shear wave to travel into steel at 70°, what would the incident angle through the Lucite be? 2. What would be the beam spread using a one inch diameter, two MHz transducer on an Al test part? 3. A clad material is to be tested for bond defects. One material has a thickness of 0.3 inches arid an acoustic impedance of 5.0x10* gm/om’.sec. The other material is 4.0 inches thick and has an acoustic impedance of 5.0x10* gm/ cm’.sec. a.If the bond is perfect and acceptable, what would percentage of sound would you expected to be reflected from the interface? b, Would you inspect the bonded material through the thick side or through the thin side? Why? dal) 9 Clits hall) Cub) es Chae, dara sty] Scanned with CamScannerSuez University Faculty of Petroleum and Mining Engineering Final Exam 2 Semester 2018/2019 Course Name: New Materials (Code: MTE 452.8) Department: Metallurgical and Materials Eng. (Fourth Grade) Duration: 3 Hrs | Date: 27/05/2019 | Total Marks: 60. | Instructors: Dr. Sara, Elnetally 1- Answer the following Multiple-Choice Questions (MCQ) in your bubble sheet. Choose the correct answer: (One point each) 1 Which plot represents the relation between the applied magnetic field and the superconductor eritical temperature? 8, y) B-buperconducting B,| Be normal Superconducting superconducting fl Cs) TAK) TK) TAO a) (8) - © 0) material, 2- Pyrolitic Carbon is a... pyrionctive ) bioinert C) resorbable D) degradable 3+ The external stress applied for detwinning, gives... A)~4.5 % strain P85 % strain ‘C) a stress higher than the martensite yield strength D) None of the above 4- In shape memory alloys, the phase that is found at high temperature is. A) twinned martensite austenite C) reoriented martensite D) None of the above __ 5- It is an example of soft tissue: to exhibit the shape memory effect for Cu based alloys, Page i of 3 Scanned with CamScannerDuration: 3 Hrs | Date: 27/05/2019 | Total Marks: 60 | instructors: Dr. Sarah A. Elnekhally N 6- Carbon nanotubes have electrical conductivity .. A) much higher than B) much lower than {PQ Elose to 7- Choose the plot that represents the resistance versus temperature of mercury. .. that of copper. 0.180 oes 0.135 0.3100 0.100 S ows Soars 0.050 ® 0.050 0.025 0.025 ° 60 61 62 63 6A ° ol 909192 93 98 io Ta12 13 14 TUK) 11K) TK) a) 8) or 8- Single Walled Carbon Nanotubes are made of a single layer of. A) Diamond B) Graphite 2) Graphene D) Fullerene 9- Shape memory alloys undergo. A) sloid-solid transformation B) martensitic transform: ) diffusion less transform: all of the above 10- Which one of the following statements, concerning superconductors, is false? A) Below its critical temperature, the resistivity of a superconductor is ~ zero Q-m. Critical temperatures for some superconductors exceed 100 K. ‘C) All materials are superconducting at temperatures near absolute zero kelvin. D) Superconductors are perfect conductors 11- In chemical vapor deposition for carbon nanotube synthesis, ........ is usually adopted as (a) catalyst/s. ‘A) magnesium and/or nickel B) cobalt and/or iron C) aluminum and/or iron (DyAandc _ 12- Materials that upon placement within the human inert biomaterials bioactive materials body starts to dissolve bable materials Scanned with CamScannerDuration: 23 Hrs Hrs | Date: 27/05/2019 | Total Marks: 60 | Instructors: Dr. Sarah A. Elnekhaity 2 Atma ts wi IC oo sr the following True and False Questions (TF) in your bubble sheet. (One point each) LA ith chi ; 40 With chiral angle =30° will create a zigzag carbon nanotube.X. Ee bon nanotube’s stiffness is higher than that of the high-speed steely” ~ Superconductivity is a state of thermodynamic equilibrium. 4 In industry, high criti ture less effective than low critical ry, high critical tempera i iti ; . me superconductors are I ti low critical 5- In Type I superconductors Meissner effect is obvious. ;-~ 6- Type II superconductors are kni 1 own as hard superconduct i ivity i tere ae iperconductors because their superconductivity is 7 The external stress applied for detwinning is above the martensite yield strength, ~~ 8- Shape memory alloy composition affects both the martensite finish and austenite finish temperatures. »--— 9- Gold/Cadmium alloy is an example of a shape memory alloy..-~ 10- Alumina is used as a non-toxic biomaterial. ~~ 11- Metals and ceramics are chosen for soft tissue applications 12- Biomaterials might interact with surrounding tissues. 1 ~ 3- Answer the following questions: Use sketches if possible. 1a) The structure of a carbon nanotube depends on the roll-up (Chiral) vector. Discuss this statement showing the different carbon nanotube structures that can be formed. ‘Discuss briefly two of current and/or future applications of carbon nanotubes. (22 points) 2-a) Define the following: supercofiductors, superconduetivity, cooper pairs, supereoriductor critical temperature. ; _BYBCS theory does not follow the classical electron theory. Discuss, [py Write in details about Meissner effect. , (12 points) 3- a) What are the biomaterials requirements? oo | _ ) Polymers are the most widely used materials in biomedical applications. 7) What are they mostly used in? — ‘4 gm. Jom? 2 | Light metals have sp. gr. intherange => (@) "1-7" gm. /em* (b)<4 gm. fom? (c)<7 gm. /em? (@) <5 gm. /em? 3- | Refractory metals have m.p. above: 1650°C (b) 1850°C (c) 1900 °C (d) None 4 | Noble (Precious) metals such as: {a) Au, Pt, Hg (Av, Ag, Pt (©) Au, Ag, Cr (d) None 5- | Temperatures of pyrometallurgical processes are: (a) > 700°C >500°C__(@"700-1650"°C__(d) > 300°C 6- | Temperatures of hydrometallurgical processes are: @<300°C__(b)< 500°C __(@)"100- 500" °C (@ At room temp. 7- | Oxidizing roasting involves heating the ore inz (a) Reducing atmosphere Air or oxygen (Nitrogen. _(d) None 8 | Zn0, can be reduced by C to Zitvap. at temp. Lhe > 920 °C (b) < 920°C (co) > 900°C (d) None 9- | The raw Zn from the retort and blast furnace processes contains as major impurities: (a) Fe and Si (b) Pb and Cd fe¥P and S (d) None 10- | Zinc fumes are finely divided zinc oxide formed by: (@) Oxidation of zinc vapor (6) Reduction of zine concentrate | LeF Roasting of zinc ore (d) None of the above 11- | Zine fumes are carried with the furnace gases and are collected in: t (a) Bag filters Electrostatic precipitators (c) Cyclone separator (a) None of the above 12- | What is the first process of Zinc extraction from its ore? (2) Reduction FB Roasting (c) Galvanizing _ (d) Sacrificial Protection [3- | How to remove oxygen in the Zn extraction from Zn conc.? (a) Sacrificial Protection (b) Galvanizing eduction (d) None of the above || 14- [Through pyrometallurgical processing Zn is extracted from Zn co 7 | |__| @ soli (byLiquid ___ferVapor__(d) None of the abe Which one of the following process has the obj ‘ ijective of Selective dissolution of (2) Cementation _ g/f Leaching (©) Converting (A) Roasting” of Metal? Zinc-ores generally have low content of zine metal, which is i Zion seer be ly entant of net is in the range: ()< 11% -| Which one of the following minerals is the main Zn-mineral? Sphalerite ©) Smithsonite (€) Willemite (4) Hemimorphi és e Scanned with CamScanner18-] The rate controlling step during reduction of ZnO (a) The Boud ; - iffusion © (e) Redkacth louard reaction on C surface a idatio of Zn 79-f Resection with CO onthe Zn0 suraeé (a) Roos astral Zn process hoe disadvantage of Horizontal Retort a5 2000 and fuel | ifficulty of mechanization cost (la } mm (c) CO burns to waste “all of the above - | Roasting converts the zine sulfide concentrate t0: (©) Zine vapor ine oxide —_(b) Zine sulfate (¢) Zine carbonate \ 21- | The shape of Verti i is: cal Re ‘ion of Zn is: ® Cylindrical shaft stort used for Pre eectangulat shaft () Spherical shaft (a) None of the above - c aii jal application; 22- ia Sterling process for production of Zn has not found any wide industrial application; reason may be: . (a) Low production (0s) Difficulty of | mechanization | (c) The large electric energy consumption “All of the aboveo— = 7 23- [In the Sterling process the mixture of Zinc sinter and coke is heated in an electric arc | furnace to a temperature at which iquid slag is formed (b) Molten zine is formed (c) Zn vapor is formed (d) Ashes is formed 24- | Al alloys are used in construction of aircraft due to thei (a) Strength __(b) Low density __(c) Easy shaping All of the above 25- | The base ore for Al production is: Bauxite (b) Kaolinite ()Corundum __(d) Diaspore 26-1’ The principal impurities in bauxite are: (a) Fex0s (b) SiOz (©) TiO _LATAIL of the above 27-| The grade of bauxite depends on ‘Al:0s and SiOz (b) Al2Os and Fe2Os (c) AlOs and TiO> (d) Fe20s , SiO and TiO2 38- | For purification of bauxite to ‘AbOs, powdered bauxite is mixed with approximately: /|7 [gffio% NaOH (b) 20% NaOH (©) 30% NaOH (a) 40% NaOH BEL Pressure and temp. required during purifiation of bauxite to AlOs in NaOH solution 47° | are: (a) 4 atm. and 550 °K (b) 1.5 atm, and 420 °K (c) 2.2 atm, and 550 °K atm, and 420 °K 3O-| Aluminum hydroxide is heated in rotary kilns to produce AizOs at about: 7300 °K (6) 1100°K (6) 950°K_(@) 640° S| Which of the Tollowing is used to dissolve alumina during the electrolytic process? (a) Aluminum Hydroxide _(b) Sodium Aluminste _(c) luorsilici acid eta (@) "4-7" (b) "7 (d) "13-16" kWh 55 The anodes used inthe electrolyte redustion of AlOs to Al are made of (a) Copper (bo) Lead AS Graphite (@) Steel of “Amgunt of AlzO3 added to the molten cryolite in electrolytic reduction 5 79 oma cell is: Bs % (BNE 7"% ——_—*(©)"7~10"% ("10-12"% | FE] The side walls of the box (reduetion cel) of AL are ined with: | Carbon (b) Alumina (c) Silica (@) Magnesia | Scanned with CamScannerDuration: 3 Hrs, 37- | To adjust the Date: 30/05) 30/05/2019 | Tot tal Marks: 90 | 'nstructors: Dr. Mohamed Mi, &: Ahmed Dr. Adel Amer To a electrol ith = (2) Cryolite is addan oe Om Pesitin in the reduetion call ana and to make up fluoride losses. (c) Hy : ) Hydrogen fluoride is added Pr Auminum fluoride is added 38- In operation (Ne , the bod (ro ) None of the (a) 1500% Xx fr eduetion cell) of Alis filled ‘with cer Stas ae (0) 1400°K fo acu molten eryolite at temp.: i ri @)Silien le : m ‘duced By the reaetion beloen aaah aeaaraa turning, (c) Hydrogen Fluoride 4¢¥Fluorosilicic acid 39. During purification of bauxite (a) Distillation Al(OH)s is separated from sodium hydroxide solution by: 40- PB Filtzation (Va - ‘aporization lens Ore minerals of Al include: (d) Condensation (a) Corund TV Geaai (b) Cyanite (©) Kaolinite LAA of the above 41- 42- Huge q iti el ‘ici ke a is quantities of electricity ae Fequired (10-13 kWh / kg of AD) so Al smelters need to ‘cap electric power, such as: (a) Thermal power plants (b) Nuclear power plants (c)Hydro-clectrie power plants __4éySolar power plants The most important mineral of the mercury ores is: (a) Metacinnabarite fey Cinmabar (c) Livingstonite (a) Corderoite Which one of the following minerals is a souree of Lead (a) Pyrolusite_(b) Malachite _(c) Calomal__{afCerussite Copper is most commonly present in the earth’s erust as \S (a) Native copper _(b) Cu-Fe Sulfides _(c) Cu-Sulfides _faf(b) and (0) ileal ‘one of the following process has the objective of Precipitation of metal in aqueous solution. (a) Leaching fof Cementation (c) Converting _(d) Roasting which one of the following process has the objective of Selective dissolution of metal ‘Leaching _(b) Cementation _(c) Converting _(d) Roasting ‘An important objective of matte smelting is to produce a slag which contain: as possible, this can be done by adding (a) CaO flux _(b) CaCOs flux __4FSiO2 flux__(@) MgCOs s as little Cu 49- ‘are used to make machines such as rock crushers and power shovels, which must withstand extremely hard use. (a) Stainless steel _(b) Tool steel Ao Manganese alloy steel__(d) Constructional steel During Pyrite leaching, the maif role of the bacterial step is (a) Producing energy Bis Regeneration ofreactant (c) Oxidize the sulfur (d) All of the above 50- 51- industrially the anodes are In electrowinning process, Pb-alloy sheets (a) Al-alloy sheets (©) Cu-alloy sheets (d) Stainless steel sheets Tn electrowinning process, industrially the cathodes are (a) Al-alloy sheets (b) Pb-alloy sheets (¢) Cwwalloy sheets LB Stainless steel sheets The electrolyte in Cu electrorefining process is (a) CuSO«_(b) CuSOsand HeSOs cone.) _(c) HaSO« (di) EF Cu80e and Ho$Os dil) Blister copper is (a) Native copper_ 6 impure copper _(c) ore of copper__(d) none of the above The molten matté to impure molten copper can be done by-..++++..- Process, (a) Forth flotation —(b) Smelting AF eConverting (d) Fire- and Blectrorefining Scanned with CamScannerDy tration: 3 Hrs. | Date: 300s/2019 | TotalMarks:90 |] 7 cell 55- | The behavior of sulfur as an impurity in Cu * fons solid slimes issolves in the electrolyte de theres to ano —~ crane to cathode (@) ache 56- | Sulphur ores are concentrated by \ (a) roasting APeriroth flotation 6 ee | (c)_calcination d)_ smelting na | 57- | Which of the following statements are correct? he froth cl ot (a) A depressant cannot prevent certain type of particle to come ( (b) Copper matte contains Cu2S and ZnS. istered appearance duc to | feFThe solidified copper obtained from reverberatory furnace has blistered aPP evolution of SO during the extraction. (a) Lead can be extracted by self-reduction 58- | Which of the following ores are concentrated by froth flotation? (a) Hematite _AoTGalena (©) Native Copper (d) Magnetite. 59- | In electrorefining cell, Cu++ ions migrate towards the cathode by .. (a) Diffusion process (b) Convection process | Ee and (b) (d) none of the above 60-| When copper ore is mixed with silica, in a reverberatory furnace copper matte is produced. The copper matte contains. a . (a) sulphides of copper (II) and iron (11) (b) sulphides of copper (II) and iron (LID) sulphides of copper (1) and iron (11) (d) sulphides of copper (1) and iron (ITN) Giz] In some cases, particularly when the gold is present in the ore as discrete coarse particles, a gravity concentrate can be directly smelted to form gold.......-- (a) flakes (b) nuggets ey bars (a) billets 62- | Which of the following reactions is an example of autoreduction? (a) Fex0s + 4CO — 3Fe + 4CO2 (b) CO + C + 2Cu+CO (c) Cu** (aq) + Fe (s) > Cu (s) + Fe?" (aq) Cu20 + Ys CwS — 3Cu+% S02 63-| Extraction of gold involves leaching the metal with CN-ion. The metal is recovered by... isplacement of metal by some other metal from the complex ion. (b) roasting of metal complex. (©) calcination followed by roasting. (d) thermal decomposition of metal complex - @i-| The group of metals which is composed of transition metals such as tungsten, molybdenum, niobium, and tantalum is .. ts (a) Scattered metals __(b) Nobel metals __Aefrefractory metals _(d) precions metals 65- | In the extraction of copper from its sulphide ore, the metal is formed by the reduction of Cu20 with (a) FeS (b) CO Af Cw (d) SO 3 is made from pig iron by melting ina furnace lined with ferrqas on : ft vrouen iron (b) White cast iron rrous oxide, (©) grey cast iron (@) Ductile cast iron is characterized by its power to damp vibrations and b || imparted by the lubricating effect of graphite | (a) Wrought iron (b) White cast iron grey cast iron () Ductile cast iron :: s hard, brittle, and unmachinable 1) Wrought iron AP White cast iron — grey cast iron (@ Ductile cast iron y the Wear resistane Scanned with CamScannerDuration: 3Hrs. | Date: 300872019 | Total Marks: 90. | Insftors: Or Mohamed M8. Ahmed Dr, Adel Amer . isa high-carbon ferrous product containing graphite in the form of spheroids. (a) Wrought iron White cast iron (©) grey cast iron fey Ductile east iron Cyanide leaching process is mainly used to extract gold from its ore that has | 70- sau +» Bold concentration iow () high (c)medium —__(@) __ 71- | Cu from Cu-Fe-S minerals are mainly extracted using 2 FPyrometallury b) hydrometallurgy —__(¢) clectrometallurgy _@.all of above: 72- | Production of copper from recycled used objects production. (A) 0.5% 10 5% (8) 5% 10 10% __fe)'10% to 15% _() 15% 920% _____—| 73- | Copper is extracted from sulphide ore using the method (4 Carbon reduction (b) Carbon monoxide reduction _|4eJ" Auto reduction (d) None of the above | FA-| The floated’ Cu-mineral particles overflow the Motation ceil in w froth to Pecome concentrate.. | (a) 20% Cu @F30%Cu_() 40% Cu_(a) 50% Cu — 75- | Matte smelting oxidizes and melts flotation concentrate in a large, hot ...---++- furnace. | (a) 1000 °C (b) 100°C __fey"F250°C__(a) 1350.°C _ | 76-| The Betts clectrolytic process is an industrial process for electrorefining of .-...- | (a) impure zinc (6) impure copper _AG impure lead (all of above =] 77 | In the extraction of copper from its sulphide ore, the metal is formed by the reduction of | Cu20 with — | (a) FeS (CO fF CwS @Cc ; 7B} The main product of copper smelting process is molten sulfide matte whieh contains \ (a) 35% to 55% Cu 45% to 75% Cu___(¢) 55% to 85% Cu 30% to 70% Cu | 79-| Gold alloys with lower category, typically 22k, 18k, 14k or 10k contains 2 “er | ercentage of... in the alloy. yeoner (b) silver (o) palladium Ball of above ‘80- | During Pyrite leaching, the main role of the bacterial step —— \ jegeneration of reactant (b) Producing energy (©) Mass transfer (@) Allof the above Bi-| The microbial oxidation process during Pyrite leaching occurs a ell membrane of the bacteria (b) Nuclea of the bacteria (c) Interspace of the bacteria (d) None of the above During Pyrite leaching, the electrons pass into the cell of the bacteria’s are used in biochemical processes to (a) Transfer electricity roduce energy for the bacteria (c) Equalization of the medium (d) None of the above: Q2: True or False [0.625 mark/point] ‘As compared to other metals, mercury is a good conductor of heat and electricity, ¢ ‘Mercury and its compounds are very toxic, 7 ‘Mercury ores found in the earth crust is low but it is not a rare element. /~ The red ore called cinnabar is available abundantly on the earth. ¥ <5. | Mercury (Hg) is considered as a noble metal which is easy to produce. x 6- | Since, mercury has a high boiling point; it can easily be extracted via vacuum distillation. 7- | Thermodynamically, Hg0 is easily decomposed by heating to above 600°C. Yo 8- | Commercial-grade mercury with 99.9% purity is called triple-distilled mercur = Ulirapure mercury is called virgin-grade mercury. — Scanned with CamScanner—Fi6. (11 2412-1 Gn cows eds: ‘The te antwin te Wives purity rere Chhoridizing ros | Peduction, | Reduction ro 114) Za Gy VIS | he solubility « $20- | tn bauxit sting p isch of zine in production, -An the lead refining | oxidation » [and sodiuin hyde | Gold ions in jagent of EAD |The tout eo ‘ely removed ixture of sodium nitrate (NaN( OH) at 7: olution are readi th to become concentrate | containing 2A-| Ine e a id refining process, dive -| Parkes pr | In lead refining proce [| at 1000, a S426 In pyrometallurgy re | process and gold are removed and recovered economically using s, tin can be removed by adding ammonium chloride to the molten lead ing of crude lead, removal of sulfur is carried out by the Parkes Fire-refined copper is adequate for noneritical epplications sack as water tubing, bar stock. or CP | ingots for alloying, Copper intended for electrical uses, however, is produced by rorefining or sometimes electrowinning techniques objective of the matte smelting is to oxidize Fe Tom Gal molten sulfic Fe-S to produce Cu-enriched | pha | ‘The major use of copper in modern times has been as an electrical conductor, and about 50% of the current demand is for electrical uses || the electrolyte for Betts electrolytic process used in the extraction of lead is @ mixture of lead | Sluorosilicate (PbSiFc) and hexafluorosilicie acid (H»SiF.) heated to 85°C. |.-- In an electrorefining process, the anode is the impure metal and the impurities must be low during the passage of the metal from the anode to the cathode during electrol sis | Lletroretining of Cus a much more common process than eles ageless Sheet-Jead is used as a sound deadening layer in sound studios \/ ‘as projectiles for firearms and fishing sinkers because of is comosion resistance old presents in the ore as fine particles, the concentrares are treated with sulfide When the for clectrorefining copper is typical of those carried out in aqueous solution, As and Sb are selectively removed by oxidation with either air enriched with oxygen or mixture of 1zSO« and NaOH ; In Cu clectrorefining, gold is the only element that can contaminate the cathode by deposition onit > _ en - _ Gold is the most malleable and ductile of all of metals, a single gram can be beaten into a sheet of one square meter, 47 —__ Cyanide is principally used for the recovery of gold from its ores by amalgamation Y Scanned with CamScanner1 “| etme: 99 | seustore: Age. | Pats | process is a hydrometallozgical procas ao. | Ag, Au and Pt are more noble than co, i Le | will be found as metals in the anode stirs vu Reale ot Sn, Bi und Sb dissolve anodical: ly but will pr Tr | compounds which will be found in the anode apie: in the eles jold occurs in rare alloys with copper lead and tin - | dissolve anodically. They we as oxide or hydroxide Betterton-Kroll proc ‘Most lead ores contain janificant © containing silver as a contam impurities that are more noble than lead, such as bismuth and tin, 7 dissolves and settle to the bottom of the vessel as "anode mud”. Manganese alloy Steel are used (@ make machines such ws rock crushers end power shovels, vhich must withstand extremely herd use_ The molten copper is mostly cast in continuous casting machines from where it goes to rolling, extrusion and manufacturing, The melting of elecirorefined and electrowon copper is mostly done ts horizontal Tampere I which descen ding alae sheets are melted by ascending hot combustion gases. rm only. __% muh fromlead Os 3: Mi fatching 10. 625 mark Caen Match the blanks in the following flow diagram with the given appropriate terms t & ‘A- Electrolysis. a. B- Roasted Cone. 3. Teaching. D- Zn Slabs. - Zn Concentrate. F- Leaching Residu> G- Spent Electrolysis H- Zn Cathode. 1-Zn Sulfate Soin. J- Roasting. : Hydrometalurgical process for Zn recovery from Zn concentrates soe * Scanned with CamScanner