UNIVERSITY OF MALTA

FACULTY OF ENGINEERING
B.ENG. (HONS) COURSE
MECHANICAL ENGINEERING STREAM
YEAR 1V SEMESTER 1
JANUARY 2010 SESSIONS OF EXAMINATIONS
3rd February 2010

MME 4006 Advanced Materials & Composites

13.00 15.00

This paper contains two Sections. Section A is compulsory. Section B contains

FOUR questions and you have to attempt only three from this Section.

SECTION A (Compulsory)
cos 2

[T ] = sin 2
sin cos

cos 2

[T ] 1 = sin 2
sin cos

sin 2
cos
sin cos
2

sin 2
cos
2

sin cos

21
E 22
1
E 22
0

E11

[ S ] = 12
E
11
0

2 sin cos

2 sin cos
cos 2 sin 2

2 sin cos

2 sin cos
cos 2 sin 2

1
G12

Ars = Qrsj [h j h j 1 ]
j =1

Brs =

1
2

Drs =

1
3

Q
j =1

rsj

Q
j =1

rsj

[h 2j h 2j 1 ]

[h 3j h 3j 1 ]

Page 1 of 6

1.

Suppose we take a CFRP 0.375mm thick multi-layered composite shown in

Figure 1 with the following properties:
E11 = 138GPa, E22 = 8.96GPa, G12=7.10GPa, 12=0.3

Figure 1
(i) Work out the following:
(a)

The Compliance Matrix (S)

(1 Mark)

(b)

The Stiffness Matrix (Q)

(3 Marks)

(c)

The Transformed stiffness matrix ( Q ) for a unidirectional lamina with

fibres oriented at +45
(8 Marks)

(d)

The Transformed stiffness matrix( Q ) for a unidirectional lamina with

fibres oriented at -45
(8 Marks)

(e)

The A matrix for the laminate CFRP composite

(4 Marks)

(f)

The B matrix for the laminate CFRP composite

(1 Mark)

(g)

The D matrix for the laminate CFRP composite

(4 Marks)

(ii) Mention:
(a) one application where such multi-directional laminates are used
(1 Mark)
(b) one process used in the manufacturing of these multi-directional laminates
(1 Mark)
(iii) What is the main advantage in using such multi-directional laminates?
(3 Marks)
Page 2 of 6

SECTION B (Attempt only THREE Questions)

2.

A builder was breaking up some concrete slabs with an engineers hammer when
a large fragment of metal broke away and narrowly missed his eye. Figure 2
shows the general shape of the hammer head, and marks the origin of the
offending fragment.
The hardness of the hammer at different positions was tested and this is
illustrated in Figure 2. The hammers materials composition is according to the
BS 576-95 standard that states that hammers shall me made from a mediumcarbon forging steel with the following limits on composition: 0.5 to 0.6% C,
0.5 to 0.9% Mn and 0.1 to 0.4% Si. We would expect this steel to have a
hardness of between 1.8 and 2.2 GPa in the as-received state.

Figure 2 Failed Hammer and hardness values

Figure 3 The hardness of untempered martensite as a percentage of carbon

Question Continued

Page 3 of 6

(i) Utilising Figure 2 and 3:

(a) Explain the possible cause of the hammers failure.
(7 Marks)

(b) The hammers core is soft whilst the ball pein and the striking face are
hard. Why is this considered a desirable feature in the functionality of
the hammer?
(3 Marks)
(c) Mention and explain in detail two surface engineering techniques that
can be used to harden a similar hammer only at the ball pein and the
striking face.
(4 Marks)
(d) What extra measures after the surface treatment would you take to
ensure that the problem mentioned in this question will not arise again?
(1 Mark)
(ii) With reference to Low Temperature Plasma Carburising of Austenitic
Stainless steel write short notes on the following:
(a) Process details;
(2 Marks)

(b) Mechanism of Hardening;

(2 Marks)

(c) Corrosion Resistance retention;

(2 Marks)

(d) One Application for this treatment.

(1 Mark)

Page 4 of 6

3. The processes used to produce Polymer matrix composites (PMCs) listed

below fall in the indicated areas in figure 4.

(A) Vacuum bagging

(B) Resin Transfer Moulding (RTM)
(C) Matched die moulding

Figure 4 Processing methods of PMCs showing the ranges of manufacturing

variables appropriate for different processing methods

(i) Give a detailed explanation of the three processes mentioned

above.
(15 Marks)

(ii) Discuss why each of these processes fall within the regions A, B
and C.
(4 Marks)
(iii) State one component that can be produced utilising each of the
three processing methods mentioned above. Use a different
component in each case.
(3 Marks)

Page 5 of 6

4.

(i)

Explain the difference between a Plain weave and a Twill weave.

Highlight the advantages and the disadvantages of both weaves.
(4 Marks)

(ii)

Define the terms fibre sizing and fibre finishing.

(4 Marks)

(iii) Give a detailed description of glass fibres. The detailed description should
include:
(a) General Properties
(2 Marks)
(b) Different kinds of glass fibres
(2 Marks)
(iv) Give a detailed description of carbon fibres. The detailed description
should include:
(a) General Properties
(2 Marks)
(b) Manufacturing methods
(2 Marks)
(v) Compare the general properties of glass fibres and carbon fibres.
(2 Marks)
(vi) Give two main reasons why ceramic matrix composite (CMC) development
has lagged behind other composites.
(4 Marks)

5.

You have been assigned with the task to build a small sailing boat. With your
knowledge of composite materials, suggest fibre reinforced polymer composite
materials that can be used in this construction. Explain the reasons for your
choice. (Hint: A combination of fibres and resin systems can be selected).
Your account should include the following:
(i) Resin-fibre selection in different hull areas
(ii) Cost considerations
(iii) Aesthetic considerations
(iv) Manufacturing method
(v) Surface Finish
(vi) Degradation Protection

(6 Marks)
(4 Marks)
(2 Marks)
(6 Marks)
(2 Marks)
(2 Marks)

Page 6 of 6