Midterm-Examination

(Structure and Properties of Metals and Alloys) 2006/4/17

[10 points each]

1. Draw an Fe-C phase diagram up to the carbon composition showing pure Fe3C. In your diagram indicate
temperatures and carbon compositions of eutectic and eutectoid reactions. Also indicate the maximum solubility
of -ferrite and -austenite in the diagram.

2. Carbon steel containing 0.5wt.% of carbon was slowly cooled to room temperature. Calculate the wt.% of the
cementite in the pearlite.

3. Mr. Cho found that the gray iron brake disk of his imported passenger car produced serious squeal noise (high
frequency noise) and judder (vibration) during braking. He carefully examined the disk using optical
microscopy and found out that the graphite morphology was type E with the flake size approximately No.6 in
ASTM (& AFS) standard. What can you do to improve brake performance of the gray iron disks? It is well
known that gray iron with type A and longer graphite flake size outperforms than others. Please write, in detail,
at least 3 different methods to improve the brake performance of the disk. (each method should include at least
70 English Words or 100 Korean words in each paragraph)

4. Explain why the mechanical property of gray iron is mainly described by tensile strength? (Your answer should
include at least 70 English Words or 100 Korean words for explanation)

5. Miss Hong found that a portion of the stainless guide rail in her apartment began to corrode at the welded
junctions and the corroded junctions were easily broken by leaning against it. What is the main cause of the
problem and how do you fix this problem considering austenitic stainless steels?

6. Describe the effect of Mn in the carbon steel in detail.

7. Mr. Kim annealed a heavily cold worked steel at 900C for 3 hours and found out that the average grain size
number (n) in ASTM standard was 5 with average grain size of 0.1mm and the yield strength approximately 30
Mpa. On the other hand, the same cold worked steel after annealing at 950C for 3 hours showed that the
grain size was increased to 0.2mm with the yield strength of 20 Mpa. If he found that the yield strength was
increased to 40Mpa after annealing at 800C for 3 hours, what will be the grain size after the annealing at 800C
for 3 hours?

8. Assuming that the surface energy of a newly appeared phase is and volume free energy change during the
transformation is G, derive the relation between critical size of the nuclei (r*) and the amount of supercooling
(T). Assume homogeneous nucleation and the cubic shape of nuclei in your derivation.

9. Describe the difference of the light microscope and electron microscope in terms of resolution and depth of
focus? Your answer should include the explanation concerning why they are inherently different?

10. Describe the characteristics of martensite transformation of plain carbon steels.

 Structure and Properties of Metals and Alloys
2007-10-21
1. Miss Kim investigated the correlation between a schematic drawing of phases when the alloy is cooled
microstructure of three gray cast iron samples and its from 950C to below A1 temperature. Calculate the
physical properties. He found out that the average wt.% of cementite in the pearlite at immediately below
graphite flake length, hardness, and damping capacity A1 temperature and calculate the amount of carbon
were affected by the cooling speed and carbon contents (in weight %) partitioned in the proeutectoid
equivalent of the gray iron. He also tested the wear cementite, -ferrite and cementite in the pearlite. [15
characteristics of the brake disk such as wear amount points].
and the change of disk thickness variation (DTV) using 7. Describe the four typical characteristics of martensitic
the same gray iron. His test results are listed in the Table transformation in plain carbon steel.
1. Please find your choice of gray iron for the best brake 8. Using the isothermal transformation diagram below,
performance in terms vibration and explain why. [15 describe the final microstructures (in terms of micro-
points] constituents present and approximate percentage) of an
Table 1. alloy steel (type 4340: C = 0.4 wt.%) that has been
Gary Iron Type A B C subjected to the following time-temperature heat
C.E. 4.6 4.3 4.0 treatments. Assume that the heat treatment begins at
Cooling speed slow medium fast 760C.
Hardness (HRB) 166 187 204
Wear amount (g) 0.23 0.42 0.93
Ave. graphite length(mm) 35 31 23
DTV change (m) 3 8 16
Measured internal friction 0.004 0.0006 0.0002
2. During the cooling of pure iron, allotropic
transformation is observed with thermal arrests at
different transition temperatures; explain the reason for
the thermal arrests and list the transition temperatures.
The temperatures do not have to be exact values (10C
is acceptable). [10 points]
3. Explain why heterogeneous nucleation is easier than
homogeneous nucleation. (Your answer should include
mathematical formula for the critical size of nuclei,
graphical comparisons of G vs. nuclei radius, and (1) Rapidly cooled to 625C and hold for 10000 sec and
nucleation rate vs. temperature.) [10 points] quenched to room temperature. [5 points]
4. Describe the sensitizing of stainless steel. Under what (2) Rapidly cooled to 550C and hold for 100 sec and
engineering situations does the sensitization of quench again to 400C and hold for 900 sec and quench
stainless steel occur? How can you avoid it? [10 points] to room temperature. [5 points]
5. Draw an Fe-C diagram with the composition and 9. Describe the effect of the following alloying elements
temperature of the invariant reactions. [10 points] on the shape of eutectoid composition and temperature:
6. Describe the transformation of Fe-1.0 wt.% C using Cr, Mn, Ti, Ni, Mo. [10 points]
 Introduction to Metals and Alloys
(midterm examination)
2008-04-22
1. The following graph was obtained from Avrami plots of pearlite transformation at different temperatures.
Assuming that the transformation was begun from austenitic phase of the Fe-C system at 740C, calculate the
critical cooling speed to avoid pearlite and bainite phases after transformation. Describe the microstructural
features after transformation when the transformation was preceded at 250C, 600C and 650C, respectively. [20
points]

2. Describe the effect of alloying elements such as Si, Ti, Cr, Mo, W, Mn, and Ni on the eutectoid point of steel. [10
points]

3. Describe the mechanism of the spheroidal graphite formation in the ductile iron. [10 points]

4. Describe the transformation of Fe-0.9 wt.% C using a schematic drawing when the alloy is cooled from 950C
to below A1 temperature. Calculate the wt.% of cementite in the pearlite at immediately below A1 temperature
and calculate the carbon contents (in weight %) partitioned in the proeutectoid cementite, -ferrite, and
cementite in the pearlite. (Assume that max. carbon solubility of ferrite is 0.02 wt% and eutectoid composition is
0.8wt.%, and carbon content of cementite is 6.67wt.%) [20 points]

5. Describe the sensitizing of austenitic stainless steel. How do you circumvent this phenomenon? [10 points]

6. Briefly describe the iron making and steel making processes. [10 points]

7. Using your knowledge of the kinetics of phase transformation explain why heterogeneous nucleation is easier than
homogeneous nucleation. [10 points]

8. Describe the characteristic features of martensite transformation of plain carbon steels. [10 points]

Thank you!
 Introduction to metals and alloys
(Midterm examination)
2009-4-17
1. There are two different types of high speed tool steels. Typical compositions of two steels are Fe-0.75%C-
18%W-4%Cr-1%V-5%Co for a tungsten type and Fe-0.8%C-4%W-5%Mo-4%Cr-1.5%V-12%Co for a
molybdenum type. (1) Describe the advantages and disadvantages of tungsten type and molybdenum type
tool steels, respectively. (2) What are the roles of the alloying elements to improve the properties of high
speed tool steel? [10 points]

2. Describe the effects of alloying elements such as (1) Mn, (2) P, (3) Mg, (4) Ni, (5) Pb, (6) Cu, (7) Cr, (8)
Mg in cast iron. [8 points]

3. Describe the intergranular corrosion mechanism of austenitic stainless steel and its preventive
methodology. [10 points]

4. Why heterogeneous nucleation is easier than homogeneous? Describe the reason using the critical free
energy of nuclei formation (G*) and critical size of nuclei (r*).[10 points]

5. Describe the 4 important characteristics of martensite transformation in plain carbon steel. [12 points]

6. Describe the three annealing stages and the size of the grain after annealing in terms of annealing
temperature and the amount of cold work. [10 points]

7. (1) Describe the transformation of Fe-1.0 wt.% C using a schematic drawing when the alloy is cooled
from 950C to below A1 temperature. (2) Calculate the wt% of cementite in the pearlite at immediately
below A1 temperature and (3) calculate the carbon contents (in weight %) partitioned in the proeutectoid
cementite, -ferrite, and cementite in the pearlite. (Assume that max. carbon solubility of ferrite is 0.02
wt% and eutectoid composition is 0.8wt%, and carbon content of cementite is 6.67wt%) [20 points]

8. The following graph was obtained from Avrami plots of pearlite transformation at different temperatures.
Assuming that the transformation was begun from austenitic phase of the Fe-C system at 740C, (1)
calculate the critical cooling speed to
avoid pearlite and bainite phases after
transformation. (2) Describe the
microstructural features after
transformation when the transformation
was preceded at 250C, 600C and
650C, respectively. [20 points]

2010-04-21

1. (a) Describe the transformation of Fe-2.0 wt.% C using a schematic drawing of phases when the alloy is
cooled from 950C to below A1 temperature. (b) Calculate the wt.% of cementite in the pearlite at
immediately below A1 temperature and calculate the amount of carbon contents (in weight %) partitioned
in the proeutectoid cementite, -ferrite and cementite in the pearlite. [15 points]

2. Assuming that the surface energy of a new phase is and volume free energy change during the
transformation is Gv, derive the relation between critical size of the nuclei (r*) and the amount of
supercooling (T). Assume homogeneous nucleation and the cubic shape of nuclei in your derivation. (10
points)

3. (a) Describe the sensitizing of stainless steel. (b) Under what engineering situations does the sensitization
of stainless steel take place and describe how to avoid it? [10 points]

4. A student annealed heavily cold worked steel at 900C for 3 hours and found out that the average grain
size number (n) in ASTM standard was 5 with average grain size of 0.1mm and the yield strength
approximately 30 Mpa. On the other hand, the same cold worked steel after annealing at 950C for 3
hours showed that the grain size was increased to 0.2mm with the yield strength of 25 Mpa. If the same
steel was annealed at 800C for 3 hours and obtained the yield strength as 40MPa, what will be the grain
size? (10 points)

5. Describe the characteristics of the martensite transformation in plain carbon steel. (10 points)

6. (a) Describe the three stages of annealing of steel and (b) the relationship among annealing temperature,
amount of cold working, and hardness of the annealed steel using a schematic diagram. (15 points)

7. Describe the effect of alloying elements such as Cr, Ti, Ni, Mn, Si, Mo on the eutectoid composition and
eutectoid temperature of carbon steel. (10 points)

8. Briefly describe the difference of ferritic stainless steel, martensitic stainless steel, and austenitic stainless
steel in term of composition, mechanical properties, and corrosion resistance. (10 points)

9. Classify the microstructure of gray cast iron in terms of (a) distribution and (b) length of graphite flakes.
(10 points)

Thank you!
 Introduction to Metals and Alloys
(Mid-term examination)
2011-4-26

1. It is well known that the atomic packing density of FCC is higher than BCC. On the other hand, the carbon

solubility of -iron is greater than -iron in the Fe-C diagram. (1) Explain why -iron has a higher solubility

than -iron using the atomic structures of iron and size of the carbon. (2) Why the maximum solubility of

-iron is smaller than -iron. Assume that the radii of iron and carbon are 0.14 and 0.07 nm, respectively.

[25 points].

2. (1) Describe the transformation of Fe-0.55 wt.% C using schematic drawings of the phases when the alloy

is cooled from 950C to below A1 temperature. (2) At the same composition, calculate the wt.% of

cementite in the pearlite at immediately below A1 temperature and (3) calculate the amount of carbon

contents (in wt. %) partitioned in the proeutectoid cementite, -ferrite, and cementite in the pearlite. [20

points].

3. From the nucleation and growth kinetics of pearlitic transformation of carbon steel, show that the TTT

diagram for pearlite formation should be in C shape. [25 points]

4. Describe the role of Si and S in cast iron. [10 points]

5. Describe the three annealing stages and the grain size after annealing in terms of annealing temperature

and degree of cold work. [20 points]

Thank you!
 Introduction to Metals and Alloys
2012-4-19

1. Draw an Fe-C phase diagram with the composition and temperature of eutectoid and eutectic point. Using
the phase diagram, describe the evolution of phases as a function of temperature during slow cooling of
Fe-1.0 wt.%C. What are the final carbon contents of the phases produced after slow cooling? [20 points]

2. Describe important features of scanning electron microscopy. [10 points]

3. Describe 4 different chractaristics of martensite transformation of plain cabon steel [10 points]

4. Describe 3 stages of annealing process of steel. Your answer should include the parameters that determine
the final grain size after annealing [15 points]

5. Describe two different methods to measure hardenability of steel [10 points]

6. (1) Compare ferritic, martensitic, and austenitic stainless steel in terms of composition, hardenability,
corrosion resistance. (1) List at least one application for each stainless steel. [15 points]

7. Describe the mechanism of spheroidal graphite formation in ductile cast iron. [10 points]

8. (1) Discuss the factors that affect the friction force when two bodies are rubbed each other. (2) Are those
factors in (1) influenced by the temperature, load, and speed? Describe why? (3) What determines the wear
rate of materials during sliding? [10 points]

Thank you!

()
2014-4-16
1. Assuming homogeneous phase transformation, (1) show that the critical size of the nucleus and
activation barrier for nucleation are inversely related to the amount of undercooling. (2) How do they
change when the phase transformation follows heterogeneous nucleation? [10 points]

2. Calculate the amount of carbon partitioned in the cementite in the pearlite phase when the austenite
with 1.1 wt.% carbon is slowly cooled from 950C. [10 points]

3. The eutectoid steel showing the lamellar spacing approximately 1.2 m after isothermal
transformation at the temperature just below the A1 line showed the yield strength of 100 MPa.
When the same steel was isothermally transformed at lower temperature, the lamella spacing
changed to 0.5 m with the yield strength of 232 MPa. Calculate the yield strength when the lamella
spacing was controlled to have 0.3 m after proper control of the transformation? [10 points]

4. Describe the characteristics of martensitic transformation of plain carbon steel. [10 points]

5. Describe the two typical methods to evaluate hardenability of carbon steel after quenching. [10
points]

6. An engineer found corroded regions near the welding line of an austenitic stainless steel pipe.
Describe the mechanism of corrosion and the preventive methodology to avoid corrosion. [10 points]

7. Describe the type of wear and Archards wear equation. [10 points]

8. (1) Describe the property requirements of steel for robust tools. (2) What would you do to achieve
required properties? [10 points]

9. Brake discs for vehicles are made of cast iron and their performance is substantially influenced by
the size and morphology of graphite. (1) What will you do to produce brake discs with type A gray
iron with No. 1 flake size. (2) Can you change the flaky graphite into spherical shape to produce
ductile cast iron? How would you do it and describe the cons and pros if you change the graphite
shape of the brake disc into spherical ones. [10 points]

10. Describe the microstructural change during tempering of quenched plain carbon steel. [10 points]

Thank you!
 ()
2015-4-21

1. (annealing) (driving force)

. [10]

2. 4
100% . [15]

3. . [10]

4. Fe - 0.1 wt.% C A1
. [10]

5. 400 (stainless steel) (sensitizing)

. [10]

6. . [10]

7. , ,
. [15]

8. 2
. [15]

[95]+[5]=100
 Structure and Properties of Metals and Alloys
(Midterm examination)

2016-4-21

1. Draw an Fe-C equilibrium phase diagram with the composition and temperature of eutectic and

eutectoid points. Using the phase diagram, calculate the amount of carbon in the ferrite in the

pearlite when the austenite with 1.0 wt.% C is slowly cooled to room temperature from 1000C.

[15 points]

2. Describe the two typical methods, which were suggested by Jominy and Grossmann, to compare

hardenability of carbon steel. In your description, include the effect of carbon content and average

grain size on the hardenability. [15 points]

3. Describe the microstructural change of carbon steel during annealing and the final grain size as

functions of annealing temperature and the amount of cold working. [15 points]

4. Describe the relation between the average pearlite spacing of carbon steel and the temperature

during isothermal transformation using the theory of nucleation and growth of solid-state phase

transformation. [15 points]

5. Describe the effect of graphite morphology on the properties of gray cast iron. How do you

increase the length of the graphite flakes to improve thermal conductivity of gray iron? [10 points]

6. Describe the role of Cr, C, and Ni in stainless steel. Your description should include sensitizing

and embrittlement phenomena of stainless steel. [10 points]

7. Describe four important characteristics of martensitic transformation in plain carbon steel. [10

points]

8. Describe the important features of the scanning electron microscope and optical microscope. [10

points]

Thank you.