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)

Pure metal Metal alloys

Fluidity High Low
freezing range Short Long
Structure Form mushy zone within
Solidification front moves
freezing range
as a plane without mushy
temperature which consist
zone.
of columnar dendrites
Explanation Presence of mushy zone
Molten metal exist in
(liquid + solid or paste)
forms of liquid which has
lowered the fluidity of
high fluidity
metals

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

1 Viscosity Viscosity and viscosity index (its

2 Surface Tension
sensitivity to temperature) increase,
fluidity decreases
High surface tension reduces fluidity
Oxide films on the surface of the
molten metal effect fluidity (increase
the surface
tension)
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)

The ceramic mold is preheated by radiant heating, and the mold is supported by a
water- cooled chill plate. After the metal is poured into the mold, the chill-plate
assembly is lowered slowly. Crystals begin to grow at the chill plate surface and on
upward. The metal thus is solidified directionally, with longitudinal, but no
transverse, grain boundaries.

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)

i. Low pressure die casting

The casting process is cyclic and begins with the pressurization of the furnace, which
contains a reservoir of molten aluminum. The excess pressure in the holding furnace
forces liquid aluminum up into the die cavity, where it is cooled and solidified by the
transfer of heat from the aluminum to the die and then out to the environment. After
solidification is complete, the side dies open and the top die is raised vertically. The
wheel remains fixed to the top die (owing to thermal contraction) for a short time and
is then ejected onto a transfer tray rolled under the top die. The die is then closed and
the cycle restarted

ii. Permanent Mold Casting

Mold preparation - First, the mold is pre-heated to around 300-500°F (150-260°C) to
allow better metal flow and reduce defects. Then, a ceramic coating is applied to the
mold cavity surfaces to facilitate part removal and increase the mold lifetime.

Mold assembly - The mold consists of at least two parts - the two mold halves and
any cores used to form complex features. Such cores are typically made from iron or
steel, but expendable sand cores are sometimes used. In this step, the cores are
inserted and the mold halves are clamped together.

Pouring - The molten metal is poured at a slow rate from a ladle into the mold through
a sprue at the top of the mold. The metal flows through a runner system and enters the
mold cavity.

Cooling - The molten metal is allowed to cool and solidify in the mold.

Mold opening - After the metal has solidified, the two mold halves are opened and the
casting is removed.

Trimming - During cooling, the metal in the runner system and sprue solidify attached
to the casting. This excess material is now cut away.

http://www.custompartnet.com/wu/permanent-mold-casting
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)

Sketches Microstructure
Wrought grain
structure-
Finer grain and
Hot rolling enhanced ductility due
to recrystallization and
stress relief after
deformation

Elongated grain- slip

dislocation due to
Cold rolling
deformation without
recrystallization

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)

Plate is the product with a thickness > 6 mm

Viola will answer...

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)

Small-diameter rolls large-diameter rolls

Small-diameter rolls or small thickness Conversely, large-diameter rolls or high

reductions per pass tend to plastically deform
the metal more at its surfaces than in the
bulk. This situation results in compressive
residual stresses on the surfaces and tensile
stresses in the bulk
reductions per pass tend to deform the bulk
more than the surfaces (Fig. 13.9b). This is
due to the higher frictional constraint at the
surfaces along the arc of contact ― a
situation that produces residual stress
distributions that are the opposite of those
with small-diameter rolls

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

A cylindrical billet is forced through a die The cross section of solid rod, wire, or tubing
(‘push’) is reduced or changed in shape by pulling it
through a die (‘pull’)

Process variables in direct extrusion. The die
angle, reduction in cross-section, extrusion
speed, billet temperature, and lubrication all
affect the extrusion pressure
Process variables in wire drawing. The die
angle, the reduction in cross-sectional area per
pass, the speed of drawing, the temperature,
and the lubrication all affect the drawing force,
F

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

During extrusion, the metal divides and flows around the supports for the internal
mandrel into strands.

The strands then become rewelded under the high pressure in the Welding chamber
before they exit through the die.

The rewelded surfaces have good strength because they have not been exposed to the
environment; otherwise they would develop oxides on the surfaces, thereby inhibiting
good welding
Lubricants, of course, cannot be used, because they prevent rewelding of the metal in the die.

Question 3 (25 marks)

(a) Explain the main difference between thermoplastic and thermoset polymers.
(3 marks)
 Thermoplastics Thermosets
Polymers that can be shaped when heated
Polymers that become permanently set
and regain original hardness & strength
when heated
upon cooling.
Have a linear or branched structure (weak Have a cross-linked structure (strong
secondary bonds) secondary bonds)
Process is reversible Process is irreversible

(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)

Type Description
A linear polymer may contain
Linear Polymers some branched and cross-linked
chains
Side-branch chains are attached
to the main chain during the
synthesis.
Branched Polymers
Increase in resistance to
deformation and stress cracking
3D structure, adjacent chains
linked by covalent bonds
Cross-linked Increase hardness, strength,
polymers stiffness, brittleness, better
dimensional stability
Spatial, 3D networks of three or
more active covalent bonds
Highly cross-linked polymers =
Network polymers network polymer
high-energy radiation, increase
in strength

Linear polymer < Branched Polymer < Cross-linked polymer < Network polymer

Increasing strength
 - Branched polymer has higher strength than linear polymer because the side-branch
chain interferes with the relative movement of the molecular chains. It causes 3D
entanglements of branches thus difficult to move.
- As for Cross- linked polymer, it has 3D structure that the adjacent chains are linked
by covalent bonds. However linear and branched polymer is only linked with
secondary bond between them.
- Network polymer has the higher strength as it contained high cross-linked polymers
and form network.

(c) List THREE additives in plastics and explain their function in polymers processing.
(6
marks)
Additive Function
Plasticizer - improve the flexibility, ductility, and toughness
- reduce hardness and stiffness by lowering the glass
transition temp flexible and ductile at room temp
Filler - To improve tensile and compression strengths, abrasion
resistance, toughness, dimensional and thermal stability
and other properties.
Stabilizers - Increase resistance to UV radiation and oxygen
deterioration

(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)

Answer:

i. 3-pin plug casing

 Manufacturing process Injection molding

Diagram

1. Pellets fed into heated chamber

2. The melt is forced into the mold using a
rotating screw.
3. There are three zones in along the screw
namely feed zone, melt zone and
pumping zone.
4. Inside the screw, polymer is build up in
front of the sprue brushing. The pressure
pushes the screw backwards. When
sufficient polymer has built up, rotation
process
stops.
5. When the mold is ready, the screw is
pushed forward by a hydraulic cylinder,
filling the sprue brushing, sprue, and
mold cavity with polymer. The screw
begins rotating again to build up more
polymers.
6. After polymer is solidified/cured, the
mold opens, and ejector pins remove the
molded part.

ii. Plastic bag

Manufacturing process Extrusion of tube followed by blown-film
 Diagram

(a) Extrusion of tube

- Extrude the polymer (upward) as a continuous
tube, using a mandrel
(b) Blown-film
- Blow air to expand the film to desired film
thickness (lateral stretching)
(c) Cooling
- Cooled by air in a cooling ring also act as a
Process
barrier to further expansion thus controlling
product dimensions.
- The pinch rolls (at top) will pull the plastic
- The material is stretched and oriented in the
longitudinal direction.
- The product has undergone biaxial stretching,
imparting strength & toughness

iii. Plastic bottle

Manufacturing Extrusion-blow molding

process
Diagram

(a) (b) (c)

Process (a) First extrude a plastic preform or tube.
(b) Grip preform in a mold cavity much larger than
the preform.
(c) Blow the preform to expand it to fit shape of the
mold. Blowing usually performed with hot air
blast.
Question 4 (25 marks)
(a) With the aid of sketches, explain the detail steps in ceramics slip casting process.
(7
marks)

(i) (ii) (iii) (iv) (v)

i. A porous mold is made of plaster of paris. A slip is a suspension of colloidal
(small particles that do not settle) ceramic particles in an immiscible liquid
(insoluble in each other), which is generally water.
ii. The slip is carefully poured into the mold to avoid air entrapment. The slip must
be fluid enough with low viscosity to flow easily into mold.
iii. Allow mold to absorb some water from the suspension. Then invert the mold to
pour out remaining suspension.
iv. The product is now a hollow object, lining the cavity.
v. Trim top; Open mold; Remove part.

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

(4 marks)
Drying - A critical process because of the tendency of part to warp or
crack from variations in moisture content and in thickness.
- Loss of moisture during drying causes shrinkage of the part
by as much as 20% from the original, moist size.
Firing - Firing involves heating the part to an elevated temperature
in a controlled environment. Some shrinkage occurs during
firing.
- Firing gives the ceramic part its strength and hardness.

(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)
Thermal tempering process of glass
 i. The surfaces of the hot glass are cooled rapidly by a blast of air.
ii. The surfaces shrink; at first tensile stresses develop on the surfaces.
iii. As the bulk cools, it contracts, forcing the already cooled surfaces to contract,
developing residual compressive surface stresses; the interior develops
residual tensile stresses.

Residual stress

- Compressive surface stresses improve the strength of the glass.

- Tempered glass shatters into large number of smaller pieces when it is broken
because of the high amount of energy stored in residual stresses.

(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)
Answer:
(i) Telescope lens

Manufacturing process Centrifugal casting

Diagram

- Also known in the glass industry as spinning.

Process - The centrifugal force pushes the molten glass
against the mold wall, where it solidifies.

(ii) Syrup glass bottle

(iii) Fluorescent bulb

Manufacturing Blowing Process

process

Diagram

- Blown air expands a hollow gob of heated glass against

the inner walls of the mold.
- The mold usually is coated with parting agent (oil or
Process
emulsion) to prevent glass from sticking to the mold.
- In blow and blow process, a second blowing operation
is employed to produce the final shape.