Question 1

a) Outline briefly six parameters of a casting process

(9 marks)
b) What is solidification shrinkage and explain two methods to minimize this problem
(6 marks)
c) Correlate in terms of structure, materials behaviour and processing methods between
i) Die Casting
ii) Squeeze casting

(10 marks)

Question 2

a) Outline the process and operations involved in making powder-metallurgy parts

(5 marks)
b) Briefly describe two methods of metal-powder production by atomization techniques

(8 marks)

c) Using your own example explain the effect of mechanical alloying of metal powders
(5 marks)
d) Establish the mechanisms for sintering metal powders and their contributions to the final
properties of the product formed
(7 marks)

Question 3

a) Describe the fabrication process of a polymer composite by melt spinning of continuous

fibres. Give example of application
(5 marks)
b) Compare four important characteristics of thermoset and thermoplastic resins that are
commonly used as composite materials
(8 marks)
c) Justify the selection of the appropriate processing and fabrication technique for the
following polymer products
i) Patrol vessel boat
ii) Golf club shaft
iii) Vegetable oil container
(12 marks)

Question 4

a) Enhanced failure stress in ceramic matrix composite, CMC’s can be achieved through the
control of bonding between the matrix and reinforcement during processing, called
‘interphase’.
i) Explain the functions of interphase
ii) Give 3 examples of most commonly used CMC’s and its product
 (10 marks)

b) With the aid of relevant diagrams, show the processing techniques of CMC in the following
categories
i) Liquid-state
ii) Vapour-state
iii) Solid-state

How do you improve the performance of a piston top and explain for what purpose

(15 marks)

Question 5

a) You are able to fabricate a mobile phone casing from a polymer material
i) List reasons why plastics are choosen instead of metal
ii) Choose a processing method and write down the advantages and limitations of the
process
(15 marks)

b) Recent Grammy Award in USA shows a singer ‘Lady Gaga’ being carried away in a container
called ‘incubation egg shell’

Recommend a suitable material, give reasons for your selection and design consideration
and describe the processing method to produce the container/egg shell

(10 marks)