1. General materials science and physical metallurgy: (Maximum 5 A4 pages; 20% each weightage)
a) Describe the importance of phase diagrams in engineering the microstructure of alloys, typical phase transformations (e,g eutectic) and provide example alloy systems for each of these reactions.
b) Discuss and schematically illustrate the development of microstructures in isomorphous (35wt%Cu-65wt%Ni) alloy under equilibrium and non-equilibrium cooling conditions.
c) Why grain refinement in solidification of liquid metals is needed? Describe typical grain refining processes during liquid to solid transformation in Al, Mg and steels.
d) Describe various strengthening mechanisms, purpose of annealing, principles of age hardening and ageing processes.
e) Grain (crystal) morphology of a metal solidified from liquid can have variety of morphologies. List the morphologies and provide the solidification conditions under which these morphologies can form.
2. Light Metals: (Maximum of 5 A4 pages; 20% weightage)
a) Describe Al alloys classification (wrought and cast alloys) and the role of major alloying element in these alloys. Why some alloys are heat treatable and some are not?
b) Describe the stages involved (from pure Al ingots to final product) in producing 6xxx series aluminium alloy extrusions. Describe key metallurgical aspects and scientific principles in these stages.
c) Present examples for typical intermetallics in Al alloy systems. Discuss various heat-treatment conditions and their role in governing mechanical properties.
d) Describe most common processing methods for Al-Si cast alloys. Give some common examples of magnesium alloys and describe the processing methods for cast and wrought alloys.
e) Describe typical welding processes used for Al alloys. Which Al alloys are prone to corrosion? What types of corrosion are commonly observed in Al and Mg alloys?
3. Steels (Maximum of 5 A4 pages; 20% weightage)
a) Present detailed description of Fe-C phase diagram; types of reactions during liquid to solid transformation for steels and cast iron with various levels of Carbon;
b) Types of phases in alloys and their role on mechanical properties; Phase transformation and T-T-T diagrams;
c) Describe key differences in alloy compositions and nature of phase transformations between steels and stainless steels. What is the mechanism for corrosion resistance in stainless steels?
d) Describe the sources for corrosion in cast iron, steels and weld sections of steel.
4. Welding, corrosion and surface treatments (Maximum of 5 A4 pages)
Discuss the following:
a) Solidification processes that govern microstructures of fusion welding and microstructural features of a typical steel weld produced using a fusion welding
b) TIG welding, Resistive spot welding and Friction stir welding joints and their advantages and limitations.
c) Weldability factors and design considerations in achieving high quality joints.
d) Most commonly found forms of corrosion and prevention methods.
e) Typical coatings for materials, surface treatments methods and typical functionalities of coatings/surface treatments.
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