Principle of Manufacturing Engineering sheet 3

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1) Answer all the following questions:

1. How are engineering materials classified?

Metals and alloys are further classified into two major kind namely ferrous metals and non-ferrous metals.

2. How ferrous metals differ from non-ferrous metals?

(a) Ferrous metals are those which have the iron as their main constituent, such as pig iron, cast iron, wrought iron and steels .

(b) Non-ferrous metals are those which have a metal other than iron as their main constituent, such as copper, aluminium, brass, bronze, tin, silver zinc, invar etc

3. State the name of important iron ores?

1. Pig iron

2. Cast iron

3. Wrought iron

4. Steel

4. How cast iron differs from steel?

cast iron varies from 1.7% to 6.67% but carbon content maximum up to 1.7%.

5. Write short notes on ?

(i) Pig iron C=1.7% to 6.67%.

(ii) Grey cast iron C = 2.5 to 3.8%

(iii) White cast iron C = 3.2 to 3.6%

(iv) Ductile cast iron C=3.2 to 4.2%

(v) Malleable cast iron.

6. Discuss in brief the effect of impurities in cast iron?

Impurities in cast iron not used to for making

Bolts and machine parts low cost - good costing

Characieristics brittle and weak

7. What is wrought iron? Discuss in brief its chemical composition, properties and applications?

Wrought iron is the assumed approximately as purest iron which possesses at least 99.5% iron. It contains a large number of minute threads of slag lying parallel to each other, thereby giving the metal a fibrous appearance when broken.. This iron contains practically no carbon and therefore can not be hardened .

Chemical Composition :

C = 0.02 – 0.03%

 Properties The wrought iron can be easily shaped by hammering, pressing, forging, etc. It is never cast and it can be easily bent when cold. It is tough and it has high ductility and plasticity with which it can be forged and welded easily. Its ultimate strength can be increased considerably by cold working followed by a period of aging. It possesses a high resistance towards corrosion .

Applications It is used for making chains, crane hooks, railway couplings, and water and steam pipes .

It has application in the form of plates, sheets, bars, structural works, forging blooms and billets, rivets, and a wide range of tubular products including pipe, tubing and casing, electrical conduit, cold drawn tubing, nipples and welding fittings, bridge railings, blast plates, drainage lines and troughs, sewer outfall lines, weir plates, sludge tanks and lines, condenser tubes, unfired heat exchangers, acid and alkali process lines, skimmer bars, diesel exhaust and air brake piping, gas collection hoods, coal equipment, cooling tower and spray pond piping.

8. What are plain carbon steels? Discuss in brief the classification of plain carbon steels and also state few applications of different plain carbon steels.

*Plain carbon steel is an alloy of iron and carbon. It has good machineability and malleability .

*It is different from cast iron as regards the percentage of carbon. It contains carbon from 0.06 to 1.5% whereas cast iron possesses carbon from 1.8 to 4.2%. Depending upon the carbon content, a plain carbon steels can divided to the following types:

1. Dead carbon steel — up to 0.15% carbon2. Low carbon or mild steel — 0.15% to 0.45% carbon3. Medium carbon steel — 0.45% to 0.8% carbon

4. High carbon steel — 0.8% to 1.5% carbon

9. What are alloy steels? Discuss in brief the effects of alloying elements on steel.

Alloy of iron and carbon

Content maximum up to 1.7%

10. How are alloy steels classified?

Depending upon the carbon content, a plain carbon steels can divided

(2) State which of the following statements is true and which is false:

1- Pure metals possess low strength ( √ )

2- Metals and alloys are further classified into two major kind namely ferrous metals and non-ferrous metals. ( √ )

3- Main Type of Iron is Pig iron only ( x )

4- Cast iron cannot be used for making bolts and machine parts ( √ )

5- Plain carbon steel is an alloy of iron and carbon. It has not good machineability and malleability ( x )

(3) Put a line under the correct answer: (MCQ)

1- ……….. Is basically an alloy of iron and carbon and is obtained by re-melting pig iron with coke.

a) Cast iron b) steel c) wrought iron

2- ………. is an alloy of iron and carbon with carbon content maximum up to 1.7%

a) Cast iron b) steel c) wrought iron

3- Depending upon the carbon content, a plain carbon steels can divided to …….

a) Two types b) three types c) four types

المكان: 3CC9+F27، طريق المنصورة - دمياط، القديم الشرقي، المنصورة، الدقهلية 35511، مصر

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