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(i) Draw a material classification tree including metals,

polymers, ceramics, and composites.
* A material classification tree includes:
* Metals (Ferrous, Non-Ferrous)
* Polymers (Thermoplastics, Thermosetting Plastics)
* Ceramics (Glass, Porcelain)
* Composites (Fiberglass, Carbon Fiber)

(ii) Name two types of plastics and explain their

differences.
1. Thermoplastics: Can be melted and reshaped multiple
times (e.g., PVC, Nylon).
2. Thermosetting Plastics: Harden permanently when
heated (e.g., Epoxy, Bakelite).

(iii) What are composite materials? Give two examples.

* Composite materials are made by combining two or
more materials to improve properties.
Examples: Fiberglass (Glass + Polymer), Carbon Fiber
(Carbon + Epoxy Resin).

(iv) List four advantages of using composite materials in

engineering.
1. High strength-to-weight ratio
2. Corrosion resistance
3. Excellent durability
4. Good thermal and electrical insulation

(i) Define three types of mechanical properties and

explain each.
* Hardness: Resistance to surface deformation.
* Ductility: Ability to deform without breaking.
* Toughness: Ability to absorb energy before fracture.

(iii) What is Young’s modulus? Write its formula and unit.

Young’s Modulus (): Measures stiffness of a material.
Formula:
Unit: Pascal (Pa)

(i) What is the importance of the Iron-Carbon phase

diagram in metallurgy?
* Helps understand the behavior of steel and cast iron at
different temperatures.
* Guides heat treatment processes.

(ii) Name the five individual phases in the Iron-Carbon

phase diagram.
1. Ferrite
2. Austenite
3. Cementit
4. Pearlite
5. Ledeburite

(iii) Define the following heat treatment processes with

applications:
* Annealing: Softens metal, improves machinability.
* Quenching: Rapid cooling increases hardness.
* Tempering: Reduces brittleness after quenching.

(iv) Why is heat treatment necessary for metals?

* Improves hardness, ductility, and strength.
* Reduces internal stresses.
(i) Differentiate between hot working and cold working
processes.
* Hot Working: Above recrystallization temperature,
increases ductility.
* Cold Working: Below recrystallization temperature,
increases strength.

(ii) What is recrystallization temperature in metal forming?

* The temperature at which new grains form in a metal
without prior strain effects.

(iii) Explain expandable mold casting with two examples.

* Mold is destroyed after each casting.
* Examples: Sand Casting, Investment Casting.

(iv) List four major parts of a sand mold.

1. Pattern
2. Cope
3. Drag
4. Gating System

(i) What is galvanic corrosion? Explain with an example.

* Occurs when two dissimilar metals are in contact in an
electrolyte.
Example: Rusting of iron when in contact with copper in
seawater.

(ii) Define creep failure and its industrial importance.

* Slow deformation under constant stress, important in
turbines and boilers.

(iii) Explain the Rockwell hardness test and its

applications.
* Measures hardness by pressing a steel ball or cone into
a material.
Applications: Used for steel, aluminum, and polymers.

(iv) What is toughness in materials?

* Ability of a material to absorb energy before fracturing
(e.g., structural steels).

(i) What are alloyed metals? Give two examples.

* Mixtures of metals to enhance properties.
Examples: Stainless Steel (Iron + Chromium), Brass
(Copper + Zinc).

(ii) List five common engineering alloys.

1. Stainless Steel
2. Brass
3. Bronze
4. Duralumin
5. Inconel

(iii) Why are alloyed metals preferred in industries?

* High strength
* Corrosion resistance

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* Improved wear resistance

(01) (i) Briefly explain engineering materials and give two

examples for each.
Engineering materials are materials used in industrial
applications for manufacturing and construction. They are
classified as:
* Metals: Steel, Aluminum
* Polymers: Polyethylene, PVC
* Ceramics: Silicon carbide, Alumina
* Composites: Carbon fiber, Fiberglass

(ii) Plain carbon steels are divided into three (03) main
groups. Name them.
1. Low carbon steel (Mild steel)
2. Medium carbon steel
3. High carbon steel

(iii) State the application of steel alloys and aluminum

alloys.
* Steel alloys: Used in construction (bridges, buildings),
automotive parts, and machine tools.
* Aluminum alloys: Used in aerospace, automobile
bodies, and electrical transmission lines.

(iv) What is an alloy metal?

* An alloy is a combination of two or more elements,
where at least one is a metal, to enhance properties like
strength and corrosion resistance. Example: Brass
(Copper + Zinc).

(02) (i) Name three mechanical properties and describe

them.
1. Hardness: The ability of a material to resist indentation
or scratching.
2. Ductility: The ability to be stretched into a wire without
breaking.
3. Toughness: The ability to absorb energy before
fracturing.

(ii) Brinell hardness test is widely used for metals and

non-metals. Explain it.
* The Brinell hardness test determines a material's
hardness by pressing a steel or tungsten carbide ball
under a fixed load into the surface and measuring the
indentation diameter.

(iii) Write 03 examples for physical properties of materials.

1. Density
2. Thermal conductivity
3. Electrical resistivity

(iv) What are the technological properties? Give another

name for it.
* Technological properties refer to how materials behave
in manufacturing processes. ( manufacturing properties. )

(03) (i) Briefly describe the following terms using a

formula:
* Elongation: The percentage increase in a material's
length when subjected to stress.
* \varepsilon = \frac{\text{Final length} - \text{Original
length}}{\text{Original length}} \times 100
* E = \frac{\text{Stress}}{\text{Strain}}

(ii) The ductile wire of diameter 18 mm and original length

is 3.6 m is stretched by a force of 426 KN along its length.
The final length is 3.606 m. Find the elongation and
Young’s modulus.
Given:
* Diameter = 18 mm
* Original length = 3.6 m
* Force = 426 kN
* Final length = 3.606 m ​
Elongation and Young's modulus will be calculated.
.
(04) (i) What is the purpose of the Iron-Carbon phase
diagram?
* The Fe-C phase diagram helps understand the
microstructure, mechanical properties, and behavior of
steels and cast irons at different temperatures and carbon
compositions.

(ii) List two main points and four individual phases in the
Fe-C Phase diagram.
* Main points: Eutectoid point, Eutectic point
* Phases: Ferrite, Austenite, Cementite, Pearlite

(iii) Write down three factors involved in the heat

treatment process and describe them.
1. Temperature: Determines phase transformation in
metals.
2. Cooling rate: Controls the hardness and brittleness of
the material.
3. Holding time: Ensures uniform changes in the
material's structure.

(iv) Mention the advantages of heat treatment.

* Increases hardness and strength
* Improves wear resistance
* Reduces internal stress
* Enhances machinability

(05) (i) What is the main principle of mechanical forming?

Briefly explain with a suitable sketch.
* Mechanical forming reshapes materials using force
without removing material. It includes processes like
rolling and forging, commonly used in metalworking.

(ii) Name four mechanical forming processes.

1. Rolling
2. Forging
3. Extrusion
4. Drawing

(iii) State the distinction between hot working process and

cold working process.
* Hot working: Performed above the recrystallization
temperature; improves ductility and reduces hardness.
* Cold working: Done at room temperature; increases
strength but reduces ductility.

(iv) List four (04) advantages of the hot working process.

1. Enhances ductility
2. Reduces residual stress
3. Improves grain structure
4. Reduces the need for additional machining

(06) (i) State three modes of material failures.

1. Ductile failure (material stretches before breaking)
2. Brittle failure (material breaks suddenly without
deformation)
3. Fatigue failure (material fails due to repeated loading)

(ii) What is "corrosion of metal"?

* Corrosion is the gradual destruction of metals due to
chemical reactions with the environment, such as
oxidation.

(iii) Write down the corrosion chemical reaction.

For iron:
* 4Fe + 3O_2 + 6H_2O \rightarrow 4Fe(OH)_3
(iv) Name three permanent corrosion protection methods
and describe them.
1. Galvanizing: Applying a zinc coating to prevent rusting.
2. Anodizing: Forms a protective oxide layer on
aluminum.
3. Cathodic protection: Uses a sacrificial metal to prevent
corrosion.

(07) (i) Define the casting process.

* Casting is the process of pouring molten metal into a
mold, allowing it to cool and solidify into a desired shape.

(ii) List the 05 casting methods.

1. Sand casting
2. Die casting
3. Investment casting
4. Centrifugal casting
5. Continuous casting

(iii) What are the advantages of the casting process used

in industries?
* Suitable for complex shapes
* Cost-effective for large parts
* Allows mass production
* Compatible with various metals

(iv) There are several tools and equipment used in

casting. List them.
1. Molds
2. Crucibles
3. Ladles
4. Tongs

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5. Pattern-making tools

1. (i) Name two classifications of metals.

📎Ferrous metals (contain iron, e.g., steel, cast iron).

📎Non-ferrous metals (do not contain iron, e.g.,
aluminum, copper).

2. (ii) Briefly explain the physical and mechanical

⭕
properties of metals.

📎
Physical Properties:

📎
Density: Mass per unit volume.

📎
Thermal conductivity: Ability to conduct heat.

📎
Electrical conductivity: Ability to conduct electricity.
Melting point: Temperature at which it changes to a
liquid.

⭕Mechanical Properties:
📎Strength: Ability to resist deformation or fracture.
📎Ductility: Ability to be stretched into wire.
📎Hardness: Resistance to scratching or indentation.
📎Toughness: Ability to absorb energy before fracture.
📎
3. (iii) What are the technological properties of metals?

📎
Castability: Ability to be cast into shapes.

📎
Weldability: Ability to be welded without defects.

📎
Machinability: Ease of machining operations.
Formability: Ability to be formed into shapes without
failure.

4. (iv) Explain how to improve machinability of the

material.
📎Add sulfur or lead to reduce friction.
📎Heat treatment to improve hardness and reduce tool
📎Use cutting fluids to reduce heat generation.
wear.

📎
2. (i) Name four types of crystal systems.

📎
Cubic system.

📎
Hexagonal system.

📎
Tetragonal system.
Orthorhombic system.

📎
2. (ii) List three types of space lattices and sketch each.
Simple cubic lattice (SC): Atoms at the corners of a

📎
cube.
Body-centered cubic lattice (BCC): One atom at the

📎
center of the cube.
Face-centered cubic lattice (FCC): Atoms at the
corners and the centers of cube faces.

2. (iii) Explain the importance of the iron-carbon diagram

📎
in the engineering industry.
It helps in understanding the formation of steel and

📎
cast iron.
Explains the phases (e.g., austenite, ferrite, cementite)

📎
and their effects on material properties.
Guides in heat treatment processes (e.g., annealing,

📎
hardening).
Essential for selecting materials based on required
mechanical properties.

3. (i) Describe the stress-strain diagram for mild steel with

📎
a clear sketch.
Elastic Region: Linear portion where material returns to

📎
its original shape after unloading.
Yield Point: Stress at which permanent deformation

📎
begins.

📎
Plastic Region: Material deforms permanently.
Ultimate Strength: Maximum stress the material can

📎
withstand.
Fracture Point: The point where material breaks.
(Sketch can be drawn with the above points labeled on
the diagram.)

3. (ii) What is the difference between plastic deformation

⭕
and elastic deformation?
Elastic deformation: Temporary deformation; material

⭕
returns to its originalshape after removing the load.
Plastic deformation: Permanent deformation; material
does not return to its original shape after the load is
removed.

3. (iii) Define "Young's modulus" or "modulus of elasticity"

of metals.
It is the ratio of stress to strain in the elastic region of the
material's stress-strain curve.
Formula:
E = \frac{\text{Stress}}{\text{Strain}} = \frac{F \cdot L}{A
\cdot \Delta L}

3. (iv) Calculation of Young's modulus:

Given:
Cross-sectional area:
A = \pi r^2 = 3.1416 \times (0.001)^2 = 3.1416 \times
10^{-6} \, \text{m}^2
Stress:
\text{Stress} = \frac{F}{A} = \frac{50}{3.1416 \times
10^{-6}} = 15.92 \times 10^6 \, \text{Pa}

Strain:
\text{Strain} = \frac{\Delta L}{L} = \frac{0.0007}{0.7} =
0.001
Young's modulus:
E = \frac{\text{Stress}}{\text{Strain}} = \frac{15.92 \times
10^6}{0.001} = 15.92 \times 10^9 \, \text{Pa}
E = 15.92 \, \text{GPa}]

04. (i) Define the term "Cold Working"

Cold Working:
Cold working is the process of deforming a metal below
its recrystallization temperature, usually at room
temperature, to improve its mechanical properties such as
strength and hardness. It results in strain hardening.

04. (ii) Describe the following heat treatment processes

(a) Annealing:
Annealing is a heat treatment process where the material
is heated to a specific temperature and then cooled
slowly. This process softens the metal, improves ductility,
relieves internal stresses, and refines its grain structure.

(b) Normalizing:
Normalizing involves heating the material above its critical
temperature and allowing it to cool in air. This process
refines the grain structure, enhances toughness, and
improves machinability.

(c) Quenching & Tempering:

Quenching: Rapid cooling of a material, typically in water
or oil, after heating it to a high temperature. This
increases hardness but makes the material brittle.
Tempering: Reheating the quenched material to a lower
temperature to reduce brittleness and improve toughness.

(d) Hardening:
Hardening is a heat treatment process that increases the
hardness of a material by heating it to its critical
temperature, followed by rapid cooling (quenching). This
process enhances wear resistance.

05. (i) Name three types of Cast Irons and their

engineering applications
1. Gray Cast Iron:
Applications: Engine blocks, machine tool frames, and
pipes.
2. Ductile Cast Iron (Nodular Cast Iron):
Applications: Automotive components, such as
crankshafts, and pressure pipes.
3. White Cast Iron:
Applications: Mill liners, wear plates, and mining
equipment.

05. (ii) Name the types of steels and their applications in

the industry
1. Carbon Steel:
Applications: Construction (reinforcement bars), tools,
and automotive parts.
2. Alloy Steel:
Applications: Gears, pipelines, and aircraft components.
3. Stainless Steel:
Applications: Kitchen utensils, medical equipment, and
chemical containers.
4. Tool Steel:
Applications: Cutting tools, dies, and molds.

05. (iii) Why does continuous cold working make a

material harder?

Continuous cold working makes a material harder due to

strain hardening (work hardening). During cold working,
the dislocation density in the material increases, making
further deformation difficult and leading to an increase in
hardness and strength.

06. (i) What are the alloyed metals?

Alloyed metals are metals that are combined with one or
more elements to improve their mechanical, thermal, or
chemical properties. Examples include steel (iron with
carbon), brass (copper with zinc), and bronze (copper
with tin).

06. (ii) Name three alloyed metals with their applications

(6 Marks)
1. Brass (Copper + Zinc):
Applications: Electrical connectors, musical instruments,
and plumbing fittings.
2. Bronze (Copper + Tin):
Applications: Bearings, bushings, and sculptures.
3. Stainless Steel (Iron + Chromium):
Applications: Kitchenware, medical equipment, and
structural components.

06. (iii) Briefly explain bearing metals

Bearing metals (also known as babbitt metals) are soft,

low-friction metals used in the lining of bearings to reduce
wear and allow smooth motion. Common bearing metals
include lead-based or tin-based alloys.

06. (iv) Explain the properties of bearing metals

📎. Low Friction: Reduces wear between moving parts.

📎. Good Thermal Conductivity: Dissipates heat
📎. Softness: Prevents damage to the shaft or other
generated by motion.

📎. High Load Capacity: Can withstand heavy loads

components.

📎. Corrosion Resistance: Ensures durability in harsh

without deformation.

environments.

07. (i) "Non-Ferrous metals are very important to the

industry." Explain this statement
Non-ferrous metals (such as aluminum, copper, and
titanium) are essential in industry because they:
Have high corrosion resistance.
Are lightweight (e.g., aluminum in aerospace).
Have excellent conductivity (e.g., copper in electrical
applications).
Are versatile for various industries, including construction,
transportation, and electronics.

07. (ii) Briefly explain what properties of metal are used

📎
for the following production processes (12 Marks)
Forging:
Ductility: To allow deformation
under compressive force.

📎
Toughness: To withstand the forging process.
Drawing:
Ductility: For elongation without fracture.

📎
Tensile Strength: To handle stress during the process.
Forming:
Malleability: For reshaping without cracking.

📎
Plasticity: To retain the new shape.
Rolling:
Plasticity: To enable material flow under compressive
forces.

📎
Surface Hardness: For better finish quality.
Bending:
Elasticity: To return to shape if needed.

📎
Flexibility: To withstand bending stress without breaking.
Coining:
Plasticity: To imprint fine details.

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Hardness: To maintain durability after imprinting

(01) (i) Draw material tree including main categories of

engineering materials.
* Metals
* Ferrous Metals
* Non-Ferrous Metals
* Polymers
* Thermoplastics
* Thermosetting Plastics
* Ceramics
* Composites

(ii) There are two main types of plastics. Name them.

1. Thermoplastics: Can be melted and re-molded, e.g.,
polyethylene.
2. Thermosetting plastics: Cannot be re-molded once set,
e.g., Bakelite.

(iii) Briefly explain composite material with two examples.

* Composite materials combine two or more different
materials to achieve properties that are superior to
individual materials.
Examples:
1. Reinforced concrete (cement + steel reinforcement).
2. Fiberglass (glass fibers + resin).

(iv) What are the advantages of using composite

materials?
1. Higher strength-to-weight ratio.
2. Better durability and resistance to corrosion.
3. Customizable properties for specific applications.

(02) (i) List three types of stresses in materials.

1. Tensile stress
2. Compressive stress
3. Shear stress

(ii) Draw the basic types of stresses in materials.

* Tensile Stress: Pulling force.
* Compressive Stress: Squeezing or pushing force.
* Shear Stress: Force causing sliding.

iii) How do you separate ferrous metals from non-ferrous

metals?
* Ferrous metals can be separated from non-ferrous
metals using magnetic separation since ferrous metals
are magnetic.
(iv) State three ferrous metals and three non-ferrous
metals.
* Ferrous Metals: Steel, Cast Iron, Wrought Iron.
* Non-Ferrous Metals: Aluminum, Copper, Zinc.

(03) (i) Briefly explain the chemical properties of

materials.
Chemical properties of materials refer to how a material
reacts with other substances, such as its tendency to
corrode, its reactivity with acids, or its ability to form
alloys.

(ii) Write down three examples for the chemical properties

of materials.
1. Corrosion resistance
2. Oxidation resistance
3. Reactivity with acids or bases

(iii) Which chemical properties are involved in the

formation of alloys?
* Affinity for other elements: Determines how well a metal
combines with others.
* Melting point: Affects the alloying process.
* Solubility of elements: Determines the composition of
the alloy.

(iv) State the materials used to make the following alloys:

(a) Brass: Copper and Zinc
(b) Bronze: Copper and Tin

(04) (i) Draw a stress-strain diagram for brittle material

and mark elastic range and breaking point.
* The stress-strain diagram for brittle material shows a
steep initial slope (elastic range), followed by an
immediate fracture at the breaking point without
significant plastic deformation.

(ii) Categorize the following materials into brittle material

and ductile material:
* Brittle materials: Glass, Ceramic
* Ductile materials: Copper, Aluminum, Gold

(05) (i) Briefly describe one heat treatment process used

to remove extra hardness of the metal.
* Annealing: A process of heating a metal to a high
temperature and then cooling it slowly to reduce hardness
and improve ductility.

(ii) List four quenching media used in heat treatment.

1. Water
2. Oil
3. Air
4. Salt bath

(iii) What are the advantages that can be achieved in

annealing?
1. Improved ductility.
2. Reduced hardness.
3. Relieved internal stresses.
4. Improved machinability.

(iv) Why is heat treatment done in metals?

* Heat treatment is used to alter the mechanical
properties of metals to improve their strength, hardness,
ductility, or machinability, depending on the desired
application.

(06) (i) Differentiate hot forming process and cold forming

process.
* Hot forming: The material is heated above its
recrystallization temperature before shaping. It results in
less force needed and improved ductility.
* Cold forming: The material is shaped at room
temperature, which increases strength due to strain
hardening but can make the material more brittle.

(ii) What is meant by recrystallization temperature in

relation to metal forming?
* Recrystallization temperature is the temperature above
which a metal's grains reorganize, restoring ductility and
eliminating the effects of previous plastic deformation.

(iii) Briefly explain the expandable casting process with

two examples.
* In expandable casting, a pattern is made from a
material that can be melted away or broken down to
create a mold.
Examples:
1. Lost wax casting
2. Lost foam casting

(iv) Mention the main parts of a sand mold.

1. Pattern
2. Core
3. Sprue
4. Runner
(07) (i) Briefly explain Galvanic corrosion.
* Galvanic corrosion occurs when two dissimilar metals
are in electrical contact in the presence of an electrolyte,
causing the more reactive metal to corrode faster.

(ii) Creep failure of metals.

* Creep failure is the gradual deformation of materials
under constant stress, especially at high temperatures,
which leads to material breakdown over time.

(iii) Rockwell hardness test.

* The Rockwell hardness test measures the depth of
penetration of a diamond or steel ball into the surface of a
material under a specific load, providing a hardness
number.

(iv) Toughness.
Toughness is the ability of a material to absorb energy
and deform without breaking, indicating both strength and
ductility.
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(01) (i) Write down classification of materials.
* Metals: Ferrous (e.g., steel) and Non-ferrous (e.g.,
aluminum).
* Polymers: Thermoplastics and Thermosetting plastics.
* Ceramics: Glass, Porcelain.
* Composites: Fiberglass, Reinforced Concrete.

(ii) Briefly explain the chemical properties and

technological properties of metal.
* Chemical properties: Include corrosion resistance,
reactivity with acids, oxidation, etc.
* Technological properties: Include properties such as
machinability, weldability, formability, and hardness.

(iii) Name chemical properties of the metals.

1. Corrosion resistance
2. Oxidation tendency
3. Reactivity with acids
4. Heat resistance
5. Electrochemical properties

(iv) State the difference in composition of brass and

bronze.
* Brass: Primarily composed of copper and zinc.
* Bronze: Primarily composed of copper and tin, with
sometimes other elements like aluminum or phosphorus.

(02) (i) What are the advantages that can be gained using
an Iron-carbon diagram?
* Helps in understanding the phases and phase
transformations of steel.
* Assists in designing heat treatment processes.
* Aids in selecting the right type of steel for various
applications.

(ii) There are five individual phases included in

Iron-carbon diagram. List them.
1. Ferrite
2. Austenite
3. Cementite
4. Pearlite
5. Ledeburite

(iii) Mention three important points in an Iron-carbon

diagram.
1. The eutectoid point (0.8% carbon and 727°C).
2. The melting point of pure iron (1538°C).
3. The solubility limit of carbon in austenite.

(iv) A horizontal line always indicates an invariant reaction

in Iron-carbon phase diagram. Write down 02 invariant
reactions.
1. Eutectoid reaction: Austenite transforms to pearlite.
2. Eutectic reaction: Liquid phase transforms to a mixture
of austenite and cementite.

(03) (i) Describe the hot working process with suitable

examples
* Hot working involves deforming materials above their
recrystallization temperature.
Examples: Rolling, Forging, Extrusion.

(ii) What are the differences between hot working and

cold working?
* Hot working: Done above the recrystallization
temperature, improves ductility, no strain hardening.
* Cold working: Done below the recrystallization
temperature, increases strength but decreases ductility.

(iii) Draw and label rolling process

* Rolling process involves passing the material through
rollers to reduce thickness.
(Illustration: Material → Rolls → Reduced thickness).

(iv) Mention two different casting processes.

1. Sand casting
2. Die casting
(04) (i) Draw stress-strain diagram for brittle material.
* Brittle material: Shows a steep slope and fractures
abruptly after reaching the elastic limit without significant
plastic deformation.

(ii) What are the important points of the stress-strain

diagram of mild steel?
1. Elastic limit: The point beyond which material deforms
permanently.
2. Yield point: Where plastic deformation begins.
3. Ultimate tensile strength: Maximum stress the material
can withstand.
4. Fracture point: The point where material breaks.

(iii) Write down the formula for strain.

* \text{Strain} = \frac{\Delta L}{L}

(iv) A radius of 5 cm and 120 cm long Al bar is subjected

to tensile load. It is extended by 0.005 mm in length. If the
Young modulus of Al is 85 GN/m², what is the stress
developed in the Al bar?
Stress =
First, calculate the cross-sectional area:
A = \pi \times r^2 = \pi \times (5)^2 = 78.54 \, \text{cm}^2 =
7.854 \times 10^{-3} \, \text{m}^2
E = \frac{\text{Stress}}{\text{Strain}} \quad \text{and}
\quad \text{Strain} = \frac{\Delta L}{L} = \frac{0.005}{120}

(05) (i) Define alloyed metals that are used in various

industries.
* Alloyed metals are metals that are mixed with other
elements to improve their properties such as strength,
corrosion resistance, or hardness. Examples include
stainless steel (iron + chromium) and bronze (copper +
tin).

(ii) List any 05 alloys.

1. Stainless steel
2. Bronze
3. Brass
4. Duralumin
5. Monel

(iii) What are the advantages of using alloyed metals?

1. Improved strength.
2. Enhanced corrosion resistance.
3. Increased hardness.
4. Better machinability.

(iv) Write down various applications of alloyed metals.

1. Stainless steel: Kitchen utensils, medical instruments.
2. Bronze: Marine components, coins.
3. Brass: Musical instruments, electrical connectors.
4. Duralumin: Aircraft parts.
(06) (i) Give the classification of carbon steel and state
the carbon content of each.
1. Low carbon steel: Carbon content up to 0.3%.
2. Medium carbon steel: Carbon content 0.3% to 0.6%.
3. High carbon steel: Carbon content 0.6% to 1.0%.

(ii) A component which is to be manufactured from a plain

carbon steel requires a composition with maximum
ductility. Which category would be most suitable?
* Low carbon steel is most suitable for maximum ductility.
(iii) Write down 04 types of cast irons.
1. Gray cast iron
2. White cast iron
3. Malleable cast iron
4. Ductile cast iron

(iv) Briefly explain the difference between carbon steel

and cast irons.
* Carbon steel has low carbon content (up to 1%) and is
generally stronger and more ductile.
* Cast iron has higher carbon content (2-4%) and is more
brittle but excellent for casting.

(07) (i) What are the purposes of heat treatment

processes?
1. To increase hardness.
2. To improve strength.
3. To relieve internal stresses.
4. To improve machinability.

(ii) State the difference between annealing and

normalizing.
* Annealing: Heating the material and cooling it slowly to
reduce hardness and improve ductility.
* Normalizing: Heating the material and cooling it in air to
refine the grain structure and improve mechanical
properties.

(iii) List four quenching medium that can be used in a heat

treatment process.
1. Water
2. Oil
3. Air
4. Salt bath

(iv) Briefly explain the tempering process used in steel

manufacturing.
* Tempering involves heating steel to a specific
temperature below its critical point and then cooling it to
reduce brittleness and improve toughness after
hardening.