Metallurgy

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“Metallurgy Interview Questions and Answers will guide us now that Metallurgy is a domain of materials science that studies the physical and chemical behavior of the metallic elements, their intermetallic compounds and their mixtures, which are called alloys. In Metallurgy Interview Questions and Answers you will learn that it is also the technology of metals and the way in which science is applied to their practical use. Learn basic and advance Metallurgy by Metallurgy Interview Questions Answer”



70 Metallurgy Questions And Answers

21⟩ We make aluminum moulds by press casting, can u suggest any thing so that the moulds should shine after casting?

Shininess of castings depends on the surface quality of cast parts. Casting surface finish is always a function of mold surface and characteristics. The selection of mold materials and the accuracy of mold finish maintained in premium casting operations ensure that specified requirements are met. Sometimes there is the possibility of increasing surface finish of castings by increasing their surface tension. This is done for aluminum alloys by allowing formation of oxide inclusions, the most important of which is Al2O3, in the molten metal. The increase in surface tension prevents molten metal from penetrating into the mold depressions since as you know surface finish improves when the melt solidifies in contact with air. However, such a resolution is accompanied by decrease in mechanical properties of castings, as oxides will act as stress concentration sites.

By the way, I have not heard about usage of grain refiners as shine promoters for aluminum castings, though their application in such cases may rely on the same mechanism.

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22⟩ What is the difference between plaster used in gold investment casting and ceramic used in the process of investment casting of automobile engine parts and turbine blades etc. when both are used in the lost-wax method?

In general, the plaster used in gold investment casting is standard "plaster of Paris" or other such material it has a fine but inconsistent grain size and, for the most part, water based. The other parts you mentioned are generally a higher precision, the casting material is of a fine but consistent grain, high temperature, hard, and not always water based. This is especially important for turbine blades as the material from which they are cast is more difficult to fine finish than other metals and the precision is extremely important due to the speed of rotation. It would be safe to say that the latter could be used in place of the former but not the former in place of the latter. Hope this is helpful.

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23⟩ Does the extrusion process for A355 AND A356 alloy effect on the amount of impact energy?

Yes, it does. I am not an expert in these things, but I do know that the parameters of the extrusion process directly affect the crystalline matrix of the alloy, which in turn governs the physical characteristics of the alloy. As the differences can be quite significant, I would recommend checking with qualified references for pertinent details. I know that quenching and max temperatures are big issues. Good luck, sorry I could not be of greater assistance.

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24⟩ Does case harden steel properties detoriates over time? Especially for guns, parts like bolt carrier, the brand new parts has been kept for 10 year and properly oiled. I am worried about its surface hardness to take the blow during firing.

Hardened steel does not generally deteriorate over moderate periods, especially not as short as ten years, providing it have been protected from corrosion. Strong magnetic fields and electric fields generated through or around the steel can have an effect, but this is highly unlikely. If your bolt carrier has been kept protected and oiled it should be fine. I have a shotgun that was made in 1740 which has lost none of its hardness as well as steel swords dating back to the 1600's that are still hard and sharp. You should not have a problem.

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25⟩ How is metal heavy?

Not all metals are heavy. Hydrogen is a metal, and is the lightest element known. Lithium, also a metal is the third lightest element there are many heavy elements that are not metals. If you "Google" the definition of "metal" you will note the properties that qualify a substance as a metal. Mass (weight) is not the important factor. Common metals are heavy because they have a dense electron structure.

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26⟩ What is the melting point of E70 steel, 304,308,316 stainless steels? In addition, what is the hottest part of the flame in a fire?

You may find the melting range of some frequently used stainless steels below. Steel is an alloy and instead of a unique melting point, has a melting range, which is the range in which under equilibrium conditions, liquid, and solid phases coexist.

304: 1400-1450 (oC)

308: 1400-1420 (oC)

316: 1375-1400 (oC)

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27⟩ How one can differentiate between 304 & 316 grades of Steel (Physically)?

There is no physical distinction between these two grades of stainless steels since there are very similar compositionally. However, it might be possible to differentiate them rapidly by comparing their electrical resistance (measurable via an ohmmeter), indeed with some considerations in order to minimize the errors. I assume you already know that the most reliable method of telling them from each other would be to perform a chemical analysis of them using EDS and other spectroscopy methods.

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28⟩ Which of different types of cast irons is stronger? Is their strength superior to steels?

Generally, steels are considered to have better mechanical properties and ductility. However, there are some types of cast irons like ductile iron, which, in contrast to other types of cast irons, are not brittle. The strength of these ductile irons can be enhanced by controlling their matrix via an austempering heat treatment. This Austempered Ductile Irons (ADI) has very good mechanical properties comparable to those of some grades of steel. However, keep in mind that in spite of lower mechanical properties and being brittle, cast irons have good fluidities and are cheaper than steels. By the way, there are some special purpose gray and white irons, which are frequently used for special applications like where resistance to corrosion, wear, and heat is required.

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30⟩ What is meant by hardening ability of metals?

It is the ability of a metal to become hard (and inevitably brittle) under a given cooling rate. Therefore, the higher the hardenability of an alloy, the lower the cooling rate required to harden the metal. We have more heard about the hardenability in steels rather than other alloys. This is because in steels, there are different phases which can appear subject to the applied cooling rate below the critical temperature (the eutectoid temperature) as well as the alloying elements present in that grade of steel. Most of alloying elements in steel improve its hardenability by decreasing the critical cooling rate required to obtain the hardest possible phase i.e. martensite.

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31⟩ Can 1026 steel be welded?

Weldability of Iron-Carbon alloys is a function of their carbon content and decreases as their carbon increases. Plain carbon steels can be roughly categorized into 3 main groups: 1- low carbon plain steels which have less than 0.2wt% carbon and are the most wieldable and heat treatable carbon steels, 2- medium carbon plain steels with a carbon content of 0.2-0.5wt%C, and 3- high carbon plain steels with more than 0.5wt%C. The 1026 steel is a medium carbon steel (10 at the beginning implies its being a plain carbon steel and 26 at the ending denotes that it has 0.26wt%C). Thus, 1026 steel falls into the second category which although are not as wieldable as those of the first group, still are quite wieldable? Post heating (in order to establish controlled cooling) can reduce the risk of its becoming hard and brittle after welding operation.

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32⟩ What metal cord transfers electricity, and how can i tell?

As far as I am concerned, copper is known as a good and cheap conductor of electricity. Although there are some other elements, such as silver, with higher conductivities copper is preferred due to its being rather cheap. Sometimes because of weight considerations, aluminum is also used even though it has a lower conductivity compared to copper.

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33⟩ Is there a possibility of inducing stress cracking in an insulated stainless road tanker vessel (20 tonne capacity) if the vessel is subject to rapid filling (10 tonne /hr) with liquid methane (-160 C) assuming the vessel is at ambient. If so, where could I obtain suggested cooling rates?

Assuming a two-hour load time, insulation in good condition and steel in good condition with no existing stress cracks at the welds, and a "pre-cool" period prior to rapid loading, the unit should hold up OK.

If you start with an ambient unit, and you have an inrush of liquid methane, the initial boiling of the methane in the unit will be very vigorous until the inner surfaces are cooled down. This violent boiling will result in liquid being ejected from the unit if care is not taken, and could result in damage to the insulation and liner. It would be best to load a small amount of the liquid methane into the unit and let it boil away, collecting the fumes and re-compressing if possible, thereby cooling the inner components of the unit. This will lessen the initial thermal shock and reduce the likelihood of stress cracking.

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34⟩ What are Metallurgical microscopes?

A metallurgical microscope is an inverted scope with light sources designed for magnifying structures of metallographically prepared specimens. The magnification is no different from most normal upright scopes. Companies including Nikon and Olympus produce the scopes and you will be able to find a plethra of information about the scopes on their websites. I would also consider contacting their sales reps to ask specific technical questions about the scopes.

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35⟩ Is there any way through hardening and anodizing some type of aluminum, it could be as hard as steel? I have hardened steel rollers that run up and down on a ramp along with spring pressure. Alternatively, if you are familiar with snowmobiles, the rollers run on the helix on the secondary clutch.

Aluminum, while it is incredible for some applications due to it being lightweight, is a very soft and weak metal. There really is not any way to get it any where near the hardness of steel. What people are doing for applications requiring lightweight, but strong materials is going with some new age alloys, mostly consisting of titanium and nickel.

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36⟩ What is the minimum temperature for stress relieving of ASTM A 519 Gr.4130 material and please tell us where we can find the location.

Stress relieving of alloy steels (like 4130) has no temperature outlined in the spec of the material. However, it is common practice to stress relieve 4130 between 1050 and 1200 F. This is high enough to relieve the stress with out being hot enough that the material has an austenitic phase change, which occurs around 1350 F.

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37⟩ When using mercury to recover very, fine gold from ore, what is the best way to separate the gold laden mercury from the ore?

A centrifugal system would certainly separate the mercury assuming you could maintain a fluidized bed and that there were not large differences in the sizes of the particles in the slurry. Depending on the volume involved, a vibratory table might be better. There are many other methods, but I would need to know the relative size / volume / solid-liquid ratio information in order to make a useful recommendation. You need to take special precautions in any case to preclude the release of mercury into the environment. This is very east to do I can help you there as well if you care to divulge the nature of your processing circuit.

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38⟩ Is it possible to use metallurgical inverted microscope to other designation?

A microscope is a microscope for most purposes. First, make sure the light source on the scope is useful in seeing whatever it is you want to see. Certain items are seen well in certain lights. The second thing, as I am sure you have already realized, is that you will have a tough time determining where on the sample you are looking, as it is up side down. For this reason, I even prefer a non-inverted scope even for metallurgical tasks. In summary, if you are ok with the sample being upside down, and the light source is sufficient, there is no reason it will not work to the magnification that scope is specified.

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39⟩ Why is it so hard to find literature on the wear resistance of titanium?

Titanium in elemental form is so soft it does not even register on a Rockwell C scale. With that being said, I would guarantee that you are using a titanium alloy of some type, most likely a Titanium-Aluminum-Vanadium alloy. These types of alloys can be processed to hardness in the low 40's HRC. In terms of concentrating on wear resistance, hardness is what you are going to want to focus on. I looked in one of my books and found the mechanical properties for various titanium alloys. The book, which you may be interested in purchasing a copy of, has all of the different properties of many materials, including entire chapters on titanium and titanium alloys. Below is the Amazon link to purchasing this book.

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40⟩ How to calculate heat affected zone in weld?

Heat affected zone is measured regarding the microstructure changes in the weld. For example in steels, this is the area around the weld zone, which has undergone a transformation. In other words, this is the area, which had been austenitized. For calculating the HAZ after welding, for steels, it is better to macroetech the section of the weld HAZ can be easily recognized by the contrast it makes with the base metal and the weld metal.

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