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

41⟩ How much gold is in a troy ounce?

Troy ounce defined by the troy system of mass. In troy weight, there are 12 ounces in a pound, and a troy pound is 5760 grains (about 373.24 g), rather than 7000 (about 453.59 g). Note: at roughly 31.10 g, the troy ounce is about 10 per cent more than the more-common avoirdupois ounce. These troy ounces are now used only when weighing precious metals like gold and silver. One ounce of gold is always 31.1 g.

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42⟩ What is a silver and deming drill bit?

Silver and Denim is the name of a manufacturing company. This company could trace its history back to 1854, although the "Silver & Deming" name does not date back that far. The titular heads were Albert R. Silver and John Deming. Silver & Deming made a variety of machines that were primarily aimed at wheelwrights: hob-boxing machines, spoke-tenoning machines, etc.

Silver & Deming apparently invented the large-size twist drill bit with a turned-down shaft so they can be used in a chuck smaller than the bit's cutting diameter. They did not patent this idea, so the idea was quickly copied by others, but these bits are still called "Silver & Deming drills".

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43⟩ Which is stronger, Tungsten or Titanium?

Tungsten has high tensile strength and good creep resistance. At temperatures above 2205 OC (4000 OF), tungsten has twice the tensile strength of the strongest tantalum alloys and is only 10% denser. However, its high density, poor low-temperature ductility, and strong reactivity in air limit its usefulness. Maximum service temperatures for tungsten range from 1925 to 2480 "C (3500 to 4500 OF), but surface protection is required for use in air at these temperatures.

Wrought tungsten (as cold worked) has high strength, directional mechanical properties, and some room-temperature toughness. However, re crystallization occurs rapidly above 1370 "C (2500 OF) and produces a grain structure that is crack sensitive at all temperatures.

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44⟩ When austenitized, carbon steel is quenched, why is the BCC crystal elongated into a body-centered tetragonal crystal structure?

Martensite crystals ideally have planar interfaces with the parent austenite. The preferred crystal planes of the austenite on which the martensite crystals form are designated habit planes, which vary according to alloy composition. In steels, the parent phase is usually austenite with a face-centered cubic (fcc) crystal structure, but the crystal structure of the product phase may be body-centered cubic (bcc). Under special conditions, steels undergo martensitic transformations in which the crystal structure of the product phase reverts to that of the parent. Most medium-carbon and high-carbon steels form martensite with a bct crystal structure, because carbon atoms occupy only one of the three possible sets of octahedral interstitial positions.

Allotropy means the property by which certain elements (like Fe) may exist in more than one crystal structure. Iron exists in two allotropic forms: BCC and FCC. In other words at 700°C (1290°F) it undergoes an allotropic transformation from FCC to BCC (in quenching, i.e. iron has FCC structure above this temperature and BCC structure below that).

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45⟩ What are Ceramics?

The word ceramic is derived from the Greek word keramikos, "having to do with pottery". The term covers inorganic non-metallic materials whose formation is due to the action of heat. Up until the 1950s or so, the most important of these were the traditional clays, made into pottery, bricks, tiles and the like, along with cements and glass.

Historically, ceramic products have been hard, porous, and brittle. Technical Ceramics can also be classified into three distinct material categories:

Oxides: Alumina, zirconia

Non-oxides: Carbides, borides, nitrides, silicides

Composites: Particulate reinforced combinations of oxides and non-oxides.

Ceramic materials can be crystalline or amorphous. They tend to fracture before any plastic deformation takes place, which results in poor toughness in these materials. Additionally, because these materials tend to be porous, the pores and other microscopic imperfections act as stress concentrators, decreasing the toughness further, and reducing the tensile strength. These combine to give catastrophic failures, as opposed to the normally much more gentle failure modes of metals.

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46⟩ Do you know what metal might be considered the "most environmental"? I say aluminum because it can be recycled others on my team say brass.

Due to the consumption of a large amount of fossil energies to purify, ferrous alloys are not environmental. USA has stopped most of its steel mills, and the strategy is to concentrate mills in the developing countries. In non-ferrous alloys, let us consider only the mostly used alloys, which are copper alloys (including copper, brass, and bronze) and aluminum alloys. Because the rest are produced so much less than mentioned alloys that they are not actually a threat to the environment, furthermore, they are mostly extracted during refining Fe, Al, and Cu. Production of Cu and AL involves melting and electrolyzes procedures. However, the energy per kilogram pure Al needs is much higher than even Fe, but the most of the energy is electrical and much cleaner than that used for Fe. For Cu, through pirometallurgy methods a large amount of energy is gained autogenously, i.e. exothermal reactions occurred during copper making process supply a large amount of energy needed, but it involves producing products that are not environment. There are hydrometallurgy methods to produce copper, which are more environment-friendly.

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47⟩ What medal conducts heat best?

In physics, thermal conductivity, (showed by the Latin capital of land), is the intensive property of a material which relates its ability to conduct heat.

Thermal conductivity is the quantity of heat, Q, transmitted through a thickness L, in a direction normal to a surface of area A, due to a temperature gradient (delta T), under steady state conditions and when the heat transfer is dependent only on the temperature gradient.

In general, thermal conductivity tracks electrical conductivity metals being good thermal conductors. There are exceptions: the most outstanding is that of diamond, which has a high thermal conductivity, between 1000, and 2600 W/mk, while its electrical conductivity is low.

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48⟩ What is the difference between Stainless steel and Alloy Steel?

Stainless steels have at least 11 to 12% chromium in the alloy. Why 11 to 12% minimum you might ask? That much is required to provide a continuous layer of protective chromium oxide on the surface. Alloy steel just means that there are additional elements added to the iron-carbon. So to answer your second question; Yes, stainless steels are by definition alloy steels.

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49⟩ What affect would increasing the charpy impact toughness on an object have on the surface of an object it strikes if all else remains the same? Would it cause more damage to the object it strikes?

Charpy toughness is a measure of the metals ability to resist tearing or to absorb energy during an impact. Generally, we achieve that by altering the microstructure to be more ductile. In the quenched and tempered alloys (steels) for example, that involves tempering to convert the hard brittle martensite to softer more ductile bainite or a ferrite carbide mixture. Therefore, we are making a softer metal; therefore, if it affects another object it would tend to deform more. There would be less damage to the object being struck because the striking object would deform more and distribute its load across more of the surface of the object being struck.

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50⟩ What kind of cleaning substance or treatments keep or help prevent cast iron from rusting?

Cast iron is a mixture of graphite (carbon) flakes in a matrix of steel (iron with carbon in solution). The graphite, which has the shape of corn flakes, does not contribute much to strength. If anything, it makes the cast iron somewhat porous or sponge like. The graphite does makes it easy to machine and has a dampening effect on the cast iron. However, it also makes for a lot of surface area, which allows plenty of air (oxygen) to get to the iron and form rust.

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51⟩ Is nickel considered a non-sparking metal?

Monel and nickel form almost identical spark streams. The sparks are small in volume and orange in color. The sparks form wavy streaks with no sparklers.

So is not as bright as sparks of ferrous alloys. Therefore, that is a way to identify nickel and monel.

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52⟩ Which method has more procity in cast part? Which method has more strength in cast part?

The sand casting will have more porosity in the final product. The die cast will also have higher strength both because of the lower degree of porosity and because of the finer grain size. While I have not been directly involved in the production of cylinder blocks there are a number of reasons for the preference of die-casting versus sand casting. Die-casting provided a finer finish, greater tolerance, better repeatability, and generally higher quality casting. They used sand casting of the iron blocks and still do in many cases and initially the used this same method for aluminum. However, the lower melting point of aluminum allows them to do the die casting method.

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53⟩ What other events in history might have affected the growth of Metallurgy?

This question demands a deep historical research. Now I can point out the World War II as a historical event that causes a great progress in metallurgy. For example, it was during WWII that Germans started manufacturing single body ships with the help of welding. However, in the cold waters of north the ships cracked and split into to parts and cracks initiated in the welds! In addition, that was when they realized that in cold environments metals tend to be brittle and welding could increase this tendency. It was the beginning of a great progress in welding techniques and mechanical metallurgy.

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54⟩ Why is steel vital in the construction of an aircraft?

In the aircraft business, carbon steels provide the airframe structure, landing gear, and by alloying with nickel, chromium, and other elements it makes up most of the aircraft gas turbine engine materials. Titanium is used in some cases for the aircraft structure because it is less dense but also much more expensive.

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55⟩ How would a salt and water solution clean a penny but a vinegar and salt solution will not clean a penny? What is the cause of this?

I have been thinking about this overnight but I am not a chemist so I am unsure of the reactions. I do know that the penny gets shiny when you remove oxygen and impurities like sulfur from the surface. So lets reason together on this....The salt breaks down into hydrogen and chlorine in the water and produces a slightly acidic, HCl, solution. This breaks down the copper oxide pretty well. I do know the chlorine works well to clean of the copper oxide, I use "comet cleaner" with chlorine to clean brass. Now the vinegar has an acetic acid, but this is carbon, hydrogen and oxygen and I think that the salt combines with this to form a slightly basic solution and generates CO2. I would be interested in seeing if the vinegar salt solution with water added would improve the cleaning capability.

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56⟩ How do 304 stainless steel and 316 stainless steel weld to each other? I am hoping my medical device prospect will be able to weld a component made in 316 SS via metal injection molding toa 304 SS tube.

Both are austenitic stainless so, yes they can be easily welded but, and this is a big but, they can and are very different animals. You have not provided much information on the 304 and 316 alloys. 304 is a very common alloy that has a very wide range of compositions, this is like asking for a Chevy where you can get either a corvette or a fiesta. 316 is a little closer range of alloys but there are 316L, 316LN, 316F etc.

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57⟩ Are the grain boundaries a continuation of regular lattice structure from one grain to another? Explain.

They are called boundaries because this is where one crystal interacts with another. The lattice structure does not continue across the interface without mismatch. While there is some lattice, interaction or sharing it is not complete and there are many defects associated with the boundaries. The degree of mismatch determines if the boundary is a high angle boundary (lots of mismatch) or a low angle boundary (very little mismatch) A tilt boundary is an example of a low angle boundary. This is also one of the reasons that diffusion along grain boundaries is so much higher then through the bulk crystal.

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58⟩ A plain carbon steel contains 45 wt% of proeutectoid ferrite. What is its average carbon content in weight percent? I know that you need to use a tie line in the phase diagram, but my book does not really give a good example to go by

The calculation is so easy if you have the iron-carbon diagram in your mind. Proeutectoid ferrite is ferrite formed before eutectoid transformation. At 0.8 wt% carbon, we got 100% austenite before the transformation and at 0.02wt% carbon, we got 100% ferrite, and between these two values of carbon content, we have different amounts of proeutectoid ferrite.

Considering that, we have x wt% carbon we calculate proeutectoid ferrite using the tie line.

Proeutectoid ferrite amount = (0.8-x)/ (0.8-0.02)*100=45

==> x=0.45 wt%

You can check it with eyes. At the middle of the tie line, we must have 50% austenite, 50% ferrite; and it is at (0.8-0.02)/2=0.38%C.

We have 45% ferrite, which is less than 50% so we are closer to eutectoid point (0.8%C); so the carbon content must be more than 0.38%.

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59⟩ Is brass magnetic?

Brass is alloy of copper and zinc, of historical and enduring importance because of its hardness and workability.

However, brass is not magnetic, the basic magnetic elements are Iron, Cobalt and Nickel and their alloys. Then there are the new ceramic materials, which exhibit magnetic capabilities.

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60⟩ What is the strongest metal?

If there is any specific metal with the highest strength, I got no information about that. Everyday a new high technology material with unique characteristics is introduced. Now, the concentration is on composite materials. I guess the highest strength must belong to a composite material likely with a titanium alloy or as the matrix. Alternatively, maybe a super alloy is the strongest one. I got no more information.

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