Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

6 METALS
Review Questions
6.1

What are some of the general properties that distinguish metals from ceramics and polymers?
Answer. Typical metallic properties include: high strength and stiffness, good electrical and thermal
conductivity, and higher density than ceramics or polymers.

6.2

What are the two major groups of metals? Define them.

Answer. Ferrous metals, which are based on iron; and nonferrous, which includes all others.

6.3

What is an alloy?
Answer. An alloy is a metal comprised of two or more elements, at least one of which is metallic.

6.4

What is a solid solution in the context of alloys?

Answer. A solid solution is an alloy in which one of the metallic elements is dissolved in another to
form a single phase.

6.5

Distinguish between a substitutional solid solution and an interstitial solid solution.

Answer. A substitutional solid solution is where the atoms of the dissolved element replace atoms of
the solution element in the lattice structure of the metal. An interstitial solid solution is where the
dissolved atoms are small and fit into the vacant spaces (the interstices) in the lattice structure of the
solvent metal.

6.6

What is an intermediate phase in the context of alloys?

Answer. An intermediate phase is an alloy formed when the solubility limit of the base metal in the
mixture is exceeded and a new phase, such as a metallic compound (e.g., Fe3C) or intermetallic
compound (e.g., Mg2Pb) is formed.

6.7

The copper-nickel system is a simple alloy system, as indicated by its phase diagram. Why is it so
simple?
Answer. The Cu-Ni alloy system is simple because it is a solid solution alloy throughout its entire
composition range.

6.8

What is the range of carbon percentages which defines an iron-carbon alloy as a steel?
Answer. The carbon content ranges from 0.02% to 2.11%.

6.9

What is the range of carbon percentages which defines an iron-carbon alloy as cast iron?
Answer. The carbon content ranges from 2.11% to about 5%.

6.10 Identify some of the common alloying elements other than carbon in low alloy steels.
Answer. The common alloying elements in low alloy steel are Cr, Mn, Mo, Ni, and V.
6.11 What are some of the mechanisms by which the alloying elements other than carbon strengthen steel.
Answer. All of the alloying elements other than C strengthen the steel by solid solution alloying. Cr,
Mn, Mo, and Ni increase hardenability during heat treatment. Cr and Mo improve hot hardness.
Several of the alloying elements (Cr, Mo, V) form hard carbides with C, which increases wear
resistance. Vanadium inhibits grain growth during heat treatment which improves strength and
toughness.
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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

6.12 What is the mechanism by which carbon strengthens steel in the absence of heat treatment?
Answer. In the absence of heat treatment, carbon strengthens steel by creating a two-phase structure
in the metal.
6.13 What is the predominant alloying element in all of the stainless steels?
Answer. Chromium.
6.14 Why is austenitic stainless steel called by that name?
Answer. It is called austenitic because this alloy exists in its austenitic phase at room temperature.
The reason is that nickel has the effect of enlarging the austenitic temperature range to include room
temperature.
6.15 Besides high carbon content, what other alloying element is characteristic of the cast irons?
Answer. Silicon.
6.16 Identify some of the properties for which aluminum is noted?
Answer. Aluminum is noted for its low density, high electrical and thermal conductivity, formability,
good corrosion resistance due to the formation of a tough oxide film on its surface, and ability to be
alloyed and strengthened to achieve good strength-to-weight ratios.
6.17 What are some of the noteworthy properties of magnesium?
Answer. Magnesium is noted for its very low density (lightest of the structural metals), propensity to
oxidize (which can cause problems in processing), and low strength; however, it can be alloyed and
strengthened by methods similar to those used for aluminum alloys to achieve respectable
strength-to-weight ratios.
6.18 What is the most important engineering property of copper which determines most of its
applications?
Answer. Its high electrical conductivity.
6.19 What elements are traditionally alloyed with copper to form (a) bronze and (b) brass?
Answer. The elements are (a) tin and (b) zinc, respectivley.
6.20 What are some of the important applications of nickel?
Answer. The important applications of Ni are (1) as an alloying ingredient in steel, e.g., stainless
steel; (2) for plating of steel to resist corrosion; and (3) to form nickel-based alloys noted for
high-temperature performance and corrosion resistance.
6.21 What are the noteworthy properties of titanium?
Answer. Titanium is noted for its high strength-to-weight ratio, corrosion resistance (due to the
formation of a thin but tough oxide film), and high temperature strength.
6.22 Identify some of the important applications of zinc.
Answer. The important applications of Zn are (1) die castings - zinc is an easy metal to cast; (2) as a
coating in galvanized steel; (3) as an alloying element with copper to form brass.
6.23 What important alloy is formed from lead and tin?
Answer. Solder.
6.24 (a) Name the important refractory metals. (b) What does the term refractory mean?

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

Answer. (a) The refractory metals include columbium (Cb), molybdenum (Mo), tantalum (Ta), and
tungsten (W). Mo and W are the most important. (b) Refractory means the capability to withstand
high temperature service.
6.25 (a) Name the four principal noble metals. (b) Why are they called noble metals?
Answer. (a) The principal noble metals are copper, gold, platinum, and silver. (b) Nobel metals are
so-named because they are chemically inactive.
6.26 The superalloys divide into three basic groups, according to the base metal used in the alloy. Name
the three groups.
Answer. The three groups are (1) iron-based alloys, (2) nickel-based alloys, and (3) cobalt-based
alloys.
6.27 What is so special about the superalloys? What distinguishes them from other alloys?
Answer. The superalloys are generally distinguished by their strength and resistance to corrosion and
oxidation at elevated temperatures.
6.28 What are the three basic methods by which metals can be strengthened?
Answer. The three basic methods are (1) alloying to form solid solutions and two-phase structures
which are stronger than the elemental metals; (2) cold working, in which the strain-hardened metal is
stronger and harder than the unstrained metal; and (3) heat treatment - most of the commercial heat
treatments are designed to increase the strength of the metal.

Multiple Choice Quiz

There is a total of 20 correct answers in the following multiple choice questions (some questions have
multiple answers that are correct). To attain a perfect score on the quiz, all correct answers must be given.
Each correct answer is worth 1 point. Each omitted answer or wrong answer reduces the score by 1 point,
and each additional answer beyond the correct number of answers reduces the score by 1 point. Percentage
score on the quiz is based on the total number of correct answers.
6.1

Which of the following properties or characteristics are inconsistent with the metals (two correct
answers): (a) good thermal conductivity, (b) high strength, (c) high electrical resistivity, (d) high
stiffness, or (e) ionic bonding?
Answer. (c) and (e).

6.2

Which one of the metallic elements is the most abundant on the earth: (a) aluminum, (b) copper, (c)
iron, (d) magnesium, or (e) silicon?
Answer. (a).

6.3

The predominant phase in the iron-carbon alloy system for a composition with 99% Fe at room
temperature is which of the following: (a) austenite, (b) cementite, (c) delta, (d) ferrite, or (e)
gamma.?
Answer. (d).

6.4

A steel with 1.0% carbon is known as which one of the following: (a) eutectoid, (b) hypoeutectoid,
(c) hypereutectoid, or (d) wrought iron?
Answer. (c).

6.5

The strength and hardness of steel increases as carbon content (a) increases or (b) decreases?
Answer. (a).

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

6.6

Plain carbon steels are designated in the AISI code system by which of the following: (a) 01XX, (b)
10XX, (c) 11XX, (d) 12XX, or (e) 30XX?
Answer. (b).

6.7

Which one of the following elements is the most important alloying ingredient in steel: (a) carbon, (b)
chromium, (c) nickel, (d) molybdenum, or (e) vanadium?
Answer. (a).

6.8

Which one of the following is not a common alloying ingredient in steel: (a) chromium, (b)
manganese, (c) nickel, (d) vanadium, (e) zinc?
Answer. (e).

6.9

Solid solution alloying is the principal strengthening mechanism in high-strength low-alloy (HSLA)
steels: (a) true or (b) false?
Answer. (a).

6.10 Which of the following alloying elements are most commonly associated with stainless steel (two
best answers): (a) chromium, (b) manganese, (c) molybdenum, (d) nickel, and (e) tungsten?
Answer. (a) and (d).
6.11 Which of the following is the most important cast iron commercially: (a) ductile cast iron, (b) gray
cast iron, (c) malleable iron, or (d) white cast iron?
Answer. (b).
6.12 Which one of the following metals has the lowest density: (a) aluminum, (b) magnesium, (c) tin, or
(d) titanium.?
Answer. (b).
6.13 Which of the following metals has the highest density: (a) gold, (b) lead, (c) platinum, (d) silver, or
(e) tungsten?
Answer. (c).
6.14 From which of the following ores is aluminum derived: (a) alumina, (b) bauxite, (c) cementite, (d)
hematite, or (e) scheelite?
Answer. (b).
6.15 Which of the following metals is noted for its good electrical conductivity (one best answer): (a)
copper, (b) gold, (c) iron, (d) nickel, or (e) tungsten?
Answer. (a).
6.16 Traditional brass is an alloy of which of the following metallic elements (two correct answers): (a)
aluminum, (b) copper, (c) gold, (d) tin, (e) zinc?
Answer. (b) and (e).
6.17 Which one of the following metals has the lowest melting point? (a) aluminum, (b) lead, (c)
magnesium, (d) tin, or (e) zinc.
Answer. (d).

Problems
6.1

For the copper-nickel phase diagram in Figure 6.2, find the compositions of the liquid and solid
phases for a nominal composition of 70% Ni and 30% Cu at 1371C (2500F).

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Solutions for Fundamentals of Modern Manufacturing, 3/e (published by Wiley) MPGroover 2007

Solution: From Fig 6.2, the compositions are observed as follows:

Liquid phase composition = 65% Ni - 35% Cu.
Solid phase composition = 83% Ni - 17% Cu.
6.2

For the preceding problem, use the inverse lever rule to determine the proportions of liquid and solid
phases present in the alloy.
Solution: From Fig 6.2, measured values of CL and CS are: CL = 5 mm, CS = 12 mm.
Liquid phase proportion = 12/(12 + 5) = 12/17 = 0.71
Solid phase proportion = 5/17 = 0.29

6.3

Using the lead-tin phase diagram in Figure 6.3, determine the liquid and solid phase compositions for
a nominal composition of 40% Sn and 60% Pb at 204C (400F).
Solution: From Fig 6.3, the compositions are observed as follows:
Liquid phase composition = 56% Sn - 44% Pb.
phase composition = 18% Sn - 82% Pb.

6.4

For the preceding problem, use the inverse lever rule to determine the proportions of liquid and solid
phases present in the alloy.
Solution: From Fig 6.3, measured values of CL and CS are: CL = 10.5 mm, CS = 15 mm.
Liquid phase proportion = 15/(15 + 10.5) = 15/25.5 = 0.59
phase proportion = 10.5/25.5 = 0.41

6.5

Using the lead-tin phase diagram in Figure 6.3, determine the liquid and solid phase compositions for
a nominal composition of 90% Sn and 10% Pb at 204C (400F).
Solution: From Fig 6.3, the compositions are observed as follows:
Liquid phase composition = 78% Sn - 22% Pb.
phase composition = 98% Sn - 2% Pb.

6.6

For the preceding problem, use the inverse lever rule to determine the proportions of liquid and solid
phases present in the alloy.
Solution: From Fig 6.3, measured values of CL and CS are: CL = 7.8 mm, CS = 4.2 mm.
Liquid phase proportion = 4.2/(13) = 0.32
phase proportion = 7.8/13 = 0.68

6.7

In the iron-iron carbide phase diagram of Figure 6.4, identify the phase or phases present at the
following temperatures and nominal compositions: (a) 650C (1200F) and 2% Fe3C, (b) 760C
(1400F) and 2% Fe3C, and (c) 1095C (2000F) and 1% Fe3C.
Solution: (a) Alpha + iron carbide, (b) gamma + iron carbide, and (c) gamma.

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