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MLE1101 Tutorial 5 - Suggested Solutions

1. A hypoeutectiod plain-carbon steel was slow-cooled from 900C to 723C AT (where AT <
1C). What is the carbon concentration (in wt%) in the carbon steel if it contains 5.9wt%
eutectoid ferrite at 723C AT?
(Hint: At 723C AT, the hypoeutectoid steel contains 3 phases proeutectoid ferrite,
eutectoid ferrite and cementite.)


















Solution:
The carbon content is related to the eutectoid ferrite by considering the proeutectoid ferrite
and the total ferrite present after the eutectoid reaction.

wt% eutectoid ferrite = wt% total ferrite wt% proeutectoid ferrite








Let x be the average carbon content.
iron-iron carbide
phase diagram
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6.67 0.80
0.059
6.67 0.02 0.80 0.02
6.67 0.80
0.059
6.65 6.65 0.78 0.78
0.059 1.003 0.150 1.026 1.282
0.082 1.132
0.072%
x x
x x
x x
x
x

=

= +
= +
=
=

2. Draw time-temperature cooling paths for a 1080 steel on an isothermal transformation
diagram that will produce the following microstructures. Start with the steels in the
austenitic condition at time = 0
o
C and 850C. (a) 100% martensite,
(b) 50% martensite and 50% coarse pearlite, (c) 100% fine pearlite
(d) 50% martensite and 50% upper bainite, (e) 100% upper bainite
(f) 100% lower bainite

Solution:














3. What is the microstructure produced after austempering a eutectoid plain-carbon steel?
Does an austempered steel need to be tempered? Explain.

Solution:
After austempering, a eutectoid plain-carbon steel has a bainite microstructure. Subsequent
tempering is not necessary since the austempering results in hardness, distortion and impact
energy values comparable to or better than those associated with a marquenched and
tempered steel.








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4. Describe the four decomposition structures that can be developed when a supersaturated
solid solution of an Al-4%Cu alloy is aged.

Solution:
The four decomposition structures that can be developed are as follows:
1. GP 1 zones consist of segregated regions in the shape of disks a few atoms thick (0.4
to 0.6nm) and about 8 to 10nm in diameter. They form on the {100} cubic planes,
straining the lattice tetragonally and are coherent with the matrix.
2. GP 2 zones () are approximately 1 to 4nm thick and 10 to 100nm in diameter.
These zones are also coherent with the {100} matrix and have a tetragonal structure.
3. The phase nucleates heterogeneously and is incoherent with the matrix. This
phase has a tetragonal structure with a thickness of 10 to 150nm.
4. The phase is an incoherent equilibrium phase having the composition CuAl
2
. This
phase, which forms from or directly from the matrix, has a BCT structure.


5. Determine the mole fraction of polyvinyl chloride and polyvinyl acetate in a copolymer
having a molecular weight of 11,000 g/mol and a degree of polymerization of 150.

Solution:
The average molecular weights of PVC and PVAc mers:
PVC
MW 3H atoms 1g/mol 2C atoms 12g/mol 1Cl atom 35.5g/mol 62.5g/mol = + + =
PVAc
MW 6H atoms 1g/mol 4C atoms 12g/mol 2O atoms 16g/mol 86.0g/mol = + + =

The mole fractions of these polymers can be determined based on the average molecular
weight of the copolymer mer.

av PVC PVC PVAc PVAc PVC PVC PVC PVAc
MW (mer) MW MW MW (1 )MW f f f f = + = +
where the average molecular weight of the copolymer mer is,
av
av
MW (polymer) 11,000g/mol
MW (mer) 73.33g/mer
DP 150
= = =


The mole fraction of PVC can be obtained by equating these 2 equations.
PVC PVC
PVC
PVAc
(62.5g /mol) (1 )(86.0g /mol) 73.33g /(mol mer)
0.539
0.461
f f
f
f
+ =
=
=

Cooling curves for austempering a eutectoid plain-carbon steel
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6. How much sulphur must be added to 70 g of butadiene rubber to cross-link 3.0% of the
mers? (Assume all sulphur is used to cross-link the mers and that only one sulphur atom is
involved in each cross-linking bond.)

Solution:
Assuming only one sulfur atom is involved in each cross-linking bond with butadiene, we
know there is a one-to-one correspondence between the number of moles of sulfur and the
number of moles of butadiene in the reaction. We are therefore able to assess the amount
of sulfur required for 100% cross-linking.

S S
100%
S
butadiene
mass of S MW (No. of moles of S) MW (No. of moles of butadiene)
mass of butadiene
MW
MW (mer)
= =
| |
=
|
\ .


The average molecular weight of the butadiene mer is:
polybutadiene
MW 6H atoms 1g/mol 4C atoms 12g/mol 54g/mol = + =

Substituting,
100%
70g
mass of S (32g /mol) 41.48g S
54g /mol
| |
= =
|
\ .

Thus for only 3 percent cross-linking,
3%
mass of S 0.03 41.48g S 1.24g S = =


7. How is it possible for a polymer chain such as a polyethylene one to keep growing
spontaneously during polymerization?

Solution:
The polymer chains in chain polymerization keep growing spontaneously because the energy
of the chemical system is lowered by the chain polymerization process; the total energy of
newly created polymers is lower than the total energy of the monomers that have reacted to
form them.



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8. How does the amount of crystallinity in a thermoplastic affect
(a) its density, and
(b) its tensile strength?
Explain.

Solution:
(a) As the degree of crystallinity increases in a thermoplastic, the packing of polymer
chains increases and thus the material density also increases.

(b) Similarly, since the polymer chains become closer with increased crystallinity, the
bonding forces between polymers increase and thus the tensile strength of the
material increases.


9. How does the presence of a methyl group on every other carbon atom of the main polymer
chain affect the glass transition temperature of this material when compared to
polyethylene?

Solution:
The substitution of hydrogen atoms with methyl groups increases the bond strengths by
restricting the rotation of the polymer chains; consequently, polypropylene has a higher
glass transition temperature than polyethylene.