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engineering
materials science engineering

Questions and Answers of Materials Science Engineering

What are some of the important aspects of the service environment to be considered when selecting an engineering material? Discuss.
What are some of the possible manufacturing concerns that should be specified?
Why is it important to resist jumping to the answer and first perform a thorough evaluation of product needs and requirements?
Why is it important for all factors and all service conditions to be considered?
What are some possible pitfalls when using handbook data to assist in materials selection?
Why might it be appropriate to defer cost considerations until after evaluating the performance capabilities of various engineering materials?
Give an example of a product or component where material cost should be compared on a cost per pound basis. Give a contrasting example where cost per unit volume would be more appropriate.
In what way might failure analysis data be useful in a material selection decision?
Why should consideration of the various fabrication process possibilities be included in material selection?
Why might material selection and process selection be better performed in a parallel fashion as opposed to sequential?
Why is it likely that multiple individuals will be involved in the material and process selection activity?
Give an example of a materials substitution that has led to a subsequent problem.
What are some of the most common causes of product liability losses?
Discuss the interrelation between engineering material and the fabrication processes used to produce the desired shape and properties.
What is design?
What are the three primary phases of product design, and how does the consideration of materials differ in each?
What is the benefit of requiring prototype products to be manufactured from the same materials that will be used in production and by the same manufacturing techniques?
What precautions should be exercised when considering a new material or process for the manufacture of a product?
One simple tool that has been developed to assist in materials selection is a comparison chart, such as the one shown in Figure 9-A. The various desired properties are weighted as to their
The chalk tray on a classroom chalk board has very few performance requirements. As a result, it can be made from a wide spectrum of materials. Wood, aluminum, and even plastic have been used in this
The individual turbine blades used in the exhaust region of jet engines must withstand high temperatures, high stresses, and highly corrosive operating conditions. These demanding conditions severely
What are some of the advantages to the consumer of standardization and of interchangeable parts?
What type of fit would describe the following situations? (a) The cap of a ball-point pen (b) The lead in a mechanical lead pencil, at the tip (c) The bullet in a barrel of a gun.
Here is a table that provides a description of fits from clearance to interference. Give an example of each of these fits.
Why might you use a shrink fit rather than welding to join two steel parts? What does the word shrink imply?
Explain the difference between accuracy and precision.
What factors should be considered in selecting measurement equipment?
Explain how you could determine if your ordinary bathroom scale is linear and has good repeat accuracy, assuming the scale is analog.
Explain what is meant by the statement that usable magnification is limited by the resolution of the device.
What is parallax? (Why do linesmen in tennis sit looking down the line?)
Why is it important to interface the manufacturing engineering requirements with the design phase as early as possible?
What is the rule of 10?
What is the principle of vernier calipers?
What is the major disadvantage of a micrometer caliper as compared with a vernier caliper? The advantages?
Suppose you had a 2-ft steel bar in your super-micrometer. Could you detect a length change if the temperature of the bar changed 20°F?
In what two ways can linear measurements be made using an optical projector?
Explain the difference between attributes and variables inspection.
What is a CMM (coordinate measuring machine)?
What is the principle of a sine?
What is the primary precaution that should be observed in using a dial gage?
What tolerances are added to gages when they are being designed?
Explain how a go/not-go ring gage works for check a shaft.
Explain the principle of measurement by light-wave interference.
How does a toolmaker's flat differ from an optical flat?
Two surfaces can have the same microinch roughness but be different in appearance. Explain!
Why have so many variable-type devices in autos been replaced with attribute-type devices?
Why are surface-finish blocks often used for specifying surface finish rather than microinch values?
What limits the resolution of a stylus-type surface-measuring device in finding profiles?
What is the general relationship between surface roughness and tolerance? Between tolerance and cost to produce the surface and/or tolerance?
What is a Pascal, and how is it made up of the basic measures?
What are the different grades of gage blocks, and why do they come in sets?QUESTION CONTINUE TO NEXT PAGE
What keeps gage blocks together when they are "wrung together"?
What is the difference between tolerance and allowance?
Read the 25-division vernier graduated in English (Figure 10-A).
In Figure 10-F, the angle 9 on the part needs to be inspected. The setup used is shown in Figure 10-G. (No sine plate was available.) Determine the angle 6 from the part drawing and the valve of X
Figure 10-H shows a section of a vernier caliper. What is the reading for the outside caliper?
Read the 25-division vernier graduated in metric (direct reading) (Figure 10-B).
What is the estimated error in this measurement, given that Grade 3 working blocks are being used?
In Figure 10-E, two examples of a metric vernier micrometer are shown. The micrometer is graduated in hundredths of a millimeter (0.01 mm), and an additional reading in two-thousandths of a
Progress in machine tool technology over the last 100 years has led to the continual redefinition of precision as shown in Figure CS-10, developed by Taniguchi. The trend here is very clear-that
Why must destructive testing be performed on a statistical basis?
What types of defects can be detected in a liquid penetrant test?
Describe how the orientation of a flaw with respect to a magnetic field can affect its detectability during magnetic particle inspection.
What is the major limitation of sonic testing, where one listens to the characteristic ring of a product in an attempt to detect defects?
What is the role of a coupling medium in ultrasonic inspection?
What are three types of ultrasonic inspection methods?
What are penetrameters, and how are they used in radiographic inspection?
While radiographs offer a graphic image that looks like the part being examined, the technique has some significant limitations. What are some of these limitations?
What is a proof test, and what assurance does it provide?
What types of detection capabilities are offered by eddy-current inspection that cannot be duplicated by the other methods?
Why can't acoustic emission methods be used to detect the presence of an existing but static defect?
How can temperature be used to reveal defects?
What kinds of product features can be evaluated by electrical resistivity methods?
What are some of the techniques that can be used to determine the chemical composition of surface and near-surface material?
Why is it important to determine the distinction between allowable and critical flaws, as opposed to rejecting all materials that contain detectable flaws?
What quality-related features can a hardness test reasonably ensure?
What exactly is nondestructive testing, and what are some attractive features of the approach?
What are some possible objectives of nondestructive testing?
What are some factors that should be considered when selecting a nondestructive testing method?
How might the costs of nondestructive testing actually be considered as an asset rather than a liability?
Why should visual inspection be considered as the initial and primary means of inspection?
A manufacturing company routinely specifies X-ray radiography to assure the absence of cracks in its cast metal products. The primary reason for selecting radiography is the availability of a
For each of the inspection methods listed below, cite one major limitation to its use. a. Visual inspection b. Liquid penetrant inspection c. Magnetic particle inspection d. Ultrasonic inspection e.
Which of the major nondestructive inspection methods might you want to consider if you want to detect (1) surface flaws and (2) internal flaws in products made from each of the following materials?a.
Discuss the application of nondestructive inspection methods to powder metallurgy (metallic) products with low, average, and high density.
The pulse-echo ultrasonic technique can be used to determine the thickness of a part or structure. By accurately measuring the time it takes for a short ultrasonic pulse to travel through the
With nondestructive inspection methods using wave phenomena, the detection limit or resolution is dependent upon the wavelength being used. Compare the wavelengths of: a. Ultrasonic waves of
You are a member of a corporate failure analysis group, working out of the home office of a large petroleum corporation with production sites throughout North America. These sites generally contain a
Define a process capability study in terms of accuracy or precision.
Explain why the diameter measurements for holes produced by the process of drilling could have a skewed rather than a normal distribution.
What are some common manufactured items that may a. Receive 100% inspection. b. Receive no final inspection. c. Receive some final inspection, that is, sampling?
What are common reasons for sampling inspection rather than 100% inspection?
Fill in this table with one of the following statements: no error-the process is good, no error-the process is bad, type I or alpha error, type II or beta error.
Now explain why when we sample, we cannot avoid making type I and type II errors?
Which error can lead to legal action from the consumer for a defective product that caused bodily injury?
Define and explain the difference between a. σ′ and σ b. σ′ and c. σ, σR, σσ
What is Cp, and why is a value of 0.80 not good? How about a value of 1.00? 1.3?
What are some of the alternatives available to you when you have the situation where 6σ′ > USL - LSL?
What does the nature of the process refer to?
What is an assignable cause, and how is it different from a chance cause?

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