production Engineering

2. Duralumin
 It is an important and interesting wrought alloy.
 Its composition is as follows:
 Copper = 3.5 – 4.5%; Manganese = 0.4 – 0.7%;
Magnesium = 0.4 – 0.7%, and the remainder is
aluminium.
 This alloy possesses maximum tensile strength (upto
400 MPa) after heat treatment and age hardening.
After working, if the metal is allowed to age for 3 or 4
days, it will be hardened. This phenomenon is known
as age hardening.
 It is widely used in wrought conditions for forging,
stamping, bars, sheets, tubes and rivets.

3. IES-1993
Duralumin Alloy contains aluminium and copper
in the ratio of
%Al %Cu
(a) 94 4
(b) 90 8
(c) 88 10
(d) 86 12

4. IES-1992
Which of the following statement is incorrect
about duralumin?
(a) It is prone to age hardening
(b) It can be forged
(c) It has good machining properties
(d) It is lighter than pure aluminium

5. Magnalium
 It is made by melting the aluminium with 2 to 10%
magnesium in a vacuum and then cooling it in a
vacuum or under a pressure of 100 to 200 atmospheres.
 It also contains about 1.75% copper. Due to its light
weight and good mechanical properties, it is mainly
used for aircraft and automobile components.

6. Hindalium
 It is an alloy of aluminium and magnesium with a
small quantity of chromium.

7. Copper-zinc alloys (Brass)
 The most widely used copper-zinc alloy is brass.
 There are various types of brasses, depending upon the
proportions of copper and zinc.
 This is fundamentally a binary alloy of copper with
zinc each 50%.
 By adding small quantities of other elements, the
properties of brass may be greatly changed.
 Applications of Cu alloys include: costume jewellery,
coins, musical instruments, electronics, springs,
bushes, surgical and dental instruments, radiators, etc.
Contd…

8.  The addition of zinc strengthens the material and
incidentally changes the colour to a yellow or gold
effect.
 The ratio of copper and zinc can be varied for
advantages and the addition of other elements gives
still more variety of combinations of properties such as
machinability, strength, hardness, ductility (hot or
cold), conductivity and corrosion resistance as well as
many others.
 Lead additions are used to improve machinability. The
lead is insoluble in the solid brass and segregates as
small globules that help the swarf to break up in to
small pieces and may also help to lubricate the cutting
tool action.

9. IES-1992
Addition of which of the following improves
machining of copper?
(a) Sulphur
(b) Vanadium
(c) Tin
(d) Zinc

10. IES-1992
Cartridge brass can be
(a) Cold rolled into sheets
(b) Drawn into wires
(c) Formed into tubes
(d) Any of the above.

11. Copper-tin alloys (Bronze)
 The alloys of copper and tin are usually termed as
bronzes.
 The useful range of composition is 75 to 95% copper
and 5 to 25% tin.
 The metal is comparatively hard, resists surface wear
and can be shaped or rolled into wires, rods and sheets
very easily.
 In corrosion resistant properties, bronzes are superior
to brasses.
Contd…

12.  The hardness and strength of bronze increase with an
increase in tin content.
 The ductility is also reduced with the increase in tin
percentage above 5.
 When aluminium is also added (4 to 11%), the
resulting alloy is termed aluminium bronze, which
has a considerably higher corrosion resistance.
 Bronzes are comparatively costly compared to brasses
due to the presence of tin which is an expensive metal.
 The colour of aluminium bronze is similar to that of
22 carat gold and it is frequently called ‘imitation
gold’.

13. IES 2011
Aluminium Bronze is also known as :
(a) Muntz metal
(b) White metal
(c) Duraluminium
(d) Imitation gold

14. Phosphor bronze
 When bronze contains phosphorus, it is called
phosphor bronze.
 Phosphorus increases the strength, ductility and
soundness of castings.
 This alloy possesses good wearing qualities and high
elasticity.
 A common type of phosphor bronze has the following
composition according to Indian standards Copper =
87–90%, Tin = 9–10%, and Phosphorus = 0.1–3%.
 The material is specified for pump parts, gears,
springs, power screw nuts and bearings.

15. IES-2006
In case of power screws, what is the combination
of materials used for the screw and the nut?
(a) Cast iron screw and mild steel nut
(b) Carbon steel screw and phosphor bronze nut
(c) Cast iron screw and cast iron nut
(d) Aluminium screw and alloy steel nut

16. IES-1992
The percentage of phosphorous in phosphor bronze
is
(a) 0.1 (b) 1
(c) 11.1 (d) 98

17. Gun Metal
 It is an alloy of copper, tin and zinc.
 It usually contains 88% copper, 10% tin and 2% zinc.
 This metal is also known as Admiralty gun metal.
 The zinc is added to clean the metal and to increase its
fluidity.
 It is not suitable for being worked in the cold state but
may be forged when at about 600°C.
 It is extensively used for casting boiler fittings, bushes,
bearings, glands, etc.

18. IES-2003
Gunmetal, which is used in journal bearings,
contains
(a) 88% Cu, 10% Sn, 2% Zn
(b) 80% Cu, 10% Zn, 10% Al
(c) 85% Cu, 5% Mg, 10% Al
(d) 85% Cu, 5% Sn, 10% Pb

19. IES-1994
Which of the following pairs are correctly
matched?
1. Silicon steels ………Transformer stampings
2. Duralumin ……Cooking utensils.
3. Gun metal................. Bearings
Select the correct answer using the codes given below.
Codes:
(a) 1, 2 and 3 (b) 1 and 2
(c) 1 and 3 (d) 2 and 3

20. IES 2011
Match List –I with List –II and select the correct answer using
the code given below the lists :
Codes
A B C D A B C D
(a) 3 1 2 4 (b) 4 1 2 3
(c) 3 2 1 4 (d) 4 2 1 3
List –I List –II
A. Gun Metal 1. Worm wheel
B. Phosphor bronze 2. Cylinder block
C. Gray cast iron 3. Piston
D. Al alloy 4. Bushings

21. Monel metal
 It is an important alloy of nickel and copper.
 It contains 68% nickel, 29% copper and 3% other
constituents like iron, manganese, silicon and carbon.
It is superior to brass and bronze in corrosion resisting
properties.
 It is used for making propellers, pump fittings,
condenser tubes, steam turbine blades, sea water
exposed parts, tanks and chemical and food handling
plants.

24. IES 2011
Admirality Brass is used for
(a) Condenser Tubes
(b) Rivets
(c) Piston rods
(d) Utensils

25. IES-2006
Match List-I (Composition) with List-II (Application) and select
the correct answer using the code given below the Lists:
List- I List -II
A. Commercial bronze (10% Zn) 1. Radiator
B. Red brass (15% Zn) 2. Spring metal
C. Aluminium brass ( 22% Zn, 2% Al) 3. Forging and
stamping
D. P-bronze (11 % tin) small amount of P) 4. Power plant
and chemical
equipment
Codes:A B C D A B C D
(a) 2 4 1 3 (b) 3 1 4 2
(c) 2 1 4 3 (d) 3 4 1 2

26. IES-2003
Monel metal is an alloy of
(a) Iron and carbon
(b) Copper and zinc
(c) Aluminium and copper
(d) Copper and nickel

27. IES-2004
Match List I (Alloy) with List II (Application) and select
the correct answer using the codes given below the Lists:
List I List II
A. Silicon steel 1. Marine bearings
B. High carbon steel 2. Cutting tools
C. High speed steel 3. Springs
D. Monel metal 4. Transformer
laminations
Codes:A B C D A B C D
(a) 1 2 3 4 (b) 4 3 2 1
(c) 4 2 3 1 (d) 1 3 2 4

28. Inconel
 It consists of 80% nickel, 14% chromium, and 6% iron.
 This alloy has excellent mechanical properties at
ordinary and elevated temperatures.
 It can be cast, rolled and cold drawn.
 It is used for making springs which have to withstand
high temperatures and are exposed to corrosive action.
 It is also used for exhaust manifolds of aircraft engines.

29. Nichrome
 It consists of 65% nickel, 15% chromium and 20% iron.
 It has high heat and oxidation resistance.
 It is used in making electrical resistance wire for
electric furnaces and heating elements.

30. Nimonic
 It consists of 80% nickel and 20% chromium.
 It has high strength and ability to operate under
intermittent heating and cooling conditions.
 It is widely used in gas turbine engines.

31. Babbit metal
 The tin base and lead base babbits are widely used as a
bearing material, because they satisfy most
requirements for general applications.
 The babbit is generally used as a thin layer, 0.05 mm to
0.15 mm thick, bonded to an insert or steel shell. The
composition of the babbit metals is as follows:
 Tin base babbits : Tin 90% ; Copper 4.5% ; Antimony
5% ; Lead 0.5%.
 Lead base babbits : Lead 84% ; Tin 6% ; Anitmony
9.5% ; Copper 0.5%.

32. IES 2011
Babbit is an alloy of
(a) Sn, Cu, Sb and Pb
(b) Sn and Cu
(c) Sn, Cu and Pb
(d) Sn, Cu and Sb

33. IES-1995
Babbit lining is used on brass/bronze bearings to
(a) Increase bearing resistance
(b) Increase compressive strength
(c) Provide anti-friction properties
(d) Increase wear resistance.

34. IES-2009
Why are babbit alloys used for bearing material?
(a) They have excellent embeddability
(b) They are relatively stronger than other bearing
materials
(c) They do not lose strength with increase in
temperature
(d) They have high fatigue strength

35. IES-2008
Which one of the following is correct?
Babbitt are used for
(a) Gears (b) Bearings
(c) Bolts (d) Clutch liners

36. IES
Tin base white metals are used where the bearings
are subjected to
(a) Large surface wear
(b) Elevated temperatures.
(c) Light load and pressure
(d) High pressure and load.

37. IES-1998
Match List-I (Alloys) with List-II (Applications) and
select the correct answer using the codes given below
the lists:
List-I List-II
A. Chromel 1. Journal bearing
B. Babbit alloy 2. Milling cutter
C. Nimonic alloy 3. Thermocouple wire
D. High speed steel 4. Gas turbine blades
Code:A B C D A B C D
(a) 3 1 4 2 (b) 3 4 1 2
(c) 2 4 1 3 (d) 2 1 4 3

38. IES-2005
Match List I (Alloy) with List II (Major Constituent)
and select the correct answer using the code given
below the Lists:
List I List II
A. Babbitt 1. Nickel
B. Invar 2. Tin and lead
C. Gun Metal 3. Aluminium
D. Duralumin 4. Copper
Code:A B C D A B C D
(a) 2 4 1 3 (b) 3 1 4 2
(c) 2 1 4 3 (d) 3 4 1 2

39. IES 2007
Match List I with List II and select the correct answer using the code
given below the Lists:
List I List II
(Component) (Required Property)
A. Blades of bulldozer 1. High wear resistance and
high toughness
B. Gas turbine blades 2. Low Young’s modulus and
high fatigue strength
C. Drill bit 3. High wear and abrasion
resistance
D. Springs of automobiles 4. High creep strength and
good corrosion resistance
Code: A B C D A B C D
(a) 3 2 1 4 (b) 1 4 3 2
(b) 3 4 1 2 (d) 1 2 3 4

40. Columbium/Niobium
 Columbium finds much use in large-scale applications,
such as steel for automobile bodies and pipelines. The use
that probably will consume most of the columbium is
microalloying.
 Relatively small amount of columbium lend high strength
to steel. The microalloyed, or high-strenght, low-alloy
(HSLA) steels, are used for automobile bodies, structures
of all kinds, and high-pressure pipe, particulary in the oil
and gas industry.
 Columbium with oxygen as dominant substiutitional
alloying atoms is used in the nuclear fusion reactor.
 Nuclear material refers to the metals uranium, plutonium,
and thorium, in any form, according to the IAEA

41. IES 2011
Columbium is a :
(a) Nuclear material
(b) Automobile material
(c) Film material
(d) Foam material

42. Nimonic 90
 A precipitation hardenable nickel-chromium-cobalt alloy,
having high stress-rupture strength and creep resistance at
elevated temperatures up to about 950 °C.
 For springs exposed to lower loads, the material can be used
up to 700 °C.
 Nimonic 90 offers good resistance to corrosion and is non-
magnetic.
 Applications include the aircraft industry, gas turbines,
vehicle components and springs in high temperature
environments, and thermal.
 Operating temperature: -100 – + 550 °C

43. The End