Solution on Material Science

Question: Discuss about the Solution on Material Science? Answer: Solution1 (a): This component can be made from (i) Sand Casting (permanent pattern): (ii) Die Casting (iii) Centrifugal Casting (Vertical) Solution1 (b): (i). Sand Casting (permanent pattern): these castings basically use to produce bigger parts, in which other casting process is not suitable. To make 1000 component in a batch, we have to use two walled cylinder and a separate sand core is place just between them. Its problem is that It has grainy surface and generally internal porosity is developed. dimension is also largely variable. After casting machining is necessary, this causes extra cost. (ii) Die Casting: Basically we can use cold die casting, in this process the component in batches can be produced but one again cost of mold is high, we have to change it regularly, and main factor is that generally metal is used in die casting has generally low melting point that Iron and steel. So we can use this casting in low MP of material. (iii) Centrifugal Casting (Vertical): This is the best method by which we can produce the given component. The main characteristic of this it has finer grain structure with coarse web and rib. Solution1 (c): My recommendation goes with the third one, because we can produce it in a batch. Not bothering about core in this process. High strength of casting is also possible. It is widely used in industries now, So setup is also easily available and cost effective. Solution2 (a): It looks like; the component is galvanized for protection against corrosion. So we have to describe about types of corrosion prevention method these are (i) By control of electrode potential (ii) By blockage (iii) By metal coating or metal spray Solution2 (b): (i) By control of electrode potential: this method is suitable for Large old sections whose replacement is costly affairs. To controlling the corrosion, we have to design the component in such a way that drainage of water is easy. Moisture accumulation is removed etc. By doing this we can achieve 30% of corrosion prevention. (ii) By blockage; in this process we have to provide extra covers to the surfaces of component. Its also permanent process by covering the component is itself is sometimes costly affairs. it is easier to make new component. that is why is not frequently used iii) By metal coating or paint spray: Metal coating is generally done through galvanizing. This is the cheapest and durable process, galvanized material last for about 20 yrs. from corrosion. Nos of steel companies are selling galvanized sheets, by which the above component can be made. Solution2 (c): My recommendation goes with galvanized material, because it is coated with Zn of Al, By doing this component not only prevented from corrosion but also strengthen, and leakage free, Component made from galvanized material is also cheaper as compared to above process. Solution3 (a): The other two characteristics are shape of particles and size distribution of particles. Solution3 (b): The nucleation and growth kinetics of the condensed phase is the factor which determines the particle size in metal powder production by chemical reaction. i.e. Decomposition of Carbonyl gives particles of sizes between 0.2 and 20 m. As per reaction mechanism, reaction with different ionic solution is as follows AgNO3(I) + K2SO3(I) = Ag(s) + 1/2K2SO4(l)+KNO3 + 1/2SO2(g). The particle size is based on nucleation and growth kinetic, it is about 1 m dia. range References: Campbell, J, 2011, Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques, Elsevier, USA. Randall, M, 2005, Powder Metallurgy Particulate Materials Processing, Metal Powder Industry, USA.