NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR

Department of Metallurgical & Materials Engineering

End-Semester Examination ( on-line ),DEC-2020

Class : B.Tech( Hons ),5th Semester Time :3hrs

Full Marks : 50

SUBJECT : IRON MAKING TECHNOLOGY (MT1505 )

INSTRUCTIONS :

1.Answer any Five Questions only ,

2.Answers must be to the point ,

3.Avoid un-necessary writing .

1.Explain with a neat & Clean diagram of SL-RN /Solid route techniques of
DRI /Sponge Iron making in INDIA & ABROAD. ‘’Germany ,Japan & Mexico are
the father of Sponge Iron Technology ,, .Justify your answer by your concept .
5+5=10

2. Explain the thermodynamics & Kinetics of Slag-metal reactions / formation

in the hearth of the Blast Furnace . Why do you maintain a very high Enthalpy
of the blast . Give your suggestion to get good Slag-metal product .

5+3+2= 10

3. Draw a neat & Clean Flow chart of Iron Blast Furnace with hot blast Gas
preparation Chambers .Why do you maintain 2-3 Stoves on Gas & 1-2 ON Blast
.Is it necessary .What do you think .Justify . 5+5=10

4. ‘’ SINTER is a super burden materials to be charged in the Blast Furnaces ,, .

Justify your statements by suitable technical & Economical reasons .How do
you get maximum productivity ,minimum Coke -Rate & High kinetics of
reduction . 5+5=10

5.Explain with mode of operation to get High Kinetics of ores / Sinter

reductions at lowest Coke rates by any two of the following Modern Trends :
5+5 10
A.Coal –tar injection ,B. High –top pressures ,C. Pulverised coal injection .

6.Write Short notes on : 2.5 X 4 =10

A.MIDREX –Technology

A. Bedding & Blending’s of fines

C.Blast Furnace gas

D.Hot metal treatment

E. Solution loss reactions .

BEST OF LUCK
 NATTIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR

Department of Metallurgical & Materials Engineering

Mid-Semester Examination ,OCT-2020

Sub: IRON MAKING TECHNOLOGY (MT1505 )

Class : B.Tech ( Hons ), 5th SEMESTER Time :2hrs

Full Marks : 30 Mode of Examination :

ON-LINE

INSTRUCTIONS :

1.Answer any three questions only

2.Answers must be to the point .

1.Explain with a neat & Clean diagram of IRON BLAST Furnace showing different reactions at
different temperatures emphasis on reduction kinetics of burden materials . 5+5=10

2. Explain the methods of manufacture of SINTER ,Why do you prefer to use more SINTER
THAN

-Pellets / HBI /Directly ores . Justify your answers by suitable technical / economical reasons
. 5+5=10

3.INDIA Imports Coking Coal from Australia & Dolomite from Neazealand /Netherlands
/South

Korea .Why,Justify by Economical,Technical / Geological reasons . 5+5 10

4. Write Short Notes on : 2 X 5 =10

A. 70% Lignite + 25% Bituminous + 5% Anthracite Coal for SINTER MAKING ,

B. Fuel Inject ants in to Blast Furnaces ,

C.Bedding & Blending of Fines ,

D.Slag –Metal Gas reactions in the B/Fces ,

E. Coke Rate ,

BEST OF LUCK
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR

Department of Metallurgical and Materials Engineering

Autumn Mid Semester Examination, October, 2020

B. E. (3rd Year Year): 5th Semester Course Code: 1503

(Metallurgical and Materials Engineering) Course Name: Deformation

Processing and Forming
Technology
Date of Exam : 18.10.2020

Time: 2 Hours, M. Marks: 30 Name of Faculty: Dr BB Jha

Note: Lengthy answers must be avoided. Answers to the questions

need be crisp, precise and to the point.

Question 1: 2+2+2+2+2

i) When a tensile specimen with diameter of 0.505 inch and gauge

length of 2.0 inch was loaded to 10,000 lb, it was found that the
gauge length was 2.519 inch. Assuming that the deformation was
uniform, compute the true strain and true stress.
ii) Show that maximum load in tension test starts when true strain
(€) equals to strain hardening exponent (n).
iii) Derive the equation to prove that smaller is the gauge length (L0),
higher will be the total elongation up to the point of fracture.
iv) Write down the three unfavourable conditions for Superplasticity.
v) Write the equation relating flow stress with strain rate and strain
rate sensitivity (m). If m=0.01, what would be the percentage
change in flow stress in case the strain rate is increased by a factor
of 10.
Question 2: 3+2+1+2+2

i) Define the strain rate sensitivity (m). Explain with diagrams the
two methods for determining the value of Strain rate sensitivity of
a material.
ii) Draw a plot showing the variation of flow stress with temperature
at constant strain rate. How this plot will vary with the variation of
Strain rate, depict the effect through diagram.
iii) Differentiate between homogenous deformation and redundant
deformation in drawing process depicting the effect through
diagram.
iv) Define the term Deformation efficiency and express it in terms of
equation. Draw the curve showing dependence of frictional, ideal,
redundant and total deformation in drawing process with respect
to semi-die angle.
v) What is orange peel effect and stretcher strains in drawing process.
How these defects could be inhibited.

Question 3: 3+3+2+2
i) What is barrelling in compression test, explain this with the help
of diagram showing clearly the dead metal zone. Write down the
two methods through which the barrelling could be minimised.
ii) Write down the reasons for residual stress generation in drawn bar.
Compare the residual stress generation from centre of the drawn
bar to surface of same diameter at 80% and 40% reduction by
depicting it in figure.
iii) Write down the four numbers of disadvantages of hot working
process.
iv) A round tensile specimen of initial gauge length of 100 mm and
diameter of 25 mm shows after fracture a gauge length of 130 mm
and diameter of 21 mm at fracture. If the load at yielding, at the
point of necking and at the point of fracture is 160,200 and 170 kN
respectively, calculate reduction of area at fracture and true
reduction of area at fracture.

--x--
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR

Department of Metallurgical and Materials Engineering

Autumn End Semester Examination, December 2020

B. E. (3rd Year Year): 5th Semester Course Code: 1503

(Metallurgical and Materials Engineering) Course Name: Deformation

Processing and Forming
Technology
Date of Exam : 23.12.2020

Time: 3 Hours, M. Marks: 50 Name of Faculty: Dr BB Jha

Note: Answer all questions. Lengthy answers must be avoided.

Answers to the questions need be crisp, precise and to the point.

Question 1: 2+4+4

i) Define Angle of bite, Neutral point, Specific roll pressure and

Draft.
ii) Establish the relationship between angle of bite, draft and roll
radius.
iii) Determine the maximum reduction possible in a steel plate having
250 mm thickness during cold rolling when µ= 0.1 and during hot
rolling when µ= 0.6. Also calculate the angle of bite in both the
cases.
Question 2: 5+5

i) Draw the characteristic elastic and plastic curve of the rolling mill
and explain with this diagram as to how the uniformity in final
thickness is controlled in case of eventualities like decrease in
temperature or breakdown of lubrication.
ii) Explain the roll defects- waviness and edge cracking with diagram.
What are the reasons for occurrence of these defects during rolling
and what are the remedial measures.
Question 3: 4+3+3
i) Draw the diagram depicting the variation of extrusion pressure
with travel of the ram in direct and indirect extrusion process and
explain why they are different. Why the pressure builds up at the
end of the process.
ii) A 10 mm rod of Aluminium having extrusion constant = 4.85 N/sq.
mm is extruded to 6 mm rod. Calculate the extrusion ratio,
reduction in area and extrusion force
iii) Which kind of die; flat faced or conical, is used for extrusion of
mild steel and why?
Question 4: 4+4+2

i) Define FTP, NDT and FATT in Energy absorbed vs temperature

diagram obtained as a result of charpy test and locate these points
on this diagram. Why stainless steel is considered as most suitable
material for the components of nuclear reactor.
ii) Write down the effect of four numbers of metallurgical factors as
to how they alter these transition temperatures in steel. Under these
background knowledge, explain the failure of TITANIC ship.
iii) What is blue brittleness in steel and what is the temperature range
of its occurrence and how could it be controlled.
Question 5: 4+3+3

i) Explain with the help of diagram the phenomena of friction hill

observed as a rise in deformation pressure with distance from the
edge of the plate. What is its physical significance of friction hill
in compression test?
ii) Depicting the diagram, explain how average deformation pressure
is affected by µ and length to thickness ratio of the work piece.
iii) Write down the functions (minimum six) of metal working
lubricants.

--x--
 NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

Course Name: Powder Metallurgy and Ceramics (PMC); Course Code: MM1504

Maximum Marks: 50; Duration: 3 hrs; Instructor: Dr. S.K. Vajpai

Note: Attempt All Questions. Elaborate your answers with necessary schematic
diagrams, wherever necessary. The rules for plagiarism will be strictly applied as per the
general guidelines of online exams.

1. Compacts of rapidly solidified Al-4wt%Cu alloy powder (Nitrogen gas atomized) are
prepared by conventional hot pressing as well as Vacuum Spark plasma sintering. The
sintering was carried out at 450oC for 15 minutes. What major differences between
these sintered compacts can be expected, in terms of sinter-ability, overall densification,
and microstructural evolution. Which method would you prefer and why? [10]
2. A mechanically milled alloy powder is provided and it is required to prepare near-full
density (a) sheets, and (b) rod with star-shaped cross-section. Explain the possible
method providing the step-wise details with proper justification. [10]
3. A piece of cast Titanium Aluminide is provided. How would you proceed to prepare a
fine-grained full-density compact following a suitable powder metallurgy approach?
Explain the possible process with all necessary details and proper justification. [10]
4. Explain the process of Injection Moulding, its importance, advantages, disadvantages,
limitations, and applications. Discuss with reference to both ceramics and metallic
materials. [10]
5. (a) Explain the possible differences in the morphology and microstructure of alloy
powders prepared by water atomization technique and plasma rotating electrode
process. Also mention the limitations of these two techniques. [05]
(b) Compare and Contrast between the salient features of Slurry casting and Tape
casting. [05]
 NATIONAL INSTITUTE OF TECHNOLOGY JAMSHEDPUR
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

Course Name: Powder Metallurgy and Ceramics (PMC); Course Code: MM1504

Maximum Marks: 30; Duration: 2 hrs; Instructor: Dr. S.K. Vajpai

Note: Attempt All Questions. Elaborate your answers with necessary schematic
diagrams, wherever necessary.

1. Discuss the relevance and co-relation of characteristics of powders, produced through

different methods, with the nature of intended product development. Elaborate with

suitable examples. [10]

2. Your goal is to prepare Al-Al2O3 composites with varying amount of Alumina (Al2O3)

through powder metallurgy route. You have been provided a piece of Pure Aluminum

as starting material. Please explain a possible process to achieve the goal. [10]

3. Explain the similarities and differences between solid and liquid phase sintering in

terms of underlying mechanism, process and applications. [10]

 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR
END SEMESTER EXAMINATION 2020
CLASS: B. Tech., V SEM.
BRANCH: MET. AND MAT. ENGG. FULL MARKS: 50
TIME: 3 HOURS Code: MT 1501
SUBJECT: EXTRACTIVE METALLURGY OF NON FERROUS METALS
INSTRUCTIONS:
1). Attempt all questions.
2). Marks of the questions and part their of are indicated in the right hand margin.
3). Missing data, if any, may be assumed suitably.
4). Before attempting the question paper be sure that you have got the correct question paper.
Write all parts of a question at one place only.
1 Discuss the application Kinetics in metal extraction process. 10

2 Describe the aluminum extraction process in details. 10

3 (a) Write briefly about Lead (Pb) extraction with flow diagram. 6

(b) Mention recent days development in the extraction of Pb. 2

(c) What is Speiss? What do you mean by softening and write its 2
importance?

4 (a) What are the important uses of lead metal? 4

(b) Write down the name and their chemical formula of the two minerals 2
of lead.

(c) What are the various impurities with which lead ores are associated? 2

(d) Give the important locations in India, where lead is available. 2

5 (a) Write down the reactions during roasting of Zinc Blend (ZnS) 3
and the same during extraction of zinc from roasted ore through
distillation.

(b) What are the advantages and disadvantages of the Hydro 3

metallurgical process of extraction of Zn over Pyro metallurgical
process?

(c) Draw the flow diagram of Zinc, Cadmium and Lead extraction adopted 4
by M/s Hindustan Zinc Limited located at Dadri and Tundoo (label the
each step clearly and lucidly).
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR
END SEMESTER EXAMINATION

Class: 5th Semester

Branch: Metallurgical & Materials Engg. Full marks: 50
Time: Three Hour
Subject: Manufacturing process in Metallurgy
(MM1502)
Instructions:
1. Answer all five questions.
2. Answer should be given very specific and to the point.
3. Answer of all the parts of a question must be at one place.

1 What is Eutectic solidification. What are types of eutectic solidification. How [10]
growth is taking place in eutectic solidification. Derive the equation for growth
rate (ν) and interlamellar spacing(λ). Write down the five alloy where eutectic
solidification is taking place.

2 (a) Discuss the submerged arc welding process. [5]

(b) Discuss the casting defects and possible remedies for this. [5]

3 (a) What is gating system. What are the types of gating system? Write down [5]
the difference between pressurized and non-pressurized gating system.

(b) Discuss the characteristics of moulding sand. Briefly explain the different [5]
tests for the moulding sand.

4 (a) Draw the schematic diagram of electron beam welding process and explain [5]
it.
(b) Write down the different types of welding defects and how these defects [5]
are analysed.

5 Write down the short notes on the following [2.5 x

(a) Segregation, b) Non-consumable electrode welding, (c) Die casting, 4=10]
(d)Investment Casting
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR

B.TECH, Vth MID SEMESTER EXAMINATION OF AUTUMN SEMESTER 2020-21

Course Title: Extractive Metallurgy of Non Ferrous Metals

Course code: MM1501

Branch Name: MME

Date 16/10/20

Full Marks: 30 Time: 2 hours

Candidates should answer all parts of a particular question (like a, b) at one place only.

Answer should be to the point .

1. (a) Discuss application of thermodynamics in metal extraction process. [7]

(b) Discuss common steps involved in extraction of metals from their ores. [3]

2. (a) Discuss general purification and refining of metal process. Differenciate electrorefining and

electrowinning process. [5]

(b) Discuss extraction of Cu through Hydrometallurgy and Pyrometallurgy. Why oxide ore is

treated with hydrometallurgy while sulphide ore with pyrometallurgy ? [5]

3. (a) What is basic difference between conventional route and newer route of cu extraction process?

[5]

(b) Discuss Hall-Herault process. [5]

------- End-------
 NATIONAL INSTITUTE OF TECHNOLOGY, JAMSHEDPUR
MID SEMESTER EXAMINATION

Class: 5th Semester

Branch: Metallurgical & Materials Engg. Full marks: 30
Time: Two hours
Subject: Manufacturing process in Metallurgy (MM1502)
Instructions:
1. Answer all three questions.
2. Answer should be given very specific and to the point.
3. Answer of all the parts of a question must be at one place.

1. (a) Discuss and derive the equation for Lateral Growth. [5][

(b) Discuss and derive the equation of heat flow during dendrite formation. [5]

2. (a) For the solidification of nickel, calculate the critical radius r* and the activation free energy
∆G* if nucleation is homogeneous. Values for the latent heat of fusion and surface free energy are
-2.53 x 109 J/m3 and 0.255 J/m2, respectively. The supercooling value is 319oC. [2.5]

(b) Now calculate the number of atoms found in a nucleus of critical size. Assume a lattice
parameter of 0.360 nm for solid nickel at its melting temperature. [2.5]

(c) Is ∆G *greater for a cube or a sphere? Explain with proper derivation. [5]

3. Write down the short notes on the following: [2.5 x5=20]

(a) Eutectic solidification, (b) Segregations,
(c) Ingot structure and (d) Arc welding