Materials Processing and Manufacturing Quizzes - Master Engineering (MEng) Materials Science

Question 1

In tensile testing, the plastic deformation stage of a metal is characterized by:

Accepted Answer

Increasing stress and elongation

Answer

Constant stress and elongation

Answer

Increasing stress and constant elongation

Answer

Constant stress and decreasing elongation

Question 2

Which casting process utilizes a permanent mold?

Accepted Answer

Die casting

Answer

Sand casting

Answer

Investment casting

Answer

Centrifugal casting

Question 3

Which of the following is not a conventional casting method for shaping molten metal?

Accepted Answer

Forging

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 4

In the context of castings, which of the following is NOT a typical solidification structure?

Accepted Answer

Widmanstätten structure

Answer

Columnar dendritic

Answer

Equiaxed dendritic

Answer

Cellular

Question 5

Identify the casting processes from the following options:

Accepted Answer

Sand casting

Accepted Answer

Investment casting

Accepted Answer

Die casting

Answer

Extrusion

Question 6

Which of the following is NOT a casting process used to create metal components?

Accepted Answer

Extrusion

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 7

In foundries, which of the following is NOT a casting process used to create metal components?

Accepted Answer

Extrusion

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 8

Which of the following is NOT a strengthening mechanism used in metal alloys?

Accepted Answer

Annealing

Answer

Grain refinement

Answer

Solid solution strengthening

Answer

Precipitation hardening

Question 9

Which casting technique utilizes a mold created around a wax pattern, resulting in castings with the finest surface finish?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Die casting

Answer

Centrifugal casting

Question 10

Which of the following metalworking processes does NOT involve pouring molten metal into a mold?

Accepted Answer

Forging

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 11

In sand casting, what material is used to form the mold cavity?

Accepted Answer

Compacted sand mixture

Answer

Permanent metal mold

Answer

Wax pattern

Answer

Ceramic shell

Question 12

Which of these manufacturing techniques is considered an emerging technology?

Accepted Answer

3D printing

Answer

Sand casting

Answer

Die casting

Answer

Investment casting

Question 13

In sand casting, what is the main purpose of the sprue?

Accepted Answer

To allow molten metal to flow into the mold cavity

Answer

To support the top half of the mold

Answer

To release gases from the mold cavity

Question 14

During solidification, which factor does NOT affect the rate of nucleation?

Accepted Answer

Pressure

Answer

Temperature

Answer

Presence of impurities or alloying elements

Answer

Melt agitation or stirring

Question 15

Which of the following processes is NOT a casting process?

Accepted Answer

Extrusion

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 16

Identify the metal forming process, distinct from casting processes:

Accepted Answer

Extrusion

Answer

Sand casting

Answer

Investment casting

Answer

Die casting

Question 17

Which heat treatment process is primarily employed to enhance the strength and hardness of steel?

Accepted Answer

Hardening and Tempering

Answer

Annealing

Answer

Normalizing

Answer

Powder Metallurgy

Question 18

In the heat treatment process of hardening a plain carbon steel alloy, which mechanism is primarily responsible for the significant increase in the material's hardness and strength?

Accepted Answer

Martensitic transformation

Answer

Grain refinement

Answer

Solid solution strengthening

Answer

Precipitation hardening

Question 19

Which heat treatment process enhances steel's hardness and yield strength by inducing internal stresses and triggering a martensitic transformation?

Accepted Answer

Quenching and Tempering

Answer

Annealing

Answer

Normalizing

Answer

Carburizing

Question 20

In metal solidification, which factor primarily contributes to the growth of larger crystals?

Accepted Answer

Prolonged exposure to high temperatures, allowing crystals to grow

Answer

Rapid cooling, resulting in smaller crystals

Answer

Presence of impurities, inhibiting crystal growth

Answer

Application of external pressure, promoting crystal growth

Question 21

Which of the following is a secondary solidification mechanism that involves the formation of branched, tree-like structures?

Accepted Answer

Dendritic growth

Answer

Diffusion-controlled growth

Answer

Interface-controlled growth

Answer

Grain growth

Question 22

In powder metallurgy, which method involves applying heat and pressure to eliminate internal porosity, thereby enhancing the strength and density of the final metal product?

Accepted Answer

Hot isostatic pressing

Answer

Cold isostatic pressing

Answer

Extrusion

Answer

Annealing

Question 23

In the context of solidification structures in metals, which of the following options accurately describes the morphology of a dendritic structure?

Accepted Answer

A three-dimensional network of interconnected branches or arms with a central stalk, resembling a tree-like structure.

Answer

A compact, equiaxed grain structure with uniformly sized and polygonal grains.

Answer

A layered or stacked arrangement of grains or phases, resembling a pile of plates.

Question 24

Precipitation hardening strengthens materials by forming:

Accepted Answer

Dispersed particles in the metal matrix

Answer

Continuous grain boundaries

Answer

A uniform distribution of dislocations

Question 25

What is a primary advantage of investment casting compared to sand casting?

Accepted Answer

Ability to produce more complex shapes

Answer

Higher production rates

Answer

Lower tooling costs

Answer

Suitable for mass production

Question 26

In powder metallurgy, sintering involves heating a powder compact below its melting point. What is the main purpose of this process?

Accepted Answer

Increase strength and density by promoting interparticle bonding and reducing porosity.

Answer

Soften the compact to enhance wear resistance and ductility.

Answer

Change the chemical composition of the compact to achieve desired properties.

Question 27

Which casting process entails injecting molten metal into a mold under high pressure to create a part?

Accepted Answer

Die casting

Answer

Sand casting

Answer

Investment casting

Question 28

In the process of metal solidification, which stage occurs prior to grain growth and recrystallization?

Accepted Answer

Nucleation

Answer

Melting

Answer

Grain growth

Answer

Recrystallization

Question 29

Investment casting is known for producing intricate shapes with high dimensional accuracy and surface finish. Which of the following best describes this advantage?

Accepted Answer

Investment casting is ideal for applications requiring complex geometries and exceptional surface finish.

Answer

Investment casting produces simple shapes with low dimensional accuracy.

Answer

Investment casting is suitable for mass production of large components.

Question 30

Which plastic deformation mechanism involves dislocations moving across grain boundaries?

Accepted Answer

Grain boundary sliding

Answer

Slip

Answer

Twinning

Answer

Recovery

Question 31

In casting processes, how does an increase in cooling rate generally impact the resulting microstructure and properties of a metallic alloy?

Accepted Answer

Finer grain structure and enhanced mechanical properties

Answer

Coarser grain structure and improved mechanical properties

Answer

Finer grain structure and weakened mechanical properties

Question 32

Which application is generally NOT associated with additive manufacturing (3D printing)?

Accepted Answer

Mass production of standardized automotive components

Answer

Rapid prototyping and product design iteration

Answer

Personalized medical implants and devices tailored to patient anatomy

Answer

Construction of intricate architectural structures with unique designs

Question 33

Die casting, a widely employed casting technique, offers various advantages. However, it also has certain limitations. Which of the following is NOT an advantage of die casting?

Accepted Answer

Limited material choices

Answer

Exceptional dimensional accuracy

Answer

High production efficiency

Answer

Production of complex geometries

Question 34

Describe the principles and applications of microfabrication techniques in the production of electronic devices and other advanced products.

Accepted Answer

Microfabrication involves creating small-scale structures and devices using techniques like photolithography and chemical etching.

Answer

Microfabrication is only used in the production of electronic devices, such as transistors and microchips.

Answer

Microfabrication techniques do not require high precision or specialized equipment.

Question 35

Which technique is primarily NOT employed to characterize the microstructure of materials?

Accepted Answer

Radiography

Answer

Optical microscopy

Answer

Scanning electron microscopy (SEM)

Answer

X-ray diffraction (XRD)

Question 36

In sustainable materials processing and manufacturing, which technique is used to reduce environmental impact?

Accepted Answer

Adopting manufacturing techniques that conserve energy, reduce waste, and minimize emissions

Answer

Adopting manufacturing processes that generate significant waste and emissions

Answer

Using materials with low recyclability and high carbon footprint

Question 37

Which manufacturing process is most suitable for producing large, intricately shaped components, such as vehicle frames?

Accepted Answer

Casting

Answer

Forging

Answer

Extrusion

Answer

Rolling

Question 38

Heat treatment plays a crucial role in materials processing. What is its primary objective?

Accepted Answer

Modifying the microstructure to enhance material properties

Answer

Eliminating defects and impurities

Answer

Improving corrosion resistance

Answer

Increasing electrical conductivity

Question 39

Which of the following is NOT a primary technique used in metal processing?

Accepted Answer

Coating

Answer

Casting

Answer

Extrusion

Answer

Annealing

Question 40

The microstructure of a material refers to the:

Accepted Answer

Arrangement and size of its constituents

Answer

Chemical composition

Answer

Crystalline structure

Answer

Mechanical properties

Question 41

What is a primary advantage of using computational materials science simulations in manufacturing?

Accepted Answer

Decreased need for physical experiments

Answer

Elimination of manufacturing flaws

Answer

Significant increase in production rate

Question 42

During materials processing, a rapid temperature change can induce:

Accepted Answer

Quenching

Answer

Annealing

Answer

Tempering

Answer

Normalizing

Question 43

Which factor is excluded from material processing selection considerations?

Accepted Answer

Abundance of raw materials

Answer

Material characteristics

Answer

Processing economics

Answer

Desired product geometry

Question 44

Powder metallurgy involves:

Accepted Answer

Compacting and sintering powdered materials

Answer

Melting and casting metals

Answer

Extruding and shaping materials

Answer

Electrochemical deposition

Question 45

Amorphous materials are characterized by:

Accepted Answer

Absence of long-range crystalline structure

Answer

Elevated strength

Answer

Low thermal conductivity

Answer

Brittle nature

Question 46

In materials processing, annealing refers to:

Accepted Answer

Heating and gradually cooling a material

Answer

Heating and rapidly quenching a material

Answer

Deforming a material beyond its elastic limit

Answer

Applying stress at elevated temperature

Question 47

Which of the following is NOT a primary shaping process used to transform raw materials into desired shapes?

Accepted Answer

Machining

Answer

Casting

Answer

Rolling

Answer

Extrusion

Question 48

Which of the following is an example of a non-destructive testing method?

Accepted Answer

Ultrasonic testing

Answer

Tensile testing

Answer

Metallography

Answer

Hardness testing

Question 49

Which metal refining technique involves removing impurities through electrolysis?

Accepted Answer

Electrorefining

Answer

Casting

Answer

Rolling

Answer

Powder metallurgy

Question 50

The microstructure of a material refers to its:

Accepted Answer

Arrangement and size of its grains

Answer

Chemical composition

Answer

Mechanical properties

Answer

Thermal conductivity

Question 51

Which manufacturing process shapes molten metal by forcing it through a die?

Accepted Answer

Extrusion

Answer

Casting

Answer

Forging

Answer

Rolling

Question 52

The link between processing techniques, microstructure, and material properties is known as the:

Accepted Answer

Processing-structure-property relationship

Answer

Materials processing cycle

Answer

Manufacturing science

Answer

Materials engineering

Question 53

Which of the following is considered an emerging manufacturing technology?

Accepted Answer

3D printing

Answer

Laser cutting

Answer

Vacuum casting

Answer

Hot rolling

Question 54

Fusing two metal pieces together by melting is a process known as:

Accepted Answer

Welding

Answer

Soldering

Answer

Brazing

Answer

Riveting

Question 55

Fibre-reinforced plastic is an example of which material type?

Accepted Answer

Composite material

Answer

Steel

Answer

Aluminium

Answer

Glass

Question 56

The production of materials with a controlled nanostructure is a field known as:

Accepted Answer

Nanotechnology

Answer

Microfabrication

Answer

Bioengineering

Answer

Materials science

Question 57

Which of the following is NOT a primary processing technique for metals?

Accepted Answer

Machining

Answer

Casting

Answer

Rolling

Answer

Extrusion

Question 58

Which manufacturing technology has emerged as a promising technique for high-precision and complex part production?

Accepted Answer

Additive manufacturing

Answer

Injection molding

Answer

Forging

Answer

Welding

Question 59

Which of the following factors does NOT affect the mechanical properties of a composite material?

Accepted Answer

Exposure to the environment

Answer

Matrix material

Answer

Reinforcement material

Answer

Processing conditions

Question 60

The process of fabricating a material from a powder is known as:

Accepted Answer

Powder metallurgy

Answer

Sintering

Answer

Forging

Answer

Casting

Question 61

Which manufacturing technique involves building a 3D object layer by layer, guided by a digital design?

Accepted Answer

Additive Manufacturing

Answer

Casting

Answer

Forging

Answer

Extrusion

Question 62

Which mechanism is primarily responsible for the enhanced strength of age-hardened aluminum alloys? Explain the underlying process.

Accepted Answer

Precipitation strengthening

Answer

Solid solution strengthening

Answer

Grain boundary strengthening

Answer

Work hardening

Question 63

In metal joining, which method employs a molten filler material to bond two metal pieces?

Accepted Answer

Brazing

Answer

Solid-state welding

Answer

Mechanical fastening

Answer

Adhesive bonding

Question 64

Which manufacturing technique is best suited for creating highly intricate and complex components with exceptional dimensional accuracy and a fine surface finish?

Accepted Answer

Investment casting

Answer

Sand casting

Answer

Powder metallurgy

Answer

Die casting