QCAA Engineering Materials
15 sample questions with marking guides and sample answers · Avg. score: 33.3%
Contrast the suitability of mild and high carbon steel for applications in the manufacture of automotive subframes that experience repeated loads and high impacts, using their microstructure and three relevant mechanical properties.
Reveal Answer
The composition of mild carbon steel includes a higher amount of ferrite, providing ductility. The lower amount of pearlite in the composition still provides a high yield strength.
High carbon steel includes a high amount of cementite compared to ferrite (in pearlite), contributing to a higher yield strength than mild carbon steel. The amount of cementite in the composition provides a less ductile material than mild carbon steel.
Automotive subframes are subject to repeated stresses due to a range of loads caused by different road surfaces, conditions, loading and collision impacts.
The very high yield strength and the lower ductility of high carbon steel produces lower toughness, which makes the material susceptible to fatigue cracking and less able to absorb the energy of repeated loading and collision impacts.
The relatively high yield strength and good ductility of mild carbon steel provides high toughness that allows the frame to absorb the repeated loads and impacts.
Therefore, mild carbon steel is more suitable than high carbon steel for use in the manufacture of automotive subframes.
| Descriptor | Marks |
|---|---|
Appropriately contrasts mild and high carbon steel and includes wording that indicates the microstructure of mild carbon steel is higher in ferrite than high carbon steel | 1 |
Appropriately contrasts mild and high carbon steel and includes wording that indicates lower in pearlite than high carbon steel | 1 |
Appropriately contrasts mild and high carbon steel and includes wording that indicates high carbon steel has a higher yield strength than mild carbon steel | 1 |
Appropriately contrasts mild and high carbon steel and includes wording that indicates high carbon steel is less ductile than mild carbon steel | 1 |
Appropriately contrasts mild and high carbon steel and includes wording that indicates mild carbon steel has better toughness than high carbon steel | 1 |
Appropriately contrasts mild and high carbon steel and includes wording that indicates mild carbon steel is a better material for automotive subframes, because of its higher toughness and ability to resist or absorb the repeated loads and impacts | 1 |
Explain how the chemical composition of mild carbon steel contributes to its suitability for seamless tubes. Include two properties of mild carbon steel in your response.
Reveal Answer
Mild carbon steel is suitable for seamless tubes due to its low carbon content. It is made up mainly of ferrite, which is a soft and ductile form of iron. This provides the material with ductility, which allows it to be formed into a tubular shape.
Mild carbon steel also contains pearlite with small amounts of cementite. Cementite is hard and brittle, and excessive amounts can make a material too brittle to be formed. The small amount of cementite in mild carbon steel provides toughness, allowing the material to be shaped without fracturing.
| Descriptor | Marks |
|---|---|
Identifies that mild carbon steel is mostly made of ferrite | 1 |
Identifies that ferrite adds to the ductility of the material, which allows the material to be formed into shape | 1 |
Identifies that mild steel contains pearlite | 1 |
Identifies that pearlite (or cementite in pearlite) adds to the toughness of the material, which prevents fracturing | 1 |
Which plastic is the most suitable for use as a medical screw?
nylon
polypropylene
polylactic acid
polyvinyl chloride
Reveal Answer
nylon
Nylon is a non-biodegradable polymer; while used in sutures, it would require a second surgery to remove if used as a screw, making it less suitable than bioabsorbable options.
polypropylene
Polypropylene is a non-absorbable material typically used for surgical meshes and sutures, not for temporary fixation devices that should dissolve over time.
polylactic acid
Polylactic acid (PLA) is biodegradable and biocompatible, meaning it breaks down into harmless lactic acid in the body, eliminating the need for a second surgery to remove the screw.
polyvinyl chloride
Polyvinyl chloride (PVC) is generally used for external medical devices like tubing and blood bags, not implants, due to biocompatibility issues and the presence of plasticizers.
Identify two industrial applications of high carbon steel. Describe two mechanical properties of this material that make it suitable for each application.
Application 1:
Application 2:
Reveal Answer
Application 1
An industrial application for high carbon steel could be springs because they need to have strength to resist deformation under the applied forces the spring will experience. A spring also needs to be wear/fatigue resistant for their springiness (compression/flexing during operation), so they can withstand repeated flexing without breaking.
Application 2
Another industrial application could be cutting tools, such as dies, industrial knives or punches, because they need to be hard and very strong to cut or punch out shapes.
| Descriptor | Marks |
|---|---|
Identifies one suitable industrial application for high carbon steel | 1 |
Describes appropriately a mechanical property that makes it suitable for the application | 1 |
Describes appropriately a second mechanical property that makes it suitable for the application | 1 |
Identifies a second suitable industrial application for high carbon steel | 1 |
Describes appropriately a mechanical property that makes it suitable for the application | 1 |
Describes appropriately a second mechanical property that makes it suitable for the application | 1 |
State four contemporary engineering applications for acrylonitrile butadiene styrene (ABS).
Reveal Answer
- automobile bumper bar
- electrical wall socket
- face shield
- hard hat
| Descriptor | Marks |
|---|---|
Provides a contemporary engineering application | 1 |
Provides a second contemporary engineering application | 1 |
Provides a third contemporary engineering application | 1 |
Provides a fourth contemporary engineering application | 1 |
Conventional automotive torsion bars are manufactured using steel with a carbon content of 0.3% to 0.5%, which is
low-carbon steel.
high-carbon steel.
mild-carbon steel.
medium-carbon steel.
Reveal Answer
low-carbon steel.
Low-carbon steel typically contains less than carbon (often to ), which is below the range specified for torsion bars.
high-carbon steel.
High-carbon steel generally contains between and carbon, making it harder and more brittle than the material described.
mild-carbon steel.
Mild steel is a common term for low-carbon steel (approximately to carbon), which does not match the to range.
medium-carbon steel.
Medium-carbon steel is defined by a carbon content of approximately to , providing the balance of strength and ductility required for automotive torsion bars.
List four properties of polylactic acid (PLA) that make it a useful material for medical implants.
Reveal Answer
- Biodegradable
- High tensile strength
- Non-toxic in solid form
- Resistant to chemicals
| Descriptor | Marks |
|---|---|
Provides 4 correctly identified PLA properties | 4 |
Provides 3 correctly identified PLA properties | 3 |
Provides 2 correctly identified PLA properties | 2 |
Provides 1 correctly identified PLA property | 1 |
None of the above | 0 |
State four industrial applications for carbon steel with 0.15% to 0.30% carbon content.
Reveal Answer
- Structural plates
- Stampings
- Forgings
- Seamless tubes
| Descriptor | Marks |
|---|---|
Provides a correct industrial application | 1 |
Provides a second correct industrial application | 1 |
Provides a third correct industrial application | 1 |
Provides a fourth correct industrial application | 1 |
A plastic beaker used to hold liquids in a laboratory is commonly manufactured using
polyethylene.
polypropylene.
polylactic acid.
polyvinyl chloride.
Reveal Answer
polyethylene.
While polyethylene is used for wash bottles and storage containers, it has a lower melting point than polypropylene and cannot typically be autoclaved, making it less common for general-purpose beakers.
polypropylene.
Polypropylene is the standard material for plastic beakers because it is autoclavable (heat-resistant), chemically resistant, and durable.
polylactic acid.
Polylactic acid (PLA) is a biodegradable plastic with low heat resistance, making it unsuitable for laboratory environments where heating and chemical stability are required.
polyvinyl chloride.
Polyvinyl chloride (PVC) is commonly used for tubing but is rarely used for beakers due to issues with chemical leaching and lower thermal stability compared to polypropylene.
Steel containing 0.11% carbon is
low carbon steel.
mild carbon steel.
medium carbon steel.
high carbon steel.
Reveal Answer
low carbon steel.
Low carbon steel is defined as steel containing carbon in the range of approximately to . Since falls squarely within this limit, it is classified as low carbon steel.
mild carbon steel.
While often used interchangeably with low carbon steel, the term "mild steel" typically refers to the range of to carbon. Steel with carbon is often specifically called "dead mild steel," making the broader category of "low carbon steel" the most accurate choice.
medium carbon steel.
Medium carbon steel contains a higher carbon content, typically ranging from to , which provides a balance of ductility and strength not found in the lower composition.
high carbon steel.
High carbon steel contains carbon ranging from to . A carbon content of is far too low to be classified in this category.
Waste water drainage pipe is commonly manufactured using
nylon.
polypropylene.
polylactic acid.
polyvinyl chloride.
Reveal Answer
nylon.
Nylon is primarily used for textiles and engineering components like gears; it is generally too expensive and absorbs moisture, making it unsuitable for drainage pipes.
polypropylene.
While polypropylene is used in some piping applications, it is less common than PVC for general waste water drainage due to differences in rigidity and cost.
polylactic acid.
Polylactic acid (PLA) is a biodegradable polymer used for packaging and medical devices; it lacks the long-term durability and stability required for infrastructure piping.
polyvinyl chloride.
Polyvinyl chloride (PVC) is the standard material for waste water pipes because it is chemically inert, durable, waterproof, and cost-effective.
Explain how the chemical composition of high-carbon steel contributes to two of its mechanical properties in the context of two industrial applications.
Reveal Answer
High-carbon steel has a chemical composition that includes 0.60% to 1.25% carbon. This carbon content facilitates the formation of pearlite in the microstructure. Pearlite is a fine laminar mixture of ferrite and cementite. The mechanical properties of pearlite are intermediate to soft, ductile ferrite and hard, brittle cementite. The finer pearlite microstructure of high-carbon steel increases toughness, strength, hardness and wear resistance, which makes the steel useful for industrial applications such as cutting tools, punches, dies and springs.
Explanation
| Descriptor | Marks |
|---|---|
Explains correctly and includes the carbon content of high-carbon steel | 1 |
Explains correctly and includes the microstructure of high-carbon steel | 1 |
Explains correctly and includes 2 industrial/mechanical uses for high-carbon steel | 1 |
Mechanical Properties
Marking Bands| Descriptor | Marks |
|---|---|
Includes 2 mechanical properties of high-carbon steel | 2 |
Includes 1 mechanical property of high-carbon steel | 1 |
None of the above | 0 |
High-voltage transmission cable insulation would most likely be manufactured from
polyvinyl chloride.
polypropylene.
polyethylene.
polystyrene.
Reveal Answer
polyvinyl chloride.
Polyvinyl chloride (PVC) has relatively high dielectric losses and is primarily used for low-voltage applications (like household wiring) rather than high-voltage transmission.
polypropylene.
While polypropylene has good electrical properties, it is generally less flexible and more brittle at low temperatures than polyethylene, making it less suitable for standard cable insulation.
polyethylene.
Polyethylene, specifically cross-linked polyethylene (XLPE), is the standard for high-voltage cables due to its high dielectric strength, very low dielectric loss, and excellent moisture resistance.
polystyrene.
Polystyrene is a rigid and brittle plastic, making it mechanically unsuitable for use as flexible cable insulation despite its good dielectric properties.
High carbon steel is used in the manufacture of
boiler plates.
railway tracks.
punching tools.
engine crankshafts.
Reveal Answer
boiler plates.
Boiler plates require high ductility and weldability to withstand pressure and fabrication, so they are typically made from low carbon (mild) steel rather than brittle high carbon steel.
railway tracks.
Railway tracks are generally made from medium to high carbon manganese steel to balance toughness and wear resistance, whereas plain high carbon steel is primarily reserved for tools.
punching tools.
High carbon steel (containing 0.6% to 1.5% carbon) possesses the extreme hardness and wear resistance necessary for making cutting and punching tools, such as drills, files, and chisels.
engine crankshafts.
Engine crankshafts require good toughness and fatigue strength to handle dynamic loads, so they are usually manufactured from medium carbon steel or alloy steel.
Analyse the information in the table to determine whether polyvinyl chloride (PVC) or polyethylene is the most suitable material for wastewater pipes in the home. Justify your response with four properties from the table.
| Properties | PVC | Polyethylene |
|---|---|---|
| Mechanical | resistant to abrasion, impact and weathering rigid — limited flexibility, can withstand high pressure | resistant to cracking, impact and environmental stress; strong; durable malleable — highly flexible |
| Young’s modulus | 2.41–4.14 GPa | 1.08 GPa |
| Yield strength | 40.7–44.8 MPa | 26.2–33.1 MPa |
| Tensile strength | 40.7–51.7 MPa | 22.1–31.0 MPa |
| Chemical | excellent chemical resistance (including corrosive chemicals) | good chemical resistance |
| Thermal | good heat resistance | very good heat resistance |
| Manufacturing cost | low | high |
Reveal Answer
PVC is resistant to corrosive chemicals, making it more suitable for use in wastewater pipes in the home where it is likely to come into contact with corrosive chemicals, such as bleach or drain cleaner.
Although polyethylene has greater heat resistance than PVC, the pipes won't be exposed to anything hotter than boiling water in the home so PVC will be good enough.
PVC has a higher Young's modulus than polyethylene, which means it will be more rigid/less flexible, making it suitable for long lengths of pipe under the sink, floor or ground.
PVC is cheaper than polyethylene as the manufacturing cost is lower.
The combination of these properties makes PVC a more suitable material for use in the home.
| Descriptor | Marks |
|---|---|
Describes that PVC has greater chemical resistance than polyethylene | 1 |
Describes that polyethylene has better thermal properties so is more heat resistant than PVC, but this is not an important property for this application | 1 |
Describes that PVC is more rigid or less flexible than polyethylene | 1 |
Describes that PVC is cheaper than polyethylene | 1 |
Determines that PVC would be most suitable for wastewater pipes in the home | 1 |